Engine Mechanical - 2.5l (hybrid) Mercury Mariner II рестайлинг

Material Specifications

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 4 coil-on-plug 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 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

Scheme 1018

ITEM DESCRIPTION

Scheme 1019

Exhaust Emission Control System

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

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

1. is positioned upstream from the fuel injectors on the fuel injection supply 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 galley 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 1020

1. Remove the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-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-hybrid) and «VALVE TAPPETS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.

Special Tool(s)

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

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Scheme 1032

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.

Scheme 1033

ITEM DESCRIPTION

Scheme 1034

ITEM DESCRIPTION CHART

Scheme 1035

Scheme 1036

Scheme 1037

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. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
4. Remove the Throttle Body (TB). For additional information, refer to «FUEL CHARGING AND CONTROLS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-charging-system-fuel-control-system-hybrid) article.
5. Remove the accessory drive belt tensioner. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
8. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
9. Disconnect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube from the intake manifold.
10. Disconnect the Knock Sensor (KS) electrical connector and detach the 2 pin-type retainers.
11. Detach the 2 wiring retainers from the intake manifold near the TB mounting area.
12. Detach the engine wiring harness retainer from the intake manifold.
13. Remove the 3 electric A/C compressor bolts and position aside. To install, tighten to 25 Nm (18 lb-ft).
14. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector. To install, tighten to 18 Nm (159 lb-in).
15. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
16. Remove the intake manifold and gaskets.
17. To install, reverse the removal procedure. Inspect and install new intake manifold gaskets if necessary.

MATERIAL SPECIFICATIONS

Scheme 1038

ITEM DESCRIPTION

Scheme 1039

ITEM DESCRIPTION

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. 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 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 from the valve cover.
4. Remove the 4 engine cover studs.
5. Detach the 3 wire harness retainers from the valve cover stud bolts.
6. Disconnect the Camshaft Position (CMP) sensor electrical connector.
7. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
8. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
9. Detach the 2 high-voltage wiring harness retainers from the valve cover studs.
10. Remove the oil level indicator.
11. Remove the 14 valve cover retainers, the valve cover and gasket.

Scheme 1040

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. Install the oil level indicator.
5. Attach the 2 high-voltage wiring harness retainers to the valve cover studs.
6. Connect the VCT solenoid electrical connector.
7. Connect the CHT sensor electrical connector.
8. Connect the CMP sensor electrical connector.
9. Attach the 3 wire harness retainers to the valve cover stud bolts.
10. Install the 4 engine cover studs.
11. Connect the crankcase vent hose to the valve cover.
12. 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.

Scheme 1041

ITEM DESCRIPTION

Scheme 1042

ITEM DESCRIPTION

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

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Timing Peg, Crankshaft TDC 303-507

Scheme 1043

General Equipment

GENERAL EQUIPMENT

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 1044

Scheme 1045

Scheme 1046

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 RF 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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
18. Install the RF 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-hybrid) in this service information.

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

Scheme 1057

Scheme 1058

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 or 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»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) and «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
2. Using the Oil Seal Remover, remove the crankshaft front seal.

Installation

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»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) and «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) 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 engine. For additional information, refer to «ENGINE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
3. Remove the 6 bolts and the flywheel.

Scheme 1059

1. Install the flywheel and tighten the bolts in the sequence shown in illustration in the following 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 engine. For additional information, refer to «ENGINE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.

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

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 flywheel. For additional information, refer to «FLYWHEEL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-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.

Scheme 1060

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Scheme 1063

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. 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.
5. Install the oil pan. Install the 2 oil pan bolts finger-tight.
6. Install the 4 bolts. Tighten to 10 Nm (89 lb-in).
7. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
8. Install the flywheel. For additional information, refer to «FLYWHEEL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
9. Fill the engine with clean engine oil.

SPECIAL TOOLS Aligner, Crankshaft Sensor 303-1417 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Scheme 1064

Scheme 1065

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Scheme 1066

ITEM DESCRIPTION

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 1067

Scheme 1068

Scheme 1069

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 tensioner. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
3. Remove the crankshaft pulley. For additional information refer to «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-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-hybrid) in this service information.
5. Detach the transaxle selector lever cable fastener from the engine front cover stud bolt.
6. Using the Oil Seal Remover, remove the crankshaft front seal.
7. Remove the 3 bolts and the coolant pump pulley.
8. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
9. Remove the 2 bolts and the CKP sensor.
10. Remove the bolts and the engine front cover.

Scheme 1070

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Scheme 1074

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 to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
4. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
5. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (177 lb-in).
6. Attach the transaxle selector lever cable fastener to the engine front cover stud bolt.
7. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-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-hybrid) in this service information.
9. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) 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 tensioner. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.

