Engine Mechanical - 2.5l (except Hybrid) Mercury Mariner II рестайлинг

Material

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

The 2.5L (153 CID) 4-cylinder engine has the following features

1. Dual overhead camshaft
2. Four valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder head
5. Aluminum cylinder block
6. Electronic ignition system with coil-on-plug 4 ignition coils

The 2.5L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same sprocket that drives the timing chain.

Engine Identification

Always refer to these labels when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Catalog Advantage™ or equivalent contains a complete listing of the codes and their applications.

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

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ITEMS DESCRIPTION CHART

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Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. are connected in series with the fuel pressure sensor.
5. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

Lubrication System

The engine lubrication system operates as follows

1. Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
2. Oil is pumped through the oil filter on the left front side of the cylinder block.
3. Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.
4. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.

Refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article for basic mechanical concerns or refer to the INTRODUCTION article for driveability concerns.

Scheme 3

1. Remove the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
2. Remove the 5 bolts, the pin-type retainer (not shown in illustration) and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Use a feeler gauge to measure the clearance of each valve and record its location.
4. The acceptable clearances after being fully installed are: intake: 0.22-0.28 mm (0.008-0.011 in). exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) and Valve Tappets in this service information.

Special Tool(s)

SPECIAL TOOLS DESCRIPTION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Timing Peg, Crankshaft TDC 303-507

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1. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .
3. Remove the 4 bolts and the balancer unit.
4. Remove the adjustment shims from the seat faces of the balancer unit.
5. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
7. Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft).
8. Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
9. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg.
10. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
11. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit.
12. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
13. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
14. Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft).
15. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.

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INTAKE MANIFOLD PARTS DESCRIPTION CHART

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INTAKE MANIFOLD PARTS DESCRIPTION CHART

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1. With 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 fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-charging-system-fuel-control-system-25l-except-hybrid) article.
3. Disconnect the vacuum supply hose. Depress the quick release locking ring. Pull the vacuum hose out of the quick release fitting.
4. Disconnect the fuel vapor return hose from the intake manifold.
5. Disconnect the Manifold Absolute Pressure (MAP) electrical connector.
6. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
7. Disconnect the electronic throttle control electrical connector.
8. Disconnect the Knock Sensor (KS) electrical connector. Detach the wire harness pin-type retainer.
9. Detach the heater hose pin-type retainer.
10. Detach all wiring harness pin-type retainers from the intake manifold and position the wiring harness aside.
11. Loosen the clamp and disconnect Air Cleaner (ACL) outlet pipe from the Throttle Body (TB). To install, tighten to 4 Nm (35 lb-in).
12. Remove the intake manifold lower bolt. To install, tighten to 18 Nm (159 lb-in).
13. Remove the 6 bolts and position the intake manifold aside to access the crankcase vent oil separator tube and the EGR tube. To install, tighten to 18 Nm (159 lb-in).
14. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
15. Remove the EGR tube. To install, tighten to 55 Nm (41 lb-ft).
16. Remove the intake manifold and gaskets.
17. To install, reverse the removal procedure.

1. Inspect and install new intake manifold gaskets if necessary.

MATERIAL SPECIFICATIONS

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VALVE COVER PARTS DESCRIPTION CHART

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VALVE COVER PARTS DESCRIPTION CHART

Removal

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Remove the oil level indicator.
2. Remove the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
3. Disconnect the crankcase vent hose.
4. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
5. Disconnect the Camshaft Position (CMP) sensor electrical connector.
6. Disconnect the radio capacitor electrical connector.
7. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
8. Detach all of the wiring harness retainers from the valve cover studs and position the harness aside.
9. Remove the 14 valve cover retainers, the valve cover and gasket.

Installation

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown in illustration.
3. Install the valve cover, gasket and retainers. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
4. Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs.
5. Connect the VCT solenoid electrical connector.
6. Connect the radio capacitor electrical connector.
7. Connect the CMP sensor electrical connector.
8. Connect the CHT sensor electrical connector.
9. Connect the crankcase vent hose.
10. Install the ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
11. Install the oil level indicator.

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PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedures in this service information.

SPECIAL TOOLS DESCRIPTION Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Timing Peg, Crankshaft TDC 303-507 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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General Equipment

GENERAL EQUIPMENT REFERENCE CHART

MATERIAL SPECIFICATIONS

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Scheme 23

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 front RH wheel and tire. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.

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1. Install a new diamond washer.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2- in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Remove the 6 mm x 18 mm bolt.
6. Remove the Crankshaft TDC Timing Peg.
7. Remove the Camshaft Alignment Plate.
8. Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft TDC Timing Peg.
10. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
13. Remove the Camshaft Alignment Plate.
14. Remove the 6 mm x 18 mm bolt.
15. Remove the Crankshaft TDC Timing Peg.
16. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
17. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
18. Install the front RH wheel and tire. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
19. Install the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
20. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

SPECIAL TOOLS DESCRIPTION Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

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MATERIAL SPECIFICATIONS

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Remove the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT FRONT SEAL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) and «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
2. Using the Oil Seal Remover, remove the crankshaft front oil seal.

1. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT FRONT SEAL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) and «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.

Scheme 35

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedures in this service information.

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 automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-6f35-except-hybrid) article.
3. Remove the 6 bolts and the flexplate.

