Electronically Controlled Continuously Variable Transaxle (hybrid) Mercury Mariner II рестайлинг

Material Specifications

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

Transaxle Components

The Electronically Controlled Continuously Variable Transmission (eCVT) has the following internal components

1. Traction motor
2. Generator
3. Transmission Control Module (TCM)
4. Planetary gearset

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Park

With the range selector in PARK

1. the parking pawl locks the output shaft to the case.
2. the engine may be started.
3. the ignition key can be removed.
4. the ignition switch can be cycled from OFF to START or RUN.

Reverse

With the range selector in REVERSE

1. the vehicle may be operated in a rearward direction.
2. reversing lamps are illuminated.
3. if the vehicle is not started, there is no reverse gear engagement.

Neutral

With the range selector in NEUTRAL

1. no power flows through the transmission.
2. the output shaft is disengaged from the drive wheels.

Drive

The range selector DRIVE position provides

1. low speed driving.
2. acceleration.
3. cruise conditions.
4. deceleration.
5. maximum fuel economy during normal operation.

If the vehicle is not started, there is no forward gear engagement.

Low

The range selector LOW position provides

1. engine braking.
2. improved traction on slippery roads.

If the vehicle is not started, there is no forward gear engagement.

Silent Key Start (SKS)

The Silent Key Start (SKS) is essentially the ability for the customer to get in the vehicle, turn the key to crank, and start the vehicle (it would enter run mode) with the engine OFF.

The transaxle is required to permit the vehicle to operate in a silent start mode. If both the engine coolant and the transmission fluid temperatures are between 4°C-43°C (40°F-110°F) when the driver requests the vehicle to start, the vehicle will enter run mode with the engine off.

The engine will remain off until the driver shifts out of PARK and one or more of the following conditions are met

1. the vehicle speed is greater than 16 km/h (10 mph).
2. the distance traveled is greater than 3 m (10 ft).
3. the accelerator pedal position is greater than 5 counts about 1%.

The engine may pull up at any time to facilitate the climate control function or to charge the high voltage battery.

Silent Drive Away (SDA)

Silent Drive Away (SDA) is the ability for the customer to get in, silently start the vehicle and drive away with the engine OFF.

The transaxle is required to permit the vehicle to operate in a silent drive away mode. If both the engine coolant and the transaxle fluid temperatures are greater than 43°C (110°F) when the driver requests the vehicle to start, the vehicle will enter run mode and can be driven with the engine off.

The engine will remain off until the driver shifts out of PARK and one or more of the following conditions are met

1. the vehicle speed is greater than 32 km/h (20 mph).
2. the distance traveled is greater than 50 m (150 ft).
3. the driver demanded power is greater than the lesser of either 8 kWh or the battery discharge limit existing during the silent driving event.

The engine may pull up at any time to facilitate the climate control function or to charge the high voltage battery.

Brake Shift Interlock System

The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the floor selector lever assembly. If the ignition switch is in the RUN position, the BSIA is continually on unless the brake pedal is depressed.

External Controls

The external control of the eCVT is mechanically controlled by a selector lever cable connected to the floor selector lever. The floor shifter position determines PARK, REVERSE, NEUTRAL, DRIVE and low modes.

Motor Electronics Cooling System (MECS)

The vehicle uses a pump driven cooling system (referred to as the Motor Electronics Cooling System (MECS)) to transfer heat generated by the eCVT and the Hybrid Electric Vehicle (HEV) battery pack to the atmosphere. The system uses a coolant-to-air radiator design.

The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional cooling systems, there is no thermostat in the MECS , so coolant flow should be continuous and considerably less than traditional powertrain cooling systems.

The flow direction is from the degas bottle and DC/DC converter to the MECS pump through the eCVT , then through the MECS radiator from the LH to RH side of the vehicle back to the degas bottle.