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 or 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 1075

Scheme 1076

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Scheme 1078

Scheme 1079

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-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 a 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 1080

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Scheme 1088

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 tensioner 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-hybrid) in this service information.

Scheme 1089

ITEM DESCRIPTION

Removal and Installation

1. Remove the Variable Camshaft Timing (VCT) solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-hybrid) article.
2. Remove the 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 Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Scheme 1090

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 1091

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

Scheme 1096

Scheme 1097

Scheme 1098

Scheme 1099

Scheme 1100

Scheme 1101

Scheme 1102

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. Disconnect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
3. Depower the vehicle High Voltage Traction Battery (HVTB) electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
4. Remove the degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
5. Remove the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-converterinverter) article.
6. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-hybrid) article.
7. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
8. Remove the RF wheel and tire. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
9. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
10. 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.
11. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
12. Remove the engine plug bolt.
13. Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
14. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
15. Remove the lower front cover timing hole plug from the engine front cover.
16. Remove the upper front cover timing hole plug from the engine front cover.
17. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
18. 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 (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
19. Remove the Camshaft Alignment Plate.
20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
21. Remove the timing chain from the camshaft phaser and sprocket.
22. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
23. 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.
24. 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 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

Scheme 1109

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

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 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 camshaft phaser and sprocket.
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 bolt. 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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
15. Install the RF 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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-hybrid) article.
17. Install the valve cover. For additional information, refer to «VALVE COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
18. Install the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-converterinverter) article.
19. Install the degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
20. Repower the vehicle HVTB electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
21. Connect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.

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

GENERAL EQUIPMENT

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 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

Scheme 1122

Scheme 1123

Scheme 1124

Scheme 1125

Scheme 1126

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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
3. Remove the Variable Camshaft Timing (VCT) 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-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 standard 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 (1.18 in) 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 camshaft phaser and sprocket.
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 1127

Scheme 1128

Scheme 1129

Scheme 1130

Scheme 1131

Scheme 1132

Scheme 1133

Scheme 1134

Scheme 1135

Scheme 1136

Scheme 1137

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 camshaft phaser and sprocket.
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 (1.18 in) 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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-25l-hybrid) article.
15. Install the VCT 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 1138

ITEM DESCRIPTION

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

SPECIAL TOOLS 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 1139

Scheme 1140

Scheme 1141

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 1142

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-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 the No. 1 cylinder.
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 grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

Scheme 1143

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 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-hybrid) in this service information.

SPECIAL TOOLS 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 1144

Scheme 1145

Scheme 1146

Scheme 1147

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 1148

Scheme 1149

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-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 the No. 1 cylinder.
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 grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seal.

Scheme 1150

Scheme 1151

Scheme 1152

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 grease and a small screwdriver.
4. Disconnect the compressed air supply.
5. 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.
6. Repeat the appropriate removal and installation steps for all of the other cylinders.
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-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-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. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

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

MATERIAL SPECIFICATIONS

Scheme 1153

ITEM DESCRIPTION

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 or 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 1154

Scheme 1155

Scheme 1156

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 - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
4. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-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-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-hybrid) in this service information.
12. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
13. Disconnect the EGR valve electrical connector.
14. Disconnect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose from the engine coolant outlet and the EGR valve.
15. Remove the bolts and the cylinder head. Discard the bolts and the cylinder head gasket.

Scheme 1157

Scheme 1158

Scheme 1159

Scheme 1160

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 cylinder head gasket.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in the following 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, EGR coolant hose, heater hose and coolant vent hose to the engine coolant outlet and the EGR valve.
8. Connect the EGR valve electrical connector.
9. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) .
10. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
11. Install the valve tappets in their original positions.
12. 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 the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
13. Install the Camshaft Alignment Plate.
14. Install the VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-hybrid) article.
15. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
16. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.

Scheme 1161

ITEM DESCRIPTION

Scheme 1162

ITEM DESCRIPTION CHART

Scheme 1163

ITEM DESCRIPTION

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

Scheme 1164

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 pin-type retainer (not shown in illustration), 5 bolts 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 oil filter. To install, lubricate the oil filter O-ring with clean engine oil and then 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

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 pin-type retainer, the 5 bolts 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. Apply thread sealant with PTFE to the EOP switch threads.

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. Drain the engine oil, then install the drain plug. Tighten to 28 Nm (21 lb-ft).
3. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
4. Remove the 4 oil pan-to-bellhousing bolts.
5. Remove the 13 bolts and the oil pan.