1. Install the flexplate and tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-6f35-except-hybrid) article.

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 manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-434558) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-434548) article.
3. Remove the 6 bolts and the flywheel.

1. Install the flywheel and tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
2. Install the clutch and manual transaxle. For additional information, refer to «CLUTCH»(ref-434558) article and «MANUAL TRANSAXLE/TRANSMISSION»(ref-434548) article.

SPECIAL TOOLS DESCRIPTION Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

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MATERIAL SPECIFICATIONS

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 flexplate or flywheel. For additional information, refer to «FLEXPLATE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) or «FLYWHEEL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
4. Remove the 17 bolts and the oil pan.
5. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.

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1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear oil seal with retainer plate and bolts. To install, tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan and cylinder block mating surfaces.
4. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
5. Install the 4 bolts. To install, tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
7. Install the flexplate or flywheel. For additional information, refer to «FLEXPLATE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) or «FLYWHEEL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
8. Fill the engine with clean engine oil.

SPECIAL TOOLS DESCRIPTION Aligner, Crankshaft Sensor 303-1417 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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GENERAL EQUIPMENT REFERENCE CHART

MATERIAL SPECIFICATIONS

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ENGINE FRONT COVER PARTS DESCRIPTION CHART

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Scheme 45

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 accessory drive belt and the smooth idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
3. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
4. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
5. Using the Oil Seal Remover, remove the crankshaft front oil seal.
6. Remove the 3 bolts and the coolant pump pulley.
7. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.
8. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
9. Remove and the 2 bolts and the CKP sensor.
10. Remove the bolts, stud bolt and the engine front cover.

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1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following specifications: Tighten the 8-mm bolts and stud bolt to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
4. Install the accessory drive belt idler pulley and bracket and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
5. Install the coolant pump pulley and bolts. Tighten to 20 Nm (177 lb-in).
6. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
7. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
8. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
9. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
10. Install the CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
11. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
12. Connect the CKP sensor electrical connector.
13. Remove the 6 mm x 18 mm bolt.
14. Install the accessory drive belt and smooth idler pulley. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
15. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

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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 engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. Compress the timing chain tensioner in the following sequence. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert the paper clip into the hole to retain the tensioner.
4. Remove the 2 bolts and timing chain tensioner.
5. Remove the timing chain tensioner arm.
6. Remove the timing chain.
7. Remove the 2 bolts and the timing chain guide.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
9. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the timing chain guide and the 2 bolts. To install, tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the timing chain tensioner arm. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
5. Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.
7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
9. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
10. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
11. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.

Scheme 63

VCT SYSTEM PARTS DESCRIPTION CHART

Removal and Installation

1. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.
2. Remove the VCT system oil filter plug and the VCT system oil filter from the intake camshaft thrust cap. To install, tighten to 17 Nm (150 lb-in).
3. To install, reverse the removal procedure.

SPECIAL TOOLS DESCRIPTION Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Scheme 64

GENERAL EQUIPMENT REFERENCE CHART

MATERIAL SPECIFICATIONS

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Note. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

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 accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
3. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.
4. Remove the front RH wheel and tire. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
5. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
7. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. Install the Crankshaft TDC Timing Peg.
10. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
11. Remove the lower front cover timing hole plug from the engine front cover.
12. Remove the upper front cover timing hole plug from the engine front cover.
13. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
14. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert an M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
15. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
16. Remove the Camshaft Alignment Plate.
17. Remove the timing chain from the intake camshaft drive gear.
18. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
19. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
20. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the intake camshaft drive gear.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper front cover timing hole plug. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug. Install the plug and tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the accessory drivebelt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
15. Install the front RH wheel and tire. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
16. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.

SPECIAL TOOLS DESCRIPTION Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Scheme 82

Scheme 83

GENERAL EQUIPMENT REFERENCE CHART

MATERIAL SPECIFICATIONS

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Note. Do not rotate the camshafts or crankshaft unless instructed to do so in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons.

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

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 accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
3. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.
4. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
10. Remove the lower timing hole plug from the engine front cover.
11. Remove the upper timing hole plug from the engine front cover.
12. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
13. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert the M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
14. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.
15. Remove the Camshaft Alignment Plate.
16. Remove the timing chain from the intake camshaft drive gear.
17. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
18. Remove the intake camshaft from the engine. Loosen the intake camshaft bearing cap bolts, in the sequence shown in illustration, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the intake camshaft.
19. Mark the camshaft phaser and sprocket and the camshaft for reference during installation.
20. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

1. Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
2. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the intake camshaft bearing cap bolts until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
3. Install the Camshaft Alignment Plate.
4. Install the timing chain on the intake camshaft drive gear.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the upper timing hole plug in the engine front cover. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
15. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.

Scheme 100

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedures in this service information.

SPECIAL TOOLS DESCRIPTION Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 101

Scheme 102

Scheme 103

MATERIAL SPECIFICATIONS

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

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 camshafts. For additional information, refer to «CAMSHAFTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
5. Connect the compressed air supply to cylinder No. 1.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «CAMSHAFTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.

SPECIAL TOOLS DESCRIPTION Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

MATERIAL SPECIFICATIONS

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Scheme 110

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 camshafts. For additional information, refer to «CAMSHAFTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
5. Connect the compressed air supply to cylinder No. 1.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.

Scheme 111

Scheme 112

1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 2.5L»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-25l) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.