The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt. Flow can be verified by visually inspecting for coolant flow into the degas bottle. Only a portion of the coolant flow is diverted to the degas bottle via the "T" in the coolant outlet hose.

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ITEM DESCRIPTION

Diagnostics

Refer to the INTRODUCTION article.

Symptom Chart - NVH

Note. NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION & HARSHNESS article. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer to NOISE, VIBRATION & HARSHNESS article for the next likely system and continue diagnosis.

Symptom Chart - NVH

Transaxle Drive Cycle Test

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Note. The Transaxle Drive Cycle Test must be followed exactly.

Note. The Transaxle Drive Cycle Test can be used to help diagnose NVH concerns.

1. Warm engine to normal operating temperature.
2. Make sure transmission fluid level is correct.
3. While checking the transaxle for a noise or vibration, with the selector lever in P, quickly press the accelerator pedal to Wide Open Throttle (WOT), let off the accelerator pedal for 5 seconds. Repeat 2 times. Record any noise or vibration.
4. While checking the transaxle for a noise or vibration, with the selector lever in P, raise engine speed to 1,500 rpm and perform a tip in/out. Record any noise or vibration.
5. While checking the transaxle for a noise or vibration, with the selector lever in D, EV-Mode (engine off), drive the vehicle around. Record any noise or vibration.
6. While checking the transaxle for a noise or vibration, with the selector lever in D, drive the vehicle 0-72 km/h (0-45 mph), light acceleration. Record any noise or vibration.
7. While checking the transaxle for a noise or vibration, with the selector lever in D, drive the vehicle 0-72 km/h (0-45 mph), medium acceleration. Record any noise or vibration.
8. While checking the transaxle for a noise or vibration, with the selector lever in D, drive the vehicle 0-72 km/h (0-45 mph), hard acceleration. Record any noise or vibration.
9. While checking the transaxle for a noise or vibration, with the selector lever in D, drive the vehicle 64 km/h (40 mph), cruising speed, perform tip in/out. Record any noise or vibration.

Once the Transaxle Drive Cycle Test has been performed, GO to SYMPTOM CHART - NVH in this service information.

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Turn the ignition to the OFF position.
3. Remove the splash shield retainers and remove the LH splash shield.
4. Remove the drain plug and drain the transmission fluid.
5. Remove the fill plug on the side of the transaxle.
6. Install the drain plug. Tighten to 40 Nm (30 lb-ft).
7. Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the fill plug hole.
8. Install the fill plug. Tighten to 40 Nm (30 lb-ft).
9. Install the LH splash shield and the retainers.

Special Tool(s)

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Differential Seals RH and LH 307-665 Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A)

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Turn the ignition to the OFF position.
3. Remove the retainers and remove the LH splash shield.
4. Remove the drain plug and drain the transmission fluid.
5. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
6. Using the Slide Hammer and Input Shaft Oil Seal Remover, remove and discard the LH differential seal.

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1. Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Handle, install the LH differential seal.
2. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
3. Clean the drain plug threads and apply a small amount of thread sealant on the threads, install the drain plug. Tighten to 40 Nm (30 lb-ft).
4. Remove the fill plug on the side of the transaxle.
5. Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the fill plug hole.
6. Install the fill plug. Tighten to 40 Nm (30 lb-ft).
7. Start the engine and check for correct forward and reverse operation.

SPECIAL TOOLS Handle, Driver 32 in 205-907 Installer, Differential Seals RH and LH 307-665 Remover, RH Halfshaft Fluid Seal 307-429 Slide Hammer 100-001 (T50T-100-A)

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MATERIAL SPECIFICATIONS

Removal

All Vehicles

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Turn the ignition to the OFF position.
3. Remove the retainers and remove the LH splash shield.
4. Remove the drain plug and drain the transmission fluid. Front Wheel Drive (FWD)
5. Remove the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article. All-Wheel Drive (AWD)
6. Remove the Power Transfer Unit (PTU). For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/mercury/mariner/ii-2011-2011/remont/transfer-case/#power-transfer-unit-ptu) article. All Vehicles
7. Using the Slide Hammer and RH Halfshaft Fluid Seal Remover, remove and discard the RH differential seal.