Scheme 1165

Scheme 1166

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.
3. Position the oil pan and install the 2 rear oil pan bolts finger-tight.
4. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
5. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
6. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
7. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
8. 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-hybrid) and «OIL PAN»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) 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 1167

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-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.
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 1168

Scheme 1169

Scheme 1170

Scheme 1171

Scheme 1172

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.
9. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
10. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
11. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-25l-hybrid) in this service information.
14. Fill the engine with clean engine oil.

SPECIAL TOOLS Support Bar, Engine 303-F072

Scheme 1173

Scheme 1174

ITEM DESCRIPTION

Scheme 1175

Scheme 1176

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 coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
3. Remove the DC/DC converter. For additional information, refer to «HIGH VOLTAGE CONVERTER/INVERTER»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-converterinverter) article.
4. Install the Engine Support Bar.
5. Remove the engine mount bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
6. Use the Engine Support Bar to raise the engine 25 mm (0.98 in).
7. Remove the 3 nuts and the engine mount bracket. To install, tighten to 115 Nm (85 lb-ft).
8. Remove the A/C tube bracket nut. To install, tighten to 10 Nm (89 lb-in).
9. Rotate the A/C tube brackets off of the studs. Reposition the A/C tubes to access the engine mount bolt.
10. Remove the 3 bolts and the engine mount. To install, tighten to 48 Nm (35 lb-ft).
11. To install, reverse the removal procedure.

SPECIAL TOOLS 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Powertrain Lift 014-00765 or equivalent Remover, Halfshaft Oil Seal 308-428 Remover, Tie-Rod End 211-105 (T85M-3395-A) Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) (part of 303-DS086) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