MATERIAL SPECIFICATIONS

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.

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 camshafts. For additional information, refer to «CAMSHAFTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

SPECIAL TOOLS DESCRIPTION Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Scheme 113

MATERIAL SPECIFICATIONS

Scheme 114

CYLINDER HEAD PARTS DESCRIPTION CHART

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Scheme 115

Scheme 116

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. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
4. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.
5. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
6. Remove the Camshaft Alignment Plate.
7. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
8. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts and the camshaft bearing caps. Remove the camshafts.
9. Remove the valve tappets.
10. Inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
11. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
12. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(/mercury/mariner/ii-2011-2011/remont/charging-system/#charging-system) article.
13. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
14. Disconnect the EGR valve electrical connector.
15. Disconnect the EGR coolant hose from the EGR valve.
16. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
17. Remove the 10 bolts and the cylinder head.

1. Discard the bolts and the cylinder head gasket.

Scheme 117

Scheme 118

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
4. Apply silicone gasket and sealant to the locations shown in illustration.
5. Install a new head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
8. Connect the EGR coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
11. Install the generator. For additional information, refer to «CHARGING SYSTEM»(/mercury/mariner/ii-2011-2011/remont/charging-system/#charging-system) article.
12. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
13. Install the valve tappets in their original positions.
14. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
15. Install the Camshaft Alignment Plate.
16. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
17. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-25l-except-hybrid) article.
18. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.

Scheme 119

PARTS DESCRIPTION CHART

Oil Pan, Oil Pump Screen and Pickup Tube, Front Wheel Drive (FWD) Vehicles

Note. Automatic transmission shown in illustration, manual transmission similar.

Scheme 120

PARTS DESCRIPTION CHART

Scheme 121

PARTS DESCRIPTION CHART

Scheme 122

PARTS DESCRIPTION CHART

Scheme 123

PARTS DESCRIPTION CHART

1. For additional information, refer to the procedures in this service information.

MATERIAL SPECIFICATIONS

Scheme 124

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 5 bolts, the pin-type retainer (not shown in illustration) and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the spin-on oil filter. To install, lubricate the spin-on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
5. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
6. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 125

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 5 bolts, pin-type retainer (not shown in illustration) and the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
5. To install, reverse the removal procedure.

1. Apply thread sealant to the EOP switch threads.

MATERIAL SPECIFICATIONS

All vehicles

Scheme 126

Scheme 127

Scheme 128

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 Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
3. Loosen the 2 upper bellhousing-to-engine bolts 5 mm (0.19 in). All-Wheel Drive (AWD) vehicles
4. Working from the top of the vehicle, loosen the 2 RH engine-to-bellhousing bolts 5 mm (0.19 in).
5. Working from under the vehicle, loosen the 2 RH engine bracket-to-Power Transfer Unit (PTU) bolts 5 mm (0.19 in). All vehicles
6. Remove the 7 retainers (5 shown in illustration) and the LH splash shield.
7. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in). Front Wheel Drive (FWD) vehicles
8. Loosen the 1 (manual transaxle) or 2 (automatic transaxle) RH engine-to-bellhousing bolt 5 mm (0.19 in). All vehicles
9. Remove the 2 oil pan-to-bellhousing bolts.
10. Remove the 2 bellhousing-to-oil pan bolts.
11. Slide the transaxle rearward 5 mm (0.19 in).
12. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
13. Remove the 4 engine front cover-to-oil pan bolts.
14. Remove the 13 bolts and the oil pan.

All vehicles

Scheme 129

Scheme 130

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft). FWD vehicles
6. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing bolts to slide the transaxle and engine together. Tighten to 48 Nm (35 lb-ft).
7. Tighten the 1 remaining LH bellhousing-to-engine bolt. Tighten to 48 Nm (35 lb-ft).
8. Tighten the 1 remaining RH engine-to-bellhousing bolt (automatic transaxle). Tighten to 48 Nm (35 lb-ft). AWD vehicles
9. Alternate tightening the 1 RH engine-to- PTU bracket bolt and 1 LH bellhousing-to-engine bolt to slide transaxle and engine together. Tighten the PTU bracket bolt to 45 Nm (33 lb-ft). Tighten the LH bellhousing bolt to 48 Nm (35 lb-ft).
10. Tighten the remaining RH engine-to- PTU bracket bolt. Tighten to 45 Nm (33 lb-ft).
11. Tighten the 1 remaining LH lower bolt. Tighten to 48 Nm (35 lb-ft). All vehicles
12. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
14. Install the LH splash shield and the 7 retainers (5 shown in illustration). Tighten to 9 Nm (80 lb-in). AWD vehicles
15. Working from the top of vehicle, tighten the 2 RH engine-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft). All vehicles
16. Tighten the 2 upper bellhousing-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
17. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
18. Fill the engine with clean engine oil.

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 oil pan. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) and Oil Pan in this service information.
3. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 131

1. With the engine 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 engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
3. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 4 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.
6. Remove the 2 bolts and the oil pump screen and pickup tube. To install, tighten to 10 Nm (89 lb-in).
7. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the 2 shoulder bolts and the tensioner.
8. Remove the chain from the oil pump sprocket.
9. Remove the bolt and oil pump sprocket.
10. Remove the 4 bolts and the oil pump.