Installation

All Vehicles

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1. Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Driver 32 Inch Handle, install the RH differential seal. AWD
2. Install the PTU . For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/mercury/mariner/ii-2011-2011/remont/transfer-case/#power-transfer-unit-ptu) article FWD
3. Install the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article. All Vehicles
4. Clean the drain plug threads and apply a small amount of thread sealant on the threads, install the drain plug. Tighten to 40 Nm (30 lb-ft).
5. Remove the fill plug on the side of the transaxle.
6. Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the fill plug hole.
7. Install the fill plug. Tighten to 40 Nm (30 lb-ft).
8. Start the engine and check for correct forward and reverse operation.

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ITEM DESCRIPTION

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1. Disable the high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
2. Remove the rear transmission insulator bracket. For additional information, refer to «TRANSAXLE SUPPORT INSULATOR - REAR»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#electronically-controlled-continuously-variable-transaxle-hybrid) in this service information.
3. Remove the wiring harness retainer and selector lever cable from the studs.
4. Remove the NVH shield stud. To install, tighten to 9 Nm (80 lb-in).
5. Remove the 2 transaxle harness electrical connector bracket bolts. To install, tighten to 9 Nm (80 lb-in).
6. Remove the stud bolt and disconnect the transaxle harness electrical connector. To install, tighten to 10 Nm (89 lb-in).
7. Remove the 2 nuts from the bottom of the NVH shield. To install, tighten to 9 Nm (80 lb-in).
8. Remove the NVH shield.
9. To install, reverse removal procedure.

SPECIAL TOOLS Adapters for 303-290A 303-290A-01 Adapter for 303-290A (Lifting Hook) 303-290A-12 Adapter for 313-290A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A

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ITEM DESCRIPTION

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1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-hybrid) article.
2. Install the Engine Support Bar, Support Leg Adapter, Engine Support Bar Adapter and Lifting Hook Adapter.
3. Remove the upper insulator bracket bolt, nut and the bracket. To install, tighten to 25 Nm (18 lb-ft).
4. Remove the upper insulator. Remove the upper insulator nuts. To install, tighten to 90 Nm (66 lb-ft). Remove the upper insulator through bolt. To install, tighten the bolt to 103 Nm (76 lb-ft).
5. To install, reverse the removal procedure.

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ITEM DESCRIPTION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Turn the ignition to the OFF position.
3. Remove the splash shield retainers and remove the LH splash shield.
4. Remove the bolts and the lateral support crossmember. To install, tighten to 115 Nm (85 lb-ft).
5. Remove the lower insulator through bolt. To install, tighten to 115 Nm (85 lb-ft).
6. Remove the rear roll restrictor-to-crossmember through bolt. To install, tighten to 90 Nm (66 lb-ft).
7. Remove and discard the engine support crossmember nut. Remove the 2 engine support crossmember bolts. To install, tighten the new engine support crossmember nut to 175 Nm (129 lb-ft). To install, tighten the 2 engine support crossmember bolts to 90 Nm (66 lb-ft).
8. Remove the engine support crossmember.
9. Remove the rear roll restrictor through bolt and remove the rear roll restrictor from the bracket. To install, tighten to 90 Nm (66 lb-ft).
10. To install, reverse the removal procedure.

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ITEM DESCRIPTION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Remove the rear insulator through bolt. To install, tighten to 115 Nm (85 lb-ft).
3. Remove the rear insulator nuts and bolt. To install, tighten to 80 Nm (59 lb-ft).
4. Remove the rear insulator studs. To install, tighten to 12 Nm (106 lb-in).
5. Remove the rear insulator.
6. If necessary, remove the 3 bolts and the transaxle rear support insulator bracket. To install, tighten to 80 Nm (59 lb-ft).
7. To install, reverse the removal procedure.