Scheme 1177

Scheme 1178

Scheme 1179

Scheme 1180

Scheme 1181

All vehicles

Scheme 1182

Scheme 1183

Scheme 1184

Scheme 1185

Scheme 1186

Scheme 1187

Scheme 1188

Scheme 1189

Scheme 1190

Scheme 1191

Scheme 1192

Scheme 1193

Scheme 1194

Scheme 1195

Scheme 1196

Scheme 1197

Scheme 1198

Scheme 1199

Scheme 1200

Scheme 1201

Scheme 1202

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Scheme 1206

Scheme 1207

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Scheme 1209

Scheme 1210

Scheme 1211

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Scheme 1222

Scheme 1223

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Scheme 1225

Scheme 1226

Scheme 1227

Scheme 1228

Scheme 1229

Scheme 1230

Scheme 1231

Scheme 1232

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
3. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) . article
4. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
5. Disable the vehicle high-voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
6. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics-hybrid) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
8. Drain the Motor Electronics Cooling System (MECS). For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-cooler-hybrid) . article
9. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
10. Remove the engine Air Cleaner (ACL). For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-hybrid) article.
11. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
12. Remove the front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
13. Remove the bolts and the lateral support crossmember.
14. Remove the exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
15. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
16. Disconnect the LH suspension. Remove the nut and disconnect the stabilizer bar link. Remove and discard the tie-rod end retaining nut.
17. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
18. Disconnect the RH suspension. Remove the nut and disconnect the stabilizer bar link. Remove and discard the tie-rod end retaining nut.
19. Using the Tie-Rod End Remover, disconnect the LH and RH tie-rod end from the steering knuckle.
20. 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.
21. Remove the 2 intermediate shaft bearing retainer nuts.
22. Remove the intermediate shaft.
23. Drain the transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT)»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#electronically-controlled-continuously-variable-transaxle-hybrid) article. All-Wheel Drive (AWD) vehicles
24. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/mercury/mariner/ii-2011-2011/remont/driveshaft-universal-joints/#driveshaft) article.
25. Remove the 2 catalytic converter bracket bolts.
26. Remove the 6 bolts and the PTU -to-engine bracket.
27. Remove the 3 PTU heat shield bolts and the PTU heat shield.
28. Disconnect the PTU vent hose and position it aside.
29. Remove the 4 PTU -to-transaxle bolts and remove the PTU .
30. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles
31. Remove the engine oil filter.
32. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
33. Disconnect the heater hoses from the heater core.
34. Disconnect the upper radiator hose from the radiator.
35. Disconnect the brake booster vacuum tube from the brake booster.
36. Disconnect the PCM center electrical connector. Remove the wiring harness retainer.
37. If equipped, disconnect the block heater electrical connector. Detach the harness retainer clips and position harness aside.
38. Disconnect the engine control harness electrical connector. Detach the engine control harness wiring retainer from the intake manifold.
39. Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
40. Remove the stud bolt and disconnect the transaxle harness electrical connector.
41. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
42. Disconnect the coolant vent hose.
43. Release the locking tab and disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers.
44. Remove the 3 nuts and position aside the DC-to-DC converter.
45. Disconnect the 2 vehicle high-voltage electrical system electrical connectors. Detach the wiring harness retainer.
46. Detach the 2 high-voltage electrical system wiring retainers from the valve cover stud bolts. Position wiring aside.
47. Disconnect the transaxle coolant temperature sensor electrical connector. Detach the wiring retainer from the transaxle stud bolt.
48. Disconnect the transaxle coolant hoses.
49. Detach the transaxle selector lever cable fastener from the engine front cover stud bolt.
50. Detach the transaxle selector lever cable fastener from the A/C compressor mounting bracket.
51. Remove the 2 bolts and the transaxle control snow shield.
52. Disconnect the transaxle control cable. Release the transaxle control cable from the control lever. Remove the nuts from the transaxle control cable bracket.
53. Remove the 2 harness fasteners, the nut and the ground cable.
54. Disconnect the vacuum pump assembly electrical connector and detach the harness retainer.
55. Remove the 2 bolts and position the MECS pump aside.
56. Remove the nut and disconnect the A/C tube from the A/C compressor. Discard the gasket.
57. Remove the nut and disconnect the A/C tube from the A/C compressor. Discard the gasket.
58. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
59. Disconnect the lower radiator hose from the radiator. Release the wire clip and disconnect the hose.
60. Remove the lower transaxle insulator through bolt.
61. Remove the rear roll restrictor-to-crossmember through bolt.
62. Remove the nut, bolts and the engine support crossmember. Discard the nut.
63. Remove the 2 transaxle-to-engine bolts.
64. Remove the 2 transaxle-to-engine bolts.
65. Remove the rear transaxle insulator through bolt.
66. Remove and discard the steering column coupling-to-steering gear pinch bolt and separate coupling from the steering gear.
67. Remove the 2 bolts, and the roll restrictor and bracket.
68. Using the Powertrain Lift, support the subframe.
69. Loosen the 2 subframe bolts.
70. Remove the 2 subframe nuts and lower the subframe. Remove the subframe from the Powertrain Lift.
71. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the Powertrain Lift.
72. Remove the engine mount bracket bolt.
73. Remove the 3 nuts and the engine mount bracket.
74. Remove the upper transaxle insulator bracket bolts and remove the bracket.
75. Remove the upper transaxle insulator through bolt.
76. Remove the 2 nuts and the upper transaxle insulator.
77. Lower the engine and transaxle from the vehicle.
78. Using the Floor Crane and the Spreader Bar, remove the engine and transaxle from the Powertrain Lift.
79. Release the locking tab and disconnect the high-voltage wiring harness electrical connector.
80. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
81. Remove the bolts and the transaxle damper.

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-00232 or equivalent 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Holding Tool, Crankshaft Damper 303-1416 Installer, Connecting Rod 303-462 (T94P-6136-AH) Remover, Oil Seal 303-409 (T92C-6700-CH) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 1233

Scheme 1234

Scheme 1235

Scheme 1236

Scheme 1237

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. 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 engine Assembly in this service information.