Scheme 132

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Scheme 135

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Clean all mating surfaces with metal surface prep.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
11. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
13. Fill the engine with clean engine oil.

Scheme 136

EXHAUST MANIFOLD PARTS DESCRIPTION CHART

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 exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
4. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
5. Remove and discard the 7 exhaust manifold nuts.
6. Remove the exhaust manifold and discard the exhaust manifold gasket.
7. Remove and discard the 7 exhaust manifold studs.
8. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.

1. Install the 7 new exhaust manifold studs. Tighten to 17 Nm (150 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 48 Nm (35 lb-ft). Stage 2: Tighten to 48 Nm (35 lb-ft).
3. Install the exhaust manifold heat shield and the 4 bolts. Tighten to 10 Nm (89 lb-in).
4. Connect the HO2S electrical connector.
5. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.

SPECIAL TOOLS DESCRIPTION Support Bar, Engine 303-F072

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ENGINE MOUNT PARTS DESCRIPTION CHART

Scheme 139

Scheme 140

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. Install the Engine Support Bar.
3. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
4. Use the Engine Support Bar to raise the engine 25 mm (0.98 in).
5. Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 Nm (85 lb-ft).
6. Remove the 3 bolts and the engine mount. To install, tighten to 48 Nm (35 lb-ft).
7. To install, reverse the removal procedure.

SPECIAL TOOLS DESCRIPTION Disconnect Tool, Transmission Cooler Line 307-569 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Powertrain Lift 014-00765 or equivalent Remover, Halfshaft Oil Seal 308-428 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) 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 engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
4. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
5. Drain the engine oil. Install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
6. Remove the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
8. Remove the bolts and the lateral support crossmember.
9. Remove the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
10. Remove the 2 intermediate shaft bearing retainer nuts.
11. Remove the intermediate shaft.
12. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
13. Press the locking tab to release the generator air duct and remove.
14. Remove the drain plug and drain the transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-6f35-except-hybrid) article. All-Wheel Drive (AWD) vehicles
15. Drain 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.
16. Index-mark the driveshaft to the yoke and remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire. All vehicles
17. If equipped, remove the bolt and ground eyelet.
18. Disconnect the transaxle electrical connector.
19. Detach the wiring harness retainer from the transaxle stud bolt.
20. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
21. Remove the 2 secondary latches from the transaxle fluid cooler tubes.
22. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown in illustration).
23. Remove the Power Distribution Box (PDB) cover.
24. Remove the nut and disconnect the cable from the PDB .
25. Disconnect the electrical connector from the PDB .
26. Remove the bolt and the ground strap.
27. Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.
28. Disconnect the shift cable from the transaxle manual lever.
29. Pinch the 2 tabs and remove the transmission shift cable from the bracket.
30. Detach the shift cable pin-type retainer and position the shift cable aside.
31. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
32. Disconnect the upper radiator hose.
33. Detach the heater hose support strap from the stud.
34. Disconnect the heater hoses from the heater core.
35. Disconnect the vacuum supply tube and position aside.
36. Disconnect the fuel vapor return tube. Detach the fuel vapor tube retainer from the wire harness.
37. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
38. Disconnect the PCM electrical connector and the wire harness retainer.
39. Disconnect the engine control harness electrical connector.
40. Disconnect the generator electrical connector and the 2 retainers.
41. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire. Detach the wire harness retainer.
42. Disconnect the lower radiator hose from the radiator.
43. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
44. Remove the rear nut and the engine support crossmember. Discard the nut.
45. If equipped, remove the 3 bolts and the dampener.
46. Remove the 2 transaxle-to-engine bolts.
47. Remove the 2 transaxle-to-engine bolts. AWD vehicles
48. Remove the 4 PTU bracket-to-engine bolts.
49. Remove the PTU bracket-to-engine bolt.
50. Remove the 2 PTU bracket-to- PTU bolts and remove the bracket. All vehicles
51. Remove the spin-on engine oil filter.
52. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
53. Remove the engine mount bracket bolt.
54. Remove the 3 nuts and the engine mount bracket.
55. Remove the bolt from the transaxle rear mount and the mass damper (if equipped).
56. Remove the bolt from the LH transaxle mount.
57. Lower the engine and transaxle from the vehicle.
58. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
59. Remove the nut and the ground wire.
60. Remove the 2 stud bolts and remove the starter.
61. Remove the starter motor isolator. AWD vehicles
62. Detach the PTU vent hose retainer.
63. Remove the LH lower PTU bolt.
64. Remove the 3 RH PTU bolts and the PTU .
65. Remove the 3 bolts and the PTU heat shield.
66. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles
67. Remove and discard the 4 torque converter nuts.
68. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
69. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.