SPECIAL TOOLS 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Powertrain Lift 014-00765 or equivalent Remover, Tie-Rod End 211-105 (T85M-3395-A) Spreader Bar 303-D089 (D93P-6001-A3) (part of 303-DS086) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

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All vehicles

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING & BATTERY CABLES»(ref-434539) article.
4. Using a suitable holding device, hold the steering wheel in the straight-ahead position and put the ignition key in the OFF position.
5. Disable the vehicle high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article
6. Drain the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
7. Drain the Motor Electronics Cooling System (MECS). For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-cooler-hybrid) article.
8. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
9. Remove the engine Air Cleaner (ACL). For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-hybrid) article.
10. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
11. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
12. Remove the front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
13. Remove the bolts and the lateral support crossmember.
14. Remove the catalytic converter inlet pipe-to-converter nuts.
15. Remove the catalytic converter inlet pipe-to-catalytic manifold converter nuts and remove the pipe.
16. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
17. Disconnect the LH suspension. Remove the nut and disconnect the stabilizer bar link. Remove and discard the tie-rod end retaining nut.
18. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
19. Disconnect the RH suspension. Remove the nut and disconnect the stabilizer bar link. Remove and discard the tie-rod end retaining nut.
20. Using the Tie-Rod End Remover, disconnect the LH and RH tie-rod end from the steering knuckle.
21. Drain the transmission fluid. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#electronically-controlled-continuously-variable-transaxle-hybrid) in this service information.
22. Remove the front LH halfshaft and intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article. All-Wheel Drive (AWD) vehicles
23. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/mercury/mariner/ii-2011-2011/remont/driveshaft-universal-joints/#driveshaft) article.
24. Remove the catalytic converter bracket bolts.
25. Remove the bolts and the Power Transfer Unit (PTU)-to-engine bracket.
26. Remove the PTU heat shield bolts and the PTU heat shield.
27. Disconnect the PTU vent hose and position it aside.
28. Remove the PTU -to-transaxle bolts and remove the PTU . All vehicles
29. Disconnect the heater hoses from the heater core.
30. Disconnect the upper radiator hose from the radiator.
31. Disconnect the brake booster vacuum tube from the brake booster.
32. Disconnect the PCM center electrical connector. Remove the wiring harness retainer nut.
33. If equipped, disconnect the block heater electrical connector. Detach the harness retainer clips and position harness aside.
34. Disconnect the engine control harness electrical connector.
35. Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
36. Remove the selector lever cable fastener from the engine front cover stud bolt.
37. Remove the selector lever cable fastener from the A/C compressor mounting bracket.
38. Remove the stud bolt and disconnect the transaxle harness electrical connector.
39. Disconnect the low voltage electrical connectors and the engine harness-to-body harness retainer.
40. Disconnect the coolant vent hose.
41. Release the locking tab and disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers.
42. Remove the nuts and position the DC-to-DC converter aside.
43. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
44. Disconnect the transaxle coolant hoses.
45. Remove the bolts and the transaxle control snow shield.
46. Disconnect the selector lever cable. Release the selector lever cable from the manual control lever. Remove the nuts from the selector lever cable bracket.
47. Remove the harness fasteners, the nut and the ground cable.
48. Disconnect the vacuum pump assembly electrical connector and detach the harness retainer.
49. Remove the 2 bolts and position the MECS pump aside.
50. Remove the nut and disconnect the A/C tube from the A/C compressor. Discard the gasket.
51. Remove the nut and disconnect the A/C tube from the A/C compressor. Discard the gasket.
52. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
53. Disconnect the lower radiator hose from the radiator. Release the wire clip and disconnect the hose.
54. Remove the lower insulator through bolt.
55. Remove the rear roll restrictor-to-crossmember through bolt.
56. Remove the nut, bolts and the engine support crossmember. Discard the nut.
57. Remove the transaxle-to-engine bolts.
58. Remove the transaxle-to-engine bolts.
59. Remove the rear insulator through bolt.
60. Remove and discard the steering column coupling pinch bolt and separate the coupling from the steering gear.
61. Remove the rear roll restrictor bolts, the rear roll restrictor bracket and the rear roll restrictor.
62. Using the Powertrain Lift, support the subframe.
63. Loosen the 2 subframe bolts.
64. Remove the 2 subframe nuts and lower the subframe. Remove the subframe from the Powertrain Lift.
65. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the Powertrain Lift.
66. Remove the engine mount bracket bolt.
67. Remove the 3 nuts and the engine mount bracket.
68. Remove the upper insulator bracket bolt, nut and remove the bracket.
69. Remove the upper insulator through bolt.
70. Remove the upper insulator nuts.
71. Remove the upper insulator.
72. Lower the engine and transaxle from the vehicle.
73. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the Powertrain Lift.
74. Release the locking tab and disconnect the high voltage wiring harness electrical connector.
75. Remove the remaining engine-to-transaxle bolts and separate the engine and transaxle.
76. Tighten bolts to 90 Nm (66 lb-ft). Remove the bolts and the transaxle damper.