Scheme 1238

Scheme 1239

Scheme 1240

Scheme 1241

Scheme 1242

Scheme 1243

Scheme 1244

Scheme 1245

Scheme 1246

Scheme 1247

Scheme 1248

Scheme 1249

Scheme 1250

Scheme 1251

Scheme 1252

Scheme 1253

Scheme 1254

Scheme 1255

Scheme 1256

Scheme 1257

Scheme 1258

Scheme 1259

Scheme 1260

Scheme 1261

Scheme 1262

Scheme 1263

Scheme 1264

Scheme 1265

Scheme 1266

Scheme 1267

Scheme 1268

Scheme 1269

Scheme 1270

Scheme 1271

Scheme 1272

Scheme 1273

Scheme 1274

Scheme 1275

Scheme 1276

Scheme 1277

Scheme 1278

Scheme 1279

Scheme 1280

Scheme 1281

Scheme 1282

Scheme 1283

Scheme 1284

Scheme 1285

Scheme 1286

Scheme 1287

Scheme 1288

Scheme 1289

Scheme 1290

Scheme 1291

Scheme 1292

Scheme 1293

Scheme 1294

Scheme 1295

Scheme 1296

Scheme 1297

Scheme 1298

Scheme 1299

Scheme 1300

Scheme 1301

Scheme 1302

Scheme 1303

Scheme 1304

Scheme 1305

Scheme 1306

Scheme 1307

Scheme 1308

Scheme 1309

Scheme 1310

Scheme 1311

Scheme 1312

Scheme 1313

Scheme 1314

Scheme 1315

Scheme 1316

Scheme 1317

1. Remove the 6 bolts and the flywheel.
2. Mount the engine on a suitable engine stand.
3. Release the locking tab and disconnect the Heated Oxygen Sensor (HO2S) electrical connector. Detach the connector from the engine wiring harness connector bracket.
4. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
5. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
6. Remove the bolt and the engine wiring harness connector bracket.
7. Detach the 2 engine wiring harness pin-type retainers.
8. Remove the 7 nuts and the catalytic converter manifold. Discard the nuts and the exhaust manifold gasket.
9. Remove and discard the 7 exhaust manifold studs.
10. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
11. Detach the vehicle high-voltage electrical system electrical connector retainer from the accessory drive belt tensioner.
12. Remove the 3 bolts and the accessory drive belt tensioner.
13. Disconnect the electronic throttle control electrical connector.
14. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
15. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
16. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
17. Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.
18. Disconnect the A/C compressor electrical connector.
19. Remove the 3 bolts and the A/C compressor.
20. Remove the 2 bolts and the A/C compressor bracket.
21. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
22. Detach the 2 wiring harness retainers from the fuel rail and the wiring harness retainer from the valve cover.
23. Disconnect the auxiliary coolant pump hose and the upper radiator hose.
24. Disconnect the EGR coolant hose and the auxiliary coolant pump hose. Remove the upper radiator hose and the auxiliary coolant pump as an assembly.
25. Disconnect the vacuum hose from the intake manifold.
26. Remove the 2 bolts, the nut and the vacuum pump assembly.
27. Detach the 3 wire harness pin-type retainers from the intake manifold.
28. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
29. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. Remove the intake manifold.
30. Remove the EGR tube.
31. Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
32. Detach the 2 wiring harness retainers from the ignition coil stud bolts. Remove the high-voltage wiring harness.
33. Remove the fuel rail insulator.
34. Remove the nut and the radio capacitor.
35. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
36. Disconnect the 4 coil-on-plug electrical connectors.
37. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
38. Disconnect the EGR valve electrical connector and detach the 2 wiring harness retainers from the valve cover and stud bolt. Remove the engine control wiring harness from the engine.
39. Remove the 3 bolts and the coolant pump pulley.
40. Remove the 3 bolts and the coolant pump.
41. Remove the 3 bolts and the thermostat housing.
42. Disconnect the coolant hose.
43. Disconnect and remove the coolant hose.
44. Remove the bolt and the KS.
45. Remove the 8 bolts and the crankcase vent oil separator.
46. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
47. If equipped, remove the block heater.
48. Remove the crankshaft vent tube.
49. Remove the engine cover studs.
50. Remove the 4 stud bolts and the coil-on-plugs from the valve cover.
51. Remove the oil level indicator.
52. Remove the spark plugs and the CHT sensor. Discard the CHT sensor.
53. Remove the bolts and the valve cover.
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. Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley. 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 2 bolts and the CKP sensor.
61. Remove the bolts and the engine front cover.
62. Compress the timing chain tensioner. 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 a paper clip into the hole to retain the tensioner.
63. Remove the 2 bolts and the timing chain tensioner.
64. Remove the RH timing chain guide.
65. Remove the timing chain.
66. Remove the bolts and the LH timing chain guide.
67. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
68. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
69. Remove the oil pump chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the shoulder bolts.
70. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
71. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
72. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
73. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
74. 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.
75. 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.
76. Remove the cylinder head. Remove and discard the cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
77. Support the cylinder heads 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.
78. Remove the cylinder head alignment dowels.
79. Remove the bolts and the oil pan.
80. Remove the bolts and the rear crankshaft seal.
81. Remove the bolts, oil pump pickup tube and gasket.
82. Remove the bolts and the oil pump.
83. Remove the bolts and the block-off plate.
84. 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.
85. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC .
86. Remove the 4 bolts and the balancer unit.
87. Remove the Crankshaft TDC Timing Peg.
88. 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.
89. Remove the connecting rod cap bolts and cap.
90. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed block.
91. Remove the bolts in the sequence shown in illustration. Remove the main bearing beam. Discard the bolts.
92. Remove the crankshaft from the engine block.
93. Remove the main bearings from the main bearing beam.
94. Remove the main bearings from the cylinder block.
95. Remove the 4 oil squirters.
96. 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 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 1318

Scheme 1319

MATERIAL SPECIFICATIONS

Scheme 1320

ITEM DESCRIPTION

Disassembly

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

Scheme 1321

1. Remove the 2 bolts and the EGR valve. Discard the gasket.
2. Remove the 4 bolts and the coolant outlet. Discard the gasket.
3. Remove the Cylinder Head Temperature (CHT) sensor.
4. Remove the spark plugs.
5. Remove the valve tappets.
6. Using the Valve Spring Compressors, compress the valve springs and remove the valve collets, valve spring retainers and the valve springs.
7. 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.
8. Remove the valves.
9. Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seals.
10. 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) . Install new parts, as necessary.