SPECIAL TOOLS DESCRIPTION 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 or equivalent

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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 engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
4. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
5. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
6. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
8. Remove the 4 bolts and the lateral support crossmember.
9. Remove the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
10. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
11. Press the locking tabs to release the generator air duct and remove.
12. If equipped, remove the bolt and ground eyelet.
13. Remove the Power Distribution Box (PDB) cover.
14. Remove the nut and disconnect the cable from the PDB .
15. Disconnect the electrical connector from the PDB .
16. Remove the bolt and the ground strap.
17. Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.
18. Position the clutch hydraulic line aside. Remove the clutch hydraulic line bracket-to-transaxle bolt. Disconnect the clutch hydraulic line from the clutch slave cylinder. Plug the hydraulic line. Position the clutch hydraulic line aside.
19. Disconnect the Vehicle Speed Sensor (VSS) electrical connector and the 2 pin-type retainers.
20. Detach the 2 wiring harness retainers and disconnect the reversing lamp indicator switch electrical connector.
21. Disconnect the shift cables.
22. Remove the 3 shift cable bracket bolts. Position the bracket aside.
23. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
24. Disconnect the upper radiator hose.
25. Detach the heater hose support strap from the stud.
26. Disconnect the heater hoses from the heater core.
27. Disconnect the vacuum supply tube and position aside.
28. Disconnect the fuel vapor return tube. Detach the fuel vapor tube retainer from the wire harness.
29. 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.
30. Disconnect the PCM electrical connector and the wire harness retainer.
31. Disconnect the engine control harness electrical connector.
32. Disconnect the generator electrical connector and the 2 retainers.
33. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
34. Disconnect the lower radiator hose from the radiator.
35. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
36. Remove the rear nut and the engine support crossmember. Discard the nut.
37. Remove the 2 transaxle-to-engine bolts.
38. Remove the 2 engine-to-transaxle bolts.
39. Remove the spin-on engine oil filter.
40. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
41. Remove the engine mount bracket bolt.
42. Remove the nuts and the engine mount bracket.
43. Remove the bolt from the transaxle rear mount.
44. Remove bolt from the LH transaxle mount.
45. Lower the engine and transaxle from the vehicle.
46. Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
47. Remove the nut and the ground wire.
48. Remove the 2 stud bolts and remove the starter.
49. Remove the starter motor isolator.
50. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
51. Remove the remaining 5 engine-to-transaxle bolts and separate the engine and transaxle.

SPECIAL TOOLS DESCRIPTION Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-00232 or equivalent Holding Tool, Crankshaft Damper 303-1416 Installer, Connecting Rod 303-462 (T94P-6136-AH) Remover, Oil Seal 303-409 (T92C-6700-CH) Timing Peg, Crankshaft TDC 303-507

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Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Note. For additional information, refer to the exploded views under the Engine ASSEMBLY procedure in this service information.

Vehicles with manual transaxle

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1. Remove the bolts, clutch pressure plate and clutch disc.
2. Remove the bolts and the flywheel. Vehicles with automatic transaxle
3. Remove the bolts and the flexplate. All vehicles
4. Mount the engine on a suitable stand.
5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Detach the wiring harness-to-engine retainer.
6. Disconnect the generator electrical connection and the 2 wiring harness retainers.
7. Remove the nut and the generator wiring harness.
8. Remove the 2 nuts, 1 bolt and the generator.
9. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
10. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
11. Remove and discard the 7 exhaust manifold nuts.
12. Remove the exhaust manifold and discard the exhaust manifold gasket.
13. Remove and discard the 7 exhaust manifold studs.
14. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
15. Remove the 2 bolts and the accessory drive belt tensioner.
16. Loosen the bolt and remove the accessory drive belt idler pulley.
17. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.
18. Remove the 3 bolts and the coolant pump pulley.
19. Remove the bolts and the coolant pump.
20. Remove the 3 bolts and the thermostat housing assembly.
21. Remove the coolant tube retainer from the intake manifold.
22. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
23. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
24. If equipped, remove the bolt and capacitor.
25. Disconnect the Variable Camshaft Timing (VCT) electrical connector.
26. Detach the wiring harness retainers from the RH side valve cover stud bolts.
27. Disconnect the crankcase vent hose from the valve cover.
28. Detach the wiring harness retainers from the LH side valve cover stud bolts.
29. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
30. Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.
31. Disconnect the EGR valve electrical connector.
32. Disconnect the Knock Sensor (KS) and detach the 2 wiring harness retainers.
33. Detach all the wiring harness retainers from the intake manifold.
34. Disconnect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.
35. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
36. Disconnect the radio capacitor electrical connector.
37. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers and remove the wiring harness assembly.
38. Remove the fuel rail insulator.
39. Remove the nut and the radio capacitor.
40. Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.
41. Remove the 8 bolts (3 shown in illustration) and position the intake manifold aside.
42. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
43. Remove the EGR tube.
44. Disconnect the coolant hose.
45. Disconnect and remove the coolant hose.
46. Disconnect and remove 2 the coolant hoses.
47. Remove the bolt and the KS .
48. Remove the 8 bolts and the crankcase vent oil separator.
49. If equipped, remove the block heater.
50. Remove the oil level indicator.
51. Remove the 4 bolts and the 4 coil-on-plugs.
52. Remove the 12 retainers and the valve cover.
53. Remove the bolts and the CKP sensor.
54. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
55. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
56. Remove the engine plug bolt.
57. Install the Crankshaft TDC Timing Peg.
58. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
59. Using the Oil Seal Remover, remove the crankshaft front oil seal.
60. Remove the 22 bolts and the engine front cover.
61. Compress the timing chain tensioner in the following sequence. Using a small pick, release the hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a paper clip into the hole to retain the tensioner.
62. Remove the 2 bolts and timing chain tensioner.
63. Remove the RH timing chain guide.
64. Remove the timing chain.
65. Remove the bolts and the LH timing chain guide.
66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
67. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.
68. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
69. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
70. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
71. Remove the bolt and the VCT solenoid.
72. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
73. Remove the camshafts from the engine. Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.
74. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
75. Remove the cylinder head. Remove and discard the cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
76. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
77. Remove the cylinder head alignment dowels.
78. Remove the bolts and the oil pan.
79. Remove the bolts and the rear crankshaft seal.
80. Remove the bolts, oil pump pickup tube and gasket. Discard the gasket.
81. Remove the bolts and the oil pump.
82. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
83. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC .
84. Remove the 4 bolts and the balancer unit.
85. Remove the Crankshaft TDC Timing Peg.
86. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
87. Remove the connecting rod cap bolts and cap.
88. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
89. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
90. Remove the bolts in the sequence shown in illustration. Remove the main bearing beam. Discard the bolts.
91. Remove the crankshaft from the engine block.
92. Remove the main bearings from the main bearing beam.
93. Remove the main bearings from the cylinder block.
94. Remove the 4 oil squirters.
95. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.

