Engine - 3.0L (4V): Overhaul Mercury Mariner II

DISASSEMBLY

1. Using the special tool, remove the keys, retainer and spring.
2. Remove the valve from the cylinder head.
3. Remove the valve stem seal.

ASSEMBLY

1. Using the special tool, install the valve stem seal.
2. Install the valve.
3. Using the special tool, install the valve spring, retainer and key.

Special Tools Illustration Tool Name Tool Number Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Lifting Brackets, Engine 303-050 (T70P-6000) Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Material

Scheme 58

Scheme 59

All vehicles

1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the crankcase cover, a new gasket and the bolts. Tighten to 10 Nm (89 lb-in).
3. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
8. Apply clean engine oil to the LH and RH camshafts.
9. Install the LH and RH camshafts. Locate the camshafts as shown.
10. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
11. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
12. Install the bolts. Tighten in the sequence shown to 8 Nm (71 lb-in).
13. Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
14. Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
15. Install the bolts. Tighten in the sequence shown to 8 Nm (71 lb-in).
16. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
17. Using the special tools, install a new camshaft oil seal.
18. Remove the crankshaft pulley bolt.
19. Install the crankshaft sprockets with the timing marks out.
20. Position the chain tensioner in a soft-jawed vise.
21. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
22. Slowly compress the timing chain tensioner.
23. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
24. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
25. Position the LH timing chain and guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
26. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
27. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
28. Verify that the RH camshafts are correctly positioned.
29. Install the RH timing chain and chain guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
30. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
31. Remove the LH and RH timing chain tensioner piston retaining wires.
32. Rotate the crankshaft counterclockwise 120 degrees to TDC.
33. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
34. Remove the crankshaft pulley bolt.
35. Install the ignition pulse wheel.
36. Install 3 new gaskets in the front cover.
37. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
38. Position the front cover and install the bolts and stud bolts. Tighten in the sequence shown to 25 Nm (18 lb-ft).
39. Using the special tools, install the crankshaft front oil seal.
40. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
41. Using the special tool, install the crankshaft pulley.
42. Install the crankshaft pulley washer and tighten the bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten to 90 Nm (66 lb-ft).
43. Install the belt tensioner and the bolt. Tighten to 45 Nm (33 lb-ft).
44. Install the LH idler pulley and the bolt. Tighten to 47 Nm (35 lb-ft).
45. Install the center idler pulley and the bolt. Tighten to 25 Nm (18 lb-ft).
46. Position the oil pan baffle. Install the nuts and tighten in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
47. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
48. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the bolts. Install the nut and tighten in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
49. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
50. Position the LH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
51. Position the RH valve cover and install the bolts and stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
52. Install the radio interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
53. Install the coolant pump and the bolts. Tighten to 10 Nm (89 lb-in).
54. Connect the coolant pump hose to the cylinder block outlet.
55. Install the bypass tube and the nut and bolt. Tighten to 10 Nm (89 lb-in).
56. Position the coolant tube and connect the hoses.
57. Install the special tool in the camshaft as shown in the illustration. Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
58. Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration. Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
59. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
60. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
61. Lubricate the O-ring seal and install the oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
62. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
63. Install a new gasket and the LH exhaust manifold and new nuts. Tighten in the sequence shown to 20 Nm (15 lb-ft).
64. Using the special tool, install the LH HO2S. Tighten to 47 Nm (35 lb-ft).
65. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
66. Position the oil level indicator and tube and install the stud bolt. Tighten to 10 Nm (89 lb-in).
67. Install the engine oil pressure (EOP) switch and, if equipped, the block heater. Tighten the EOP switch to 14 Nm (10 lb-ft). Tighten the block heater to 21 Nm (15 lb-ft).
68. Install the 3 bolts and the A/C compressor bracket. Tighten to 25 Nm (18 lb-ft).
69. Position the generator and install the bolt and 2 nuts. Tighten to 47 Nm (35 lb-ft).
70. Install the halfshaft support bracket and the bolts. Tighten to 48 Nm (35 lb-ft).
71. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
72. Install a new gasket and the RH exhaust manifold and new nuts. Tighten in the sequence shown to 20 Nm (15 lb-ft).
73. Connect the RH HO2S electrical connector.
74. Install the 6 coil-on-plugs and the bolts. Tighten to 6 Nm (53 lb-in).
75. Install the lower intake manifold and the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
76. Install the B+ wiring harness on the engine. Attach the 4 wiring harness retainers, and install the nut. Tighten to 6 Nm (53 lb-in).
77. Position the fuel charging wiring harness on the engine. Attach the 2 wiring harness retainers (1 shown) to the engine.
78. Connect the fuel injector electrical connectors.
79. Install the B+ wire and nut on the generator. Tighten to 8 Nm (71 lb-in).
80. Connect the generator electrical connector.
81. Connect the camshaft position sensor (CMP) and EOP switch electrical connectors. Attach the wiring retainers.
82. Connect the LH coil-on-plug electrical connectors. Attach the 2 wiring retainers.
83. Connect the radio interference capacitor electrical connector. Attach the wiring retainers.
84. Connect the RH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers.
85. Connect the engine coolant temperature (ECT) sensor electrical connector.
86. Install the upper intake manifold and the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
87. Connect the throttle body (TB) coolant hose.
88. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
89. Install the PCV tube.
90. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors. Attach the wiring retainer.
91. Position the engine control wiring harness and install the nuts. Tighten to 6 Nm (53 lb-in).
92. Connect the EGR vacuum regulator electrical connector.
93. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.
94. Position the catalyst monitor sensor electrical connector bracket. Install the nut and attach the wiring retainer. Tighten to 10 Nm (89 lb-in).
95. Attach the engine control sensor wiring connectors to the upper intake manifold.
96. Using the special tools, remove the engine from the engine stand.
97. Using the special tools, install the crankshaft rear oil seal.
98. Install the engine-to-transaxle separator plate.
99. Position the flexplate and install the bolts. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Engine Lifting Bracket Set 303-1140 Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift with Tilting Plate 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001

Material