Scheme 1322

1. Install the valves.
2. 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 grease and a small screwdriver.
4. Install the valve tappets.
5. Install the spark plugs. Tighten to 12 Nm (106 lb-in).
6. Install the CHT sensor. Tighten to 12 Nm (106 lb-in).
7. Using a new gasket, install the coolant outlet and bolts. Tighten to 10 Nm (89 lb-in).
8. Install the EGR valve, using a new gasket. Tighten to 20 Nm (177 lb-in).

MATERIAL SPECIFICATIONS

Scheme 1323

ITEM DESCRIPTION

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.

Scheme 1324

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 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

Scheme 1325

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Scheme 1331

MATERIAL SPECIFICATIONS

Scheme 1332

ITEM DESCRIPTION

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Scheme 1335

ITEM DESCRIPTION CHART

Scheme 1336

ITEM DESCRIPTION

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. 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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Scheme 1452

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 position 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-hybrid) procedure 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 block-off plate and bolts. Tighten to 25 Nm (18 lb-ft).
32. Install the oil pump assembly. Tighten the bolts in the sequence shown in illustration in the following 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
33. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
35. Tighten the crankshaft rear main oil seal bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
36. Clean and inspect all mating surfaces.
37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
38. Install the oil pan and install the 2 oil pan bolts finger-tight.
39. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
40. 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).
41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
42. 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.
43. Apply silicone gasket and sealant to the locations shown in illustration.
44. Install a new head gasket.
45. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in the following 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.
46. Install the valve tappets.
47. 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 one turn at a time until tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
48. Install the Variable Camshaft Timing (VCT) system oil filter and plug in the intake camshaft thrust cap. Tighten to 17 Nm (150 lb-in).
49. Install the VCT solenoid and the bolt. Tighten to 10 Nm (89 lb-in).
50. 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.
51. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
52. Install the shoulder bolt. Tighten to 10 Nm (89 lb-in).
53. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
54. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
55. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
56. Install the LH timing chain guide and the bolts. Tighten to 10 Nm (89 lb-in).
57. Install the timing chain.
58. 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.
59. Using the edge of a vise, compress the timing chain tensioner plunger.
60. Using a small pick, push back and hold the ratchet mechanism.
61. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
62. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
63. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
64. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 72 Nm (53 lb-ft).
65. Clean and inspect the mounting surfaces of the engine and the front cover.
66. 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.
67. 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).
68. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
69. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
70. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
71. 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 (one-fourth turn).
72. Remove the 6 mm x 18 mm bolt.
73. Remove the Crankshaft TDC Timing Peg.
74. Remove the Camshaft Alignment Plate.
75. Turn the crankshaft clockwise one and three-fourths turns.
76. Install the Crankshaft TDC Timing Peg.
77. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
78. 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.
79. 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.
80. Remove the Camshaft Alignment Plate.
81. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
82. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
83. Remove the 6 mm x 18 mm bolt.
84. Remove the Crankshaft TDC Timing Peg.
85. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
86. Clean the valve cover gasket surface with metal surface prep.
87. Apply silicone gasket and sealant to the locations shown in illustration.
88. Install the valve cover. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
89. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (106 lb-in). Tighten the spark plugs to 12 Nm (106 lb-in).
90. Install the oil level indicator.
91. Install the 4 coil-on-plugs and the 4 bolts. Install the crankshaft vent tube. Tighten to 8 Nm (71 lb-in).
92. Install the engine cover studs.
93. Install the crankshaft vent tube.
94. If equipped, install the block heater. Tighten to 40 Nm (30 lb-ft).
95. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
96. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
97. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
98. Install the coolant hose.
99. Install the coolant hose.
100. Install the thermostat housing. Tighten to 10 Nm (89 lb-in).
101. Install the new O-ring, coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
102. Install the coolant pump pulley and bolts. Tighten to 20 Nm (177 lb-in).
103. Position the engine control wiring harness on the engine.
104. Attach the wiring harness retainer to the valve cover and stud bolt. Connect the EGR valve electrical connector.
105. Connect the CHT sensor and install the rubber boot.
106. Connect the 4 coil-on-plug electrical connectors.
107. 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.
108. Install the fuel rail with the fuel injectors and stud bolts. Tighten to 23 Nm (17 lb-ft).
109. Install the radio capacitor and the nut. Tighten to 10 Nm (89 lb-in).
110. Install the fuel rail insulator.
111. Position the high-voltage wiring harness and attach the 2 wiring harness retainers to the ignition coil stud bolts.
112. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
113. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
114. Position the intake manifold and connect the PCV hose.
115. Install the intake manifold gasket, intake manifold and 7 bolts. Tighten to 18 Nm (159 lb-in).
116. Attach the 3 wire harness pin-type retainers to the intake manifold.
117. Install the vacuum pump assembly, the nut and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
118. Connect the vacuum hose to the intake manifold.
119. Connect the EGR coolant hose and the auxiliary coolant pump hose.
120. Connect the auxiliary coolant pump hose and the upper radiator hose.
121. Attach the 2 wiring harness retainers to the fuel rail and the one to the valve cover.
122. Connect the VCT electrical connector and attach the wiring harness retainer to the valve cover stud bolt.
123. Install the A/C compressor bracket and 2 bolts. Tighten to 48 Nm (35 lb-ft).
124. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
125. Connect the A/C compressor electrical connector.
126. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
127. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
128. Connect the Engine Oil Pressure (EOP) switch electrical connector.
129. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
130. Connect the electronic throttle control electrical connector.
131. Install the accessory drive belt tensioner. Tighten to 25 Nm (18 lb-ft).
132. Attach the vehicle high-voltage electrical system electrical connector retainer to the accessory drive belt tensioner.
133. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
134. Install 7 new exhaust manifold studs in the cylinder head. Tighten to 17 Nm (150 lb-in).
135. Install the new exhaust manifold gasket on the engine.
136. Position the catalytic converter and tighten the 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).
137. Attach the 2 wiring harness pin-type retainers.
138. Install the engine wiring harness connector bracket. Tighten to 15 Nm (133 lb-in).
139. Connect the Crankshaft Position (CKP) sensor electrical connector.
140. Connect the Catalyst Monitor Sensor (CMS) electrical connector.
141. Connect the Heated Oxygen Sensor (HO2S) connector. Attach the connector to the engine wiring harness connector bracket.
142. Using the Floor Crane and the Spreader Bar, remove the engine from the engine stand.
143. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in illustration in the following 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).

