Engine Mechanical - 3.0l (4v) Mercury Mariner II рестайлинг

Material Specifications

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

The 3.0L (4V) is a V-6 engine with the following features

1. Dual overhead camshafts
2. Four valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. A composite lower intake manifold and a composite upper intake manifold
5. Aluminum cylinder heads
6. Two-piece design aluminum cylinder block
7. Variable Camshaft Timing (VCT) system
8. Electronic ignition system with 6 ignition coils

Engine Identification

For quick identification, refer to IDENTIFICATION CODES for safety certification decal.

1. The decal is located on the LH front door lock face panel.

Engine Code Information Label

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

Scheme 525

ITEM DESCRIPTION

Scheme 526

Exhaust Emission Control System

Operation and required 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 6 solenoid-operated fuel injectors

1. are mounted between the fuel rail and 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.

Valve Train

The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the chains are driven by sprockets that are located on the crankshaft, just in front of the oil pump.

Variable Camshaft Timing (VCT) System

The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance, engine idle quality and exhaust emissions.

PCV System

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

Lubrication System

The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the crankshaft, connecting rod bearings and timing chain tensioners. The flow of oil to the valve tappets and valve train is controlled by a restricting orifice located in the head gaskets.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Cooling System

The engine cooling system includes the following components

1. Radiator
2. Electric cooling fan motor
3. Degas bottle (aids in maintaining the correct volume of engine coolant)
4. Coolant thermostat
5. Coolant hoses
6. Coolant pump housing

For basic engine mechanical concerns, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the INTRODUCTION article.

Scheme 527

Upper Intake Manifold (View 2 of 2)

ITEM DESCRIPTION

Scheme 528

ITEM DESCRIPTION

Removal

1. Remove the Air Cleaner (ACL) outlet pipe and the ACL . For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
2. Remove the EGR tube fitting from the EGR valve.
3. Disconnect the electronic throttle control electrical connector.
4. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
5. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
6. Disconnect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake booster vacuum tube from the upper intake manifold.
7. Detach the engine control wiring harness retainer from the upper intake manifold.
8. Disconnect the PCV tube from the upper intake manifold.
9. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
10. Remove the 2 upper intake manifold support bracket bolts from the upper intake manifold.
11. Remove the 7 bolts and the upper intake manifold. Remove and discard the gaskets.

Scheme 529

1. Position the upper intake manifold and install the 7 bolts. Tighten the bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
2. Install the 2 upper intake manifold support bracket bolts. Tighten to 10 Nm (89 lb-in).
3. Connect the MAP electrical connector and attach the wiring retainer.
4. Connect the PCV tube to the upper intake manifold.
5. Attach the engine control wiring harness retainer to the upper intake manifold.
6. Connect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
7. Connect the EGR regulator electrical connector and attach the wiring retainer.
8. Connect the EVAP canister purge valve electrical connector.
9. Connect the electronic throttle control electrical connector.
10. Install the EGR tube fitting to the EGR valve. Tighten to 40 Nm (30 lb-ft).
11. Install the ACL outlet pipe and the ACL . For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.

Scheme 530

ITEM DESCRIPTION

1. 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.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
3. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-charging-system-fuel-control-system-30l-4v) article.
4. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.

Scheme 531

1. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-charging-system-fuel-control-system-30l-4v) article.
3. Connect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.

MATERIAL SPECIFICATIONS

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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

1. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
2. Remove the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
3. Detach the upper radiator hose from the 2 retainers on the cooling fan shroud and position the hose aside.
4. Detach the 2 wiring retainers from the valve cover.
5. Detach the 2 wiring retainers from the valve cover stud bolts.
6. Disconnect the Variable Camshaft Timing (VCT) electrical connector.
7. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
8. Remove the 8 bolts, 6 stud bolts and the valve cover. Remove and discard the gasket.

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1. Install the new gasket in the valve cover in the following sequence. Install the gasket at waffle pads and then the corners. Install the gasket around bolt holes. Install the remaining part of the gasket.
2. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
3. Position the valve cover and install the bolts and stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
4. Connect the HO2S electrical connector.
5. Connect the VCT electrical connector.
6. Attach the 2 wiring retainers to the valve cover stud bolts.
7. Attach the 2 wiring retainers to the valve cover.
8. Attach the upper radiator hose to the 2 retainers on the cooling fan shroud.
9. Install the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
10. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.