SPECIAL TOOLS DESCRIPTION Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS

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CYLINDER HEAD PARTS DESCRIPTION CHART

Disassembly

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations.

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1. Remove the 4 bolts and the coolant outlet. Discard the gasket.
2. Remove the 2 bolts and the EGR valve. Discard the gasket.
3. Remove the Cylinder Head Temperature (CHT) sensor.
4. Remove the spark plugs.
5. Using the Valve Spring Compressors, compress the valve springs and remove the valve collets, valve spring retainers and the valve springs.
6. Inspect the components, if necessary. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.
7. Remove the valves.
8. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seals.
9. Inspect the valves. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article. Install new parts, as necessary.

Assembly

1. Install the valves.
2. Lubricate the valve stems and guides with clean engine oil. Using the Valve Stem Oil Seal Installer, install the valve seals.
3. Using the Valve Spring Compressors, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets, using multi-purpose grease and a small screwdriver.
4. Install the spark plugs. Tighten to 12 Nm (106 lb-in).
5. Install the CHT sensor. Tighten to 12 Nm (106 lb-in).
6. Using a new gasket, install the EGR valve and 2 bolts Tighten to 20 Nm (177 lb-in).
7. Using a new gasket, install the coolant outlet and 4 bolts.

1. Tighten to 10 Nm (89 lb-in).

MATERIAL SPECIFICATIONS

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PISTON PARTS DESCRIPTION CHART

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
3. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.

1. Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston as shown in illustration. Piston pin Upper oil control ring gap location Lower oil control ring gap location Center line of the piston pin bore and the expander gap

SPECIAL TOOLS DESCRIPTION Aligner, Crankshaft Sensor 303-1417 Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Holding Tool, Crankshaft Damper 303-1416 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Connecting Rod 303-462 (T94P-6136-AH) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

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GENERAL EQUIPMENT REFERENCE CHART

MATERIAL SPECIFICATIONS

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LOWER ENGINE BLOCK PARTS DESCRIPTION CHART

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LOWER ENGINE BLOCK PARTS DESCRIPTION CHART

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FRONT ENGINE BLOCK PARTS DESCRIPTION CHART

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CYLINDER HEAD PARTS DESCRIPTION CHART

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INTAKE MANIFOLD PARTS DESCRIPTION CHART

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage may occur.

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article.