SPECIAL TOOLS 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

Scheme 1453

MATERIAL SPECIFICATIONS

All vehicles

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1. Install the transaxle damper. Tighten to 29 Nm (21 lb-ft).
2. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Connect the high-voltage wiring harness electrical connector. Engage the electrical connector locking tab.
4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift.
5. Using the Adjustable Grip Arm, secure the engine to the Powertrain Lift.
6. Raise the engine and transaxle into the vehicle.
7. Install the upper transaxle insulator. Tighten the nuts to 90 Nm (66 lb-ft). Tighten the through bolt to 103 Nm (76 lb-ft).
8. Install the upper transaxle insulator bracket. Tighten to 25 Nm (18 lb-ft).
9. Install the 3 engine mount bracket nuts. Tighten to 115 Nm (85 lb-ft).
10. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
11. Using the Powertrain Lift, raise the subframe into position.
12. Install the 2 subframe nuts. Tighten to 150 Nm (111 lb-ft).
13. Tighten the 2 subframe bolts. Tighten to 175 Nm (129 lb-ft).
14. Install the rear roll restrictor, bracket and bolts. Tighten to 90 Nm (66 lb-ft).
15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt. Tighten to 63 Nm (46 lb-ft).
16. Install the rear transaxle insulator through bolt. Tighten to 115 Nm (85 lb-ft).
17. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
18. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
19. Install the engine support crossmember. Tighten the bolts to 90 Nm (66 lb-ft). Tighten the new nut to 175 Nm (129 lb-ft).
20. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 90 Nm (66 lb-ft).
21. Install the lower transaxle insulator through bolt. Tighten to 115 Nm (85 lb-ft).
22. Connect the lower radiator hose to the radiator. Install the retaining clip.
23. Install the auxiliary coolant pump and the 2 bolts. Connect the auxiliary coolant pump electrical connector. Tighten to 10 Nm (89 lb-in).
24. Install a new gasket and connect the A/C tube to the A/C compressor. Install the nut. Tighten to 15 Nm (133 lb-in).
25. Install a new gasket and connect the A/C tube to the A/C compressor. Install the nut. Tighten to 15 Nm (133 lb-in).
26. Install the Motor Electronics Cooling System (MECS) pump and the 2 bolts. Tighten to 20 Nm (177 lb-in).
27. Connect the vacuum pump electrical connector and attach the harness retainer.
28. Install the wiring harness fasteners, the ground cable and nut. Tighten to 20 Nm (177 lb-in).
29. Connect the transaxle control cable. Install the transaxle control cable bracket and the 2 nuts finger-tight. Attach the transaxle control cable to the control lever.
30. Position the control lever between the 2 casting ribs on the transaxle case.
31. Place the gear selector lever in the D position.
32. Tighten the transaxle control cable bracket nuts. Tighten to 22 Nm (16 lb-ft).
33. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
34. Install the transaxle control snow shield and the 2 bolts. Tighten to 22 Nm (16 lb-ft).
35. Attach the transaxle selector lever cable fastener to the A/C compressor mounting bracket.
36. Attach the transaxle selector lever cable fastener to the engine front cover stud bolt.
37. Connect the transaxle coolant hoses.
38. Connect the transaxle coolant temperature sensor electrical connector. Attach the wiring retainer to the transaxle stud bolt.
39. Attach the 2 high-voltage electrical system wiring retainers to the valve cover stud bolts.
40. Connect the 2 vehicle high-voltage electrical system electrical connectors. Attach the wiring harness retainer.
41. Position the DC-to-DC converter in place and install the 3 nuts. Tighten to 12 Nm (106 lb-in).
42. Connect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown in illustration). Engage the electrical connector locking tab.
43. Connect the coolant vent hose.
44. Connect the 2 low-voltage electrical connectors and the engine harness-to-body harness retainer.
45. Connect the transaxle harness electrical connector and install the stud bolt. Tighten to 10 Nm (89 lb-in).
46. Connect the upper evaporative emissions Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