MATERIAL SPECIFICATIONS

Scheme 537

ITEM DESCRIPTION

Scheme 538

ITEM DESCRIPTION

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

1. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
2. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) .
3. Remove the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
4. Detach the 3 main engine control wiring harness retainers from the valve cover stud bolts.
5. Detach the 3 main engine control wiring harness retainers from the valve cover.
6. Disconnect the Variable Camshaft Timing (VCT) electrical connector.
7. Detach the Crankshaft Position (CKP) wiring harness retainer from the stud.
8. Remove the 11 bolts, 3 stud bolts and the valve cover. Remove and discard the gasket.

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Scheme 540

1. Install the new gasket in the valve cover in the following sequence. Install the gasket at waffle pads and then corners. Install the gasket around bolt holes. Install the remaining part of the gasket.
2. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
3. Position the valve cover and install the 11 bolts and 3 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
4. Attach the CKP wiring harness retainer on the stud.
5. Connect the VCT electrical connector.
6. Attach the 3 main engine control wiring harness retainers to the valve cover.
7. Attach the 3 main engine control wiring harness retainers to the valve cover stud bolts.
8. Install the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
9. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) .
10. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.

Scheme 541

ITEM DESCRIPTION

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ITEM DESCRIPTION

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

Special Tool(s)

SPECIAL TOOLS 3 Jaw Puller 303-D121 (or equivalent) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)

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MATERIAL SPECIFICATIONS

Scheme 545

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 - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-30l-4v) article.
3. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

Installation

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Apply silicone gasket and sealant to the end of the keyway slot.
3. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
4. Install the bolt and washer. Tighten the bolt in 4 stages: Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
5. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-30l-4v) article.

SPECIAL TOOLS Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Oil Seal 303-409 (T92C-6700CH)

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MATERIAL SPECIFICATIONS

Scheme 549

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 crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal.

Scheme 550

1. Apply clean engine oil to the seal lip and seal bore before installing the seal.
2. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

Removal and Installation

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 transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(/mercury/mariner/ii-2011-2011/remont/automatic-trans/#automatic-transmission-6f35-except-hybrid) article.
3. Remove the bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft).
4. To install, reverse the removal procedure.

SPECIAL TOOLS Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS

Scheme 555

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.

1. Using the Crankshaft Rear Main Oil Seal Installer Bolts and the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

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

MATERIAL SPECIFICATIONS

Scheme 556

ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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 559

Scheme 560

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. Remove the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «CRANKSHAFT FRONT SEAL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
4. Remove the generator bolt and the 2 nuts.
5. Remove the stud and position the generator away from the engine.
6. Remove the 3 bolts and the accessory drive belt tensioner.
7. Detach the wiring harness retainer from the engine front cover stud bolt.
8. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
9. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
10. Remove the LH and RH Variable Camshaft Timing (VCT) oil control solenoids. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
11. Remove the 2 oil pan-to-front cover bolts.
12. Remove the engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
13. Remove the 14 bolts, 2 stud bolts and the engine front cover. Remove and discard the gaskets.

Scheme 561

1. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface prep and install new gaskets.
2. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
3. Position the engine front cover and install the bolts. Tighten in the sequence shown illustration to 25 Nm (18 lb-ft). ITEM DESCRIPTION Item Part Number Description 1 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 2 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 3 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64 4 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5 5 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 6 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 7 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 8 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 9 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 10 W708221 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 11 W708221 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 12 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5 13 W710030 Stud, Hex Flange Head Pilot, M6 x 1 x 20 / M8 x 1.25 x 47.5 14 W708222 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 64 15 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 118 16 W701525 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 47.5
4. Install the 2 oil pan-to-front cover bolts. Tighten to 25 Nm (18 lb-ft).
5. Install the engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
6. Remove the oil pan drain plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
7. Install the LH and RH VCT oil control solenoids. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
8. Connect the 2 CMP sensor electrical connectors and attach the wiring harness retainer to the engine front cover stud bolt.
9. Connect the CKP electrical connector.
10. Attach the wiring harness retainer to the engine front cover stud bolt.
11. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
12. Position the generator and install the stud. Tighten to 8 Nm (71 lb-in).
13. Install the generator bolt and 2 nuts. Tighten to 47 Nm (35 lb-ft).
14. Install the crankshaft front seal. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «CRANKSHAFT FRONT SEAL»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
15. Fill the engine with clean engine oil.
16. Connect the battery ground cable. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
17. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the onscreen instructions.