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1. Install the 4 oil squirters. Tighten to 4 Nm (35 lb-in).
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Install and tighten the 10 new main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.
20. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
22. Install the adjustment shims in their original positions on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
24. Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft).
25. Remove the Crankshaft TDC Timing Peg.
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg.
28. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to «BALANCE SHAFT BACKLASH»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-except-hybrid) in this service information.
29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
30. Install the Crankshaft TDC Timing Peg.
31. Install the oil pump assembly. Tighten the bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
32. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
33. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
34. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
35. Clean and inspect all mating surfaces.
36. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
37. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
38. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
39. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
40. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
41. Apply silicone gasket and sealant to the locations shown in illustration.
42. Install a new head gasket.
43. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
44. Install the valve tappets.
45. Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
46. Install the Variable Camshaft Timing (VCT) system oil filter and the plug in the intake camshaft thrust cap. Tighten to 17 Nm (150 lb-in).
47. Install the VCT solenoid and the bolt. Tighten to 10 Nm (89 lb-in).
48. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
49. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
50. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
51. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
52. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
54. Install the LH timing chain guide and the bolts. Tighten to 10 Nm (89 lb-in).
55. Install the timing chain.
56. Install the RH timing chain guide. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
57. Using the edge of a vise, compress the timing chain tensioner plunger.
58. Using a small pick, push back and hold the ratchet mechanism.
59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
61. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
63. Clean and inspect the mounting surfaces of the engine and the front cover.
64. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
65. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
66. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
68. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
69. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
70. Remove the 6 mm x 18 mm bolt.
71. Remove the Crankshaft TDC Timing Peg.
72. Remove the Camshaft Alignment Plate.
73. Turn the crankshaft clockwise one and three-fourths turns.
74. Install the Crankshaft TDC Timing Peg.
75. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
76. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
77. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
78. Remove the Camshaft Alignment Plate.
79. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
80. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in).
81. Remove the 6 mm x 18 mm bolt.
82. Remove the Crankshaft TDC Timing Peg.
83. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
84. Clean the valve cover gasket surface with metal surface cleaner.
85. Apply silicone gasket and sealant to the locations shown in illustration.
86. Install the valve cover. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
87. Install the 4 coil-on-plugs and the 4 bolts. Tighten to 8 Nm (71 lb-in).
88. Install the oil level indicator.
89. If equipped, install the block heater. Tighten to 40 Nm (30 lb-ft).
90. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
91. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
92. Install the 2 coolant hoses.
93. Install the coolant hose.
94. Install the coolant hose.
95. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
96. Position the intake manifold and connect the crankcase vent oil separator tube.
97. Install the intake manifold gaskets, intake manifold and the 8 bolts. Tighten to 18 Nm (159 lb-in).
98. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
99. Install the fuel rail with the fuel injectors as an assembly and the 2 stud bolts. Tighten to 23 Nm (17 lb-ft).
100. Install the radio capacitor and nut. Tighten to 10 Nm (89 lb-in).
101. Install the fuel rail insulator.
102. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
103. Connect the radio capacitor electrical connector.
104. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
105. Connect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.
106. Attach all wiring harness retainers to the intake manifold.
107. Connect the KS and attach the 2 wiring harness retainers.
108. Connect the EGR valve electrical connector.
109. Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.
110. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
111. Attach the wiring harness retainers to the LH side valve cover stud bolts.
112. Connect the crankcase vent hose to the valve cover.
113. Attach the wiring harness retainers to the RH side valve cover stud bolts.
114. Connect the VCT electrical connector.
115. If removed, install the capacitor and bolt. Tighten to 20 Nm (177 lb-in).
116. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
117. Connect the Engine Oil Pressure (EOP) switch electrical connector.
118. Install the coolant tube retainer to the intake manifold.
119. Install the thermostat housing and bolts. Tighten to 10 Nm (89 lb-in).
120. Install the coolant pump and bolts. Tighten to 10 Nm (89 lb-in).
121. Install the 3 coolant pump pulley and bolts. Tighten to 20 Nm (177 lb-in).
122. Install the accessory drive belt idler pulley and bracket and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
123. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
124. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
125. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 Nm (150 lb-in).
126. Install the new exhaust manifold gasket on the engine.
127. Position the exhaust manifold and tighten the 7 new exhaust manifold nuts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 48 Nm (35 lb-ft). Stage 2: Tighten to 48 Nm (35 lb-ft).
128. Install the exhaust manifold heat shield and the 4 bolts. Tighten to 10 Nm (89 lb-in).
129. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
130. Install the generator, 2 nuts and 1 bolt. Tighten to 47 Nm (35 lb-ft).
131. Connect the generator electrical connection and install the nut. Tighten to 6 Nm (53 lb-in).
132. Connect the generator electrical connection and attach the 2 wiring harness retainers.
133. Connect the CKP sensor electrical connector. Attach the wiring harness-to-engine retainer.
134. Using the Floor Crane and Spreader Bar, remove the engine from the engine stand. Vehicles with automatic transaxle
135. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft). Vehicles with manual transaxle
136. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
137. Lubricate the transaxle input shaft pilot bearing with front axle grease.
138. Using a suitable clutch disc aligner, position the clutch disc on the flywheel.
139. Position the clutch pressure plate and install the bolts.

1. Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.

SPECIAL TOOLS DESCRIPTION Handle 205-153 (T80T-4000-W) 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Installer, PTO Driven Gear Oil Seal 308-429 Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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1. 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).
2. Install the 4 new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
3. Using the Powertrain Lift and Adjustable Grip Arm, position the engine and transaxle onto the Powertrain Lift. All-Wheel Drive (AWD) vehicles
4. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
5. Install the Power Transfer Unit (PTU) heat shield and the 3 bolts. Tighten to 11 Nm (97 lb-in).
6. Install the PTU and the 3 RH PTU bolts. Tighten to 70 Nm (52 lb-ft).
7. Install the LH lower PTU bolt. Tighten to 48 Nm (35 lb-ft).
8. Attach the PTU vent hose. All vehicles
9. Install the starter motor isolator.
10. Install the starter motor and the 2 stud bolts. Tighten to 35 Nm (26 lb-ft).
11. Install the ground wire and the nut. Tighten to 25 Nm (18 lb-ft).
12. Install the starter motor harness connectors. Install the starter motor solenoid battery nut. Tighten to 12 Nm (106 lb-in). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
13. Raise the engine and transaxle into the vehicle.
14. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
15. Install the bolt in the rear transaxle mount and mass damper (if equipped). Tighten to 115 Nm (85 lb-ft).
16. Install the engine mount bracket and nuts. Tighten to 115 Nm (85 lb-ft).
17. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
18. Install a new spin-on engine oil filter. Lubricate the spin-on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. AWD vehicles
19. Install the PTU bracket and the 2 PTU bracket-to- PTU bolts. Tighten to 45 Nm (33 lb-ft).
20. Install the PTU bracket-to-engine bolt. Tighten to 40 Nm (30 lb-ft).
21. Install the 4 PTU bracket-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
22. Install a new intermediate shaft seal and deflector. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/mercury/mariner/ii-2011-2011/remont/transfer-case/#power-transfer-unit-ptu) article.
23. If equipped, install the dampener and the 3 bolts. Tighten to 40 Nm (30 lb-ft).
24. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
25. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
26. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
27. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
28. Connect the lower radiator hose to the radiator.
29. Install the A/C compressor and connect the A/C compressor electrical connector. Attach the wire harness retainer. Tighten the bolts to 25 Nm (18 lb-ft).
30. Attach the 2 retainers and connect the generator electrical connector.
31. Connect the engine control harness electrical connector.
32. Connect the PCM electrical connector and attach the wire harness retainer.
33. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
34. Connect the fuel vapor return tube. Attach the fuel vapor tube retainer to the wire harness.
35. Connect the vacuum supply tube.
36. Connect the heater hoses to the heater core.
37. Attach the heater hose support strap to the stud.
38. Connect the upper radiator hose.
39. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
40. Attach the shift cable pin-type retainer.
41. Attach the shift cable to the shift cable bracket.
42. Connect the shift cable to the transaxle manual lever.
43. Attach the 2 wiring harness retainers to the battery tray bracket.
44. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
45. Connect the electrical connector to the Power Distribution Box (PDB).
46. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (106 lb-in).
47. Install the PDB cover.
48. Connect the 2 transaxle fluid cooler tubes.
49. Install the 2 secondary latches to the transaxle fluid cooler tubes.
50. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
51. Attach the wiring harness retainer to the transaxle stud bolt.
52. Connect the transaxle electrical connector.
53. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in). AWD vehicles
54. Position the driveshaft to the PTU and install the 6 bolts. Tighten to 37 Nm (27 lb-ft). All vehicles
55. Install the generator air duct and make sure the tab is latched.
56. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
57. Install the intermediate shaft.
58. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 Nm (20 lb-ft).
59. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
60. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
61. Install the RH and LH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
62. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
63. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
64. Fill the engine with clean engine oil.
65. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
66. Check and fill the transmission fluid as necessary. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-6f35-except-hybrid) article. AWD vehicles
67. Check and fill the PTU fluid as necessary. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/mercury/mariner/ii-2011-2011/remont/transfer-case/#power-transfer-unit-ptu) article.
68. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