47. Connect the engine control harness electrical connector. Attach the engine control harness wiring retainer to the intake manifold.
48. If equipped, connect the block heater electrical connector. Attach the harness retainer clips.
49. Connect the PCM electrical connector. Position the harness and install the wiring harness retainer.
50. Connect the brake booster vacuum hose to the brake booster.
51. Connect the upper radiator hose to the radiator.
52. Connect the heater hoses to the heater core.
53. Install the spin-on engine oil filter. Tighten the spin-on oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter. All-Wheel Drive (AWD) vehicles
54. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
55. Position the Power Transfer Unit (PTU) in place and install the 4 bolts. Tighten to 45 Nm (33 lb-ft).
56. Connect the PTU vent hose.
57. Install the PTU heat shield and the bolts. Tighten to 11 Nm (97 lb-in).
58. Position the PTU -to-engine support bracket and install the bolts. Tighten to 40 Nm (30 lb-ft).
59. Install the 2 exhaust bracket bolts. Tighten to 25 Nm (18 lb-ft).
60. Install the driveshaft. For additional information, refer to «DRIVESHAFT»(/mercury/mariner/ii-2011-2011/remont/driveshaft-universal-joints/#driveshaft) article. All vehicles
61. Install the intermediate shaft.
62. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 Nm (20 lb-ft).
63. 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.
64. Connect the RH and LH suspension. Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link and install the nut. Tighten to 63 Nm (46 lb-ft).
65. Install the RH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (133 lb-in).
66. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (133 lb-in).
67. Install the exhaust intermediate pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
68. Install the lateral support crossmember and the bolts. Tighten to 115 Nm (85 lb-ft).
69. Install the front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/mercury/mariner/ii-2011-2011/remont/wheel-tire-system/#wheels-tires) article.
70. Connect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
71. Install the engine Air Cleaner (ACL). For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-hybrid) article.
72. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
73. Install the battery and the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
74. Fill the engine with clean engine oil article.
75. Enable the vehicle high-voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(/mercury/mariner/ii-2011-2011/remont/body-electrical/#high-voltage-traction-battery) article.
76. Reset the Passive Anti-Theft System (PATS). For additional information, refer to «ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) - HYBRID»(/mercury/mariner/ii-2011-2011/remont/door-locks-anti-theft-systems/#anti-theft-passive-anti-theft-system-pats-hybrid) article.
77. Fill and bleed the MECS . For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-cooler-hybrid) article.
78. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-hybrid) article.
79. Fill the transaxle with fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT)»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#electronically-controlled-continuously-variable-transaxle-hybrid) article.
80. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID»(/mercury/mariner/ii-2011-2011/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics-hybrid) article.

See also:
• INTRODUCTION
• ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION
• JACKING & LIFTING
• FUEL CHARGING AND CONTROLS - 2.5L
• ENGINE COOLING - HYBRID
• FUEL CHARGING AND CONTROLS - HYBRID
• ACCESSORY DRIVE - HYBRID
• ENGINE IGNITION - 2.5L
• TIRES & WHEELS
• ELECTRONIC ENGINE CONTROLS - HYBRID
• HIGH VOLTAGE TRACTION BATTERY
• HIGH VOLTAGE CONVERTER/INVERTER
• ELECTRONIC ENGINE CONTROLS - 2.5L
• FUEL SYSTEM - GENERAL INFORMATION
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID
• TRANSAXLE/TRANSMISSION COOLING - HYBRID
• INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID
• FRONT DRIVE HALFSHAFTS
• AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT)
• DRIVESHAFT
• ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) - HYBRID
• VALVE COVER