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

Note. Failure to verify correct timing drive component alignment will result in severe engine damage.

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
2. Remove the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
3. Remove the ignition pulse wheel.
4. Install the crankshaft pulley bolt and washer.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the 2 bolts and the RH timing chain guide. Remove the RH timing chain from the engine.
10. Rotate the crankcase clockwise 600 degrees (one and two-third turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the 2 bolts and the LH timing chain guide. Remove the LH timing chain from the engine.
14. Remove the crankshaft pulley bolt and the crankshaft sprocket.

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1. Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
7. Position the LH timing chain and guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
8. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
9. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. Install the RH timing chain and chain guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
12. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to TDC.
15. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
16. Remove the crankshaft pulley bolt and washer.
17. Install the ignition pulse wheel.
18. Install the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

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ITEM DESCRIPTION

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ITEM DESCRIPTION

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ITEM DESCRIPTION

Scheme 586

ITEM DESCRIPTION

Scheme 587

ITEM DESCRIPTION

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

SPECIAL TOOLS Locking Tool, Timing Chain 303-1175

Scheme 588

MATERIAL SPECIFICATIONS

LH camshaft phaser and sprocket

Scheme 589

Scheme 590

Scheme 591

Scheme 592

Scheme 593

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

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 LH Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
3. Remove the LH Camshaft Position (CMP) sensor. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
4. Remove the pin-type retainer, 5 bolts and the RH lower splash shield.
5. Rotate the crankshaft until the LH camshafts are in the neutral position as shown in illustration.
6. Install the Timing Chain Locking Tool in the LH timing chain as shown in illustration.
7. Mark the timing chain links and LH camshaft phaser and sprocket and exhaust camshaft gear as shown in illustration for installation.
8. Loosen the intake camshaft bolts evenly in the sequence shown in illustration.
9. Remove the 2 bolts and the intake camshaft bearing thrust cap.
10. Loosen the 3 bolts for the LH camshaft phaser and sprocket. Tighten to 18 Nm (159 lb-in).
11. Using your hands, press the LH camshaft phaser and sprocket bolts towards the rear of the engine while using a rocking motion to release the LH camshaft phaser and sprocket from the camshaft. Once the LH camshaft phaser and sprocket has separated from the camshaft, remove the timing chain from the LH camshaft phaser and sprocket and remove. RH camshaft phaser and sprocket
12. Remove the RH VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
13. Remove the RH CMP sensor. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
14. Remove the pin-type retainer, 5 bolts and the RH lower splash shield.
15. Rotate the crankshaft until the RH camshafts are in the neutral position as shown in illustration.
16. Install the Timing Chain Locking Tool in the RH timing chain as shown in illustration.
17. Mark the timing chain links and RH camshaft phaser and sprocket and exhaust camshaft gear as shown in illustration for installation.
18. Loosen the intake camshaft bolts evenly in the sequence shown in illustration.
19. Remove the 2 bolts and the intake camshaft bearing thrust cap.
20. Loosen the 3 bolts for the RH camshaft phaser and sprocket. Tighten to 18 Nm (159 lb-in).
21. Using your hands, press the RH camshaft phaser and sprocket bolts towards the rear of the engine while using a rocking motion to release the RH camshaft phaser and sprocket from the camshaft. Once the RH camshaft phaser and sprocket has separated from the camshaft, remove the timing chain from the RH camshaft phaser and sprocket and remove.