SPECIAL TOOLS DESCRIPTION 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 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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Scheme 524

1. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts.
2. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.
3. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
4. Install the starter motor isolator.
5. Install the starter motor and the 2 stud bolts. Tighten to 35 Nm (26 lb-ft).
6. Install the ground wire and the nut. Tighten to 25 Nm (18 lb-ft).
7. Install the starter motor harness connector. Install the starter motor solenoid battery nut. Tighten to 12 Nm (106 lb-in). Install the starter motor solenoid nut. Tighten to 5 Nm (44 lb-in).
8. Raise the engine and transaxle into the vehicle.
9. Install the bolt in the LH transaxle mount. Tighten to 103 Nm (76 lb-ft).
10. Install the bolt in the rear transaxle mount. Tighten 115 Nm (85 lb-ft).
11. Install the engine mount bracket and nuts. Tighten 115 Nm (85 lb-ft).
12. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
13. Install a new spin-on engine oil filter. Lubricate the spin-on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
14. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
15. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
16. Install the engine support crossmember and new nut. Tighten to 175 Nm (129 lb-ft).
17. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt. Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
18. Connect the lower radiator hose to the radiator.
19. Position the A/C compressor and install the 3 bolts. Tighten the bolts to 25 Nm (18 lb-ft). Connect the A/C compressor electrical connector. Attach the wire harness retainer.
20. Connect the generator electrical connector and attach the 2 retainers.
21. Connect the engine control harness electrical connector.
22. Connect the PCM electrical connector and attach the wire harness retainer.
23. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
24. Connect the fuel vapor return tube and retainer. Attach the fuel vapor tube retainer to the wire harness.
25. Connect the vacuum supply tube.
26. Connect the heater hoses to the heater core.
27. Attach the heater hose support strap to the stud.
28. Connect the upper radiator hose.
29. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
30. Install the shift cable bracket. Position the shift cable bracket. Install the 3 bolts. Tighten to 22 Nm (16 lb-ft).
31. Connect the shift cables.
32. Connect the reversing lamp indicator switch electrical connector and attach the 2 wiring harness retainers.
33. Connect the Vehicle Speed Sensor (VSS) electrical connector and attach the 2 pin-type retainers.
34. Connect the clutch hydraulic line. Position the clutch hydraulic line. Connect the clutch hydraulic line to the clutch slave cylinder. Tighten to 25 Nm (18 lb-ft). Install the clutch hydraulic line bracket-to-transaxle bolt. Tighten to 3 Nm (27 lb-in).
35. Position the wiring harness and attach the 2 wiring harness retainers to the battery tray bracket.
36. Install the ground strap and bolt. Tighten to 10 Nm (89 lb-in).
37. Connect the electrical connector to the Power Distribution Box (PDB).
38. Connect the cable to the PDB and install the nut. Tighten to 12 Nm (106 lb-in).
39. Install the PDB cover.
40. If equipped, install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
41. Install the generator air duct and make sure the tab is latched.
42. Install the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - 2.5L»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-except-hybrid) article.
43. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
44. Install the lateral support crossmember and bolts. Tighten to 115 Nm (85 lb-ft).
45. Install the LH halfshaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
46. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
47. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-25l-except-hybrid) article.
48. Fill the engine with clean engine oil.
49. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
50. Bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-434496) article.
51. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.