SPECIAL TOOLS 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001

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MATERIAL SPECIFICATIONS

All vehicles

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1. Install the transaxle damper. Tighten to 29 Nm (21 lb-ft).
2. Tighten to 90 Nm (66 lb-ft). Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Connect the high voltage wiring harness electrical connector.
4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift.
5. Using the Adjustable Grip Arm, secure the engine to the Powertrain Lift.
6. Raise the engine and transaxle into the vehicle.
7. Install the upper insulator. Tighten the nuts to 90 Nm (66 lb-ft). Tighten the through bolt to 103 Nm (76 lb-ft).
8. Install the upper insulator bracket. Tighten to 25 Nm (18 lb-ft).
9. Install the 3 engine mount bracket nuts. Tighten to 115 Nm (85 lb-ft).
10. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
11. Using the Powertrain Lift, raise the subframe into position.
12. Install the 2 subframe nuts. Tighten to 150 Nm (111 lb-ft).
13. Tighten the 2 subframe bolts. Tighten to 175 Nm (129 lb-ft).
14. Install the rear roll restrictor, bracket and bolts. Tighten to 90 Nm (66 lb-ft).
15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt. Tighten to 40 Nm (30 lb-ft).
16. Install the rear insulator through bolt. Tighten to 115 Nm (85 lb-ft).
17. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
18. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
19. Install the engine support crossmember. Tighten the 2 bolts to 90 Nm (66 lb-ft). Tighten the new nut to 175 Nm (129 lb-ft).
20. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 90 Nm (66 lb-ft).
21. Install the lower insulator through bolt. Tighten to 115 Nm (85 lb-ft).
22. Connect the lower radiator hose to the radiator. Install the retaining clip.
23. Install the auxiliary coolant pump. Install the 2 bolts. Tighten to 10 Nm (89 lb-in). Connect the electrical connector.
24. Install a new gasket and connect the A/C tube to the A/C compressor. Install the nut. Tighten to 15 Nm (133 lb-in).
25. Install a new gasket and connect the A/C tube to the A/C compressor. Install the nut. Tighten to 15 Nm (133 lb-in).
26. Position the MECS pump in place and install the 2 bolts. Tighten to 20 Nm (177 lb-in).
27. Connect the vacuum pump electrical connector and attach the harness retainer.
28. Install the wiring harness fasteners, the transaxle ground cable and nut. Tighten to 20 Nm (177 lb-in).
29. Attach the selector lever cable fastener to the engine front cover stud bolt.
30. Attach the selector lever cable fastener to the A/C compressor mounting bracket.
31. Connect the selector lever cable. Install the selector lever cable bracket and the 2 nuts finger-tight. Attach the selector lever cable to the manual control lever.
32. Position the control lever between the 2 casting ribs on the transaxle case.
33. Place the gear selector lever in the D position.
34. Tighten the selector lever cable bracket nuts to 23 Nm (17 lb-ft).
35. To verify the correct selector lever cable adjustment, observe the selector lever on the transaxle while an assistant moves the selector lever into each range position ending in the D position.
36. Install the transaxle control snow shield. Tighten to 22 Nm (16 lb-ft).
37. Connect the transaxle coolant hoses.
38. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
39. Position the DC-to-DC converter in place and install the 3 nuts. Tighten to 12 Nm (106 lb-in).
40. Connect the DC-to-DC converter electrical connector and 2 wire harness retainer (1 shown in illustration).