RH camshaft phaser and sprocket

Scheme 599

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Scheme 602

Scheme 603

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Scheme 609

Scheme 610

1. Position the RH camshaft phaser and sprocket into the timing chain with the alignment marks. Make sure the timing chain mark is in alignment with the exhaust camshaft gear mark.
2. Using the 3/8-in ratchet and extension into the D-slot on the rear of the RH intake camshaft, align the RH camshaft phaser and sprocket with the camshaft and install the 3 bolts. Tighten the 3 bolts in a clockwise pattern until the RH camshaft phaser and sprocket is seated on the camshaft. Torque the 3 bolts to 18 Nm (159 lb-in), using the 3/8-in ratchet and extension to hold camshaft from turning.
3. Lubricate the bearing surface of the RH intake camshaft bearing thrust cap with clean engine oil and install the camshaft bearing thrust cap and the 2 bolts. Do not torque at this time.
4. Tighten the RH intake camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
5. Verify the timing chain links and RH camshaft phaser and sprocket and exhaust camshaft gear are in alignment.
6. Remove the Timing Chain Locking Tool from the RH timing chain.
7. Install the RH lower splash shield, pin-type retainer and the 5 bolts. Tighten to 9 Nm (80 lb-in).
8. Install the RH CMP sensor. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
9. Install the RH VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article. LH camshaft phaser and sprocket
10. Position the LH camshaft phaser and sprocket into the timing chain with the alignment marks. Make sure the timing chain mark is in alignment with the exhaust camshaft gear mark.
11. Using the 3/8-in ratchet and extension into the D-slot on the rear of the LH intake camshaft, align the LH camshaft phaser and sprocket with the camshaft and install the 3 bolts. Tighten the 3 bolts in a clockwise pattern until the LH camshaft phaser and sprocket is seated on the camshaft. Torque the 3 bolts to 18 Nm (159 lb-in), using the 3/8-in ratchet and extension to hold camshaft from turning.
12. Lubricate the bearing surface of the LH intake camshaft bearing thrust cap with clean engine oil and install the camshaft bearing thrust cap and the 2 bolts. Do not torque at this time.
13. Tighten the LH intake camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
14. Verify the timing chain links and LH camshaft phaser and sprocket and exhaust camshaft gear are in alignment.
15. Remove the Timing Chain Locking Tool from the LH timing chain.
16. Install the RH lower splash shield, pin-type retainer and the 5 bolts. Tighten to 9 Nm (80 lb-in).
17. Install the LH CMP sensor. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.
18. Install the LH VCT oil control solenoid. For additional information, refer to «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#electronic-engine-controls-30l-4v) article.

1. Remove the camshaft phaser and sprocket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
2. Remove and discard the VCT system oil filter from the camshaft.

1. Install the new VCT system oil filter in the camshaft.
2. Install the camshaft phaser and sprocket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

SPECIAL TOOLS Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Oil Seal 303-409 (T92C-6700-CH) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455

Scheme 611

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Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

MATERIAL SPECIFICATIONS

Scheme 620

Scheme 621

Scheme 622

1. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-30l-4v) article.
2. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
3. Remove the LH camshaft phaser and socket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
4. Using the Oil Seal Remover, remove and discard the camshaft oil seal.
5. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
6. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
7. Loosen the bolts evenly in the sequence shown in illustration.
8. Remove the camshaft cap bolts. Remove the camshaft bearing thrust cap (1L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.

Scheme 623

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Scheme 625

Scheme 626

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Scheme 629

1. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown in illustration.
2. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
3. Lubricate the bearing surface of the LH exhaust camshaft bearing thrust cap with clean engine oil and install the bearing thrust cap. Loosely install the bolts.
4. Tighten the LH exhaust camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
5. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump Pulley Installer, install the camshaft oil seal.
7. Install the LH camshaft phaser and socket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
8. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
9. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
10. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/accessory-drive-belts/#accessory-drive-system-30l-4v) .

MATERIAL SPECIFICATIONS

Scheme 630

Scheme 631

1. Remove the RH camshaft phaser and socket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
2. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
3. Loosen the bolts evenly in the sequence shown in illustration.
4. Remove the camshaft cap bolts. Remove the camshaft bearing thrust cap (1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.

Scheme 