41. Connect the coolant vent hose.
42. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
43. Connect the transaxle harness electrical connector and install the stud bolt. Tighten to 10 Nm (89 lb-in).
44. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
45. Connect the engine control harness electrical connector.
46. If equipped, connect the block heater electrical connector. Attach the harness retainer clips.
47. Connect the PCM electrical connector. Position the harness and install the nut. Tighten to 6 Nm (53 lb-in).
48. Connect the brake booster vacuum hose to the brake booster.
49. Connect the upper radiator coolant hose.
50. Connect the heater hoses to the heater core. All-Wheel Drive (AWD) vehicles
51. Position the Power Transfer Unit (PTU) in place and install the 4 bolts. Tighten to 45 Nm (33 lb-ft).
52. Connect the PTU vent hose.
53. Install the PTU heat shield and the bolts. Tighten to 14 Nm (124 lb-in).
54. Position the PTU -to-engine support bracket and install the bolts. Tighten to 40 Nm (30 lb-ft).
55. Install the exhaust bracket bolts. Tighten to 25 Nm (18 lb-ft).
56. Install the driveshaft. For additional information, refer to «DRIVESHAFT»(/mercury/mariner/ii-2011-2011/remont/driveshaft-universal-joints/#driveshaft) . All vehicles
57. Install the LH halfshaft and intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
58. Connect the RH and LH suspension. Position the tie-rod end and install the new retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link and install the nut. Tighten to 63 Nm (46 lb-ft).
59. Install the RH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (133 lb-in).
60. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (133 lb-in).
61. Install the catalytic converter inlet pipe and install the nuts.
62. Remove the catalytic converter inlet pipe-to-converter nuts.
63. Install the lateral support crossmember and the bolts. Tighten to 115 Nm (85 lb-ft).
64. Install the front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
65. Connect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
66. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
67. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
68. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
69. Enable the vehicle high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
70. Remove the steering wheel holding device.
71. Reset the Passive Anti-Theft System (PATS). For additional information, refer to «ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) - HYBRID»(/mercury/mariner/ii-2011-2011/remont/door-locks-anti-theft-systems/#anti-theft-passive-anti-theft-system-pats-hybrid) article.
72. Fill and bleed the Motor Electronics Cooling System (MECS). For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-cooler-hybrid) article.
73. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
74. Fill the transaxle. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#electronically-controlled-continuously-variable-transaxle-hybrid) in this service information.

See also:
• INTRODUCTION
• NOISE, VIBRATION & HARSHNESS
• AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - HYBRID
• JACKING & LIFTING
• FRONT DRIVE HALFSHAFTS
• TRANSFER CASE - POWER TRANSFER UNIT (PTU)
• HIGH VOLTAGE TRACTION BATTERY
• INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID
• FUEL SYSTEM - GENERAL INFORMATION
• ENGINE COOLING - HYBRID
• TRANSAXLE/TRANSMISSION COOLING - HYBRID
• ACCESSORY DRIVE - HYBRID
• TIRES & WHEELS
• DRIVESHAFT
• ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) - HYBRID
• TRANSAXLE SUPPORT INSULATOR - UPPER
• SYMPTOM CHART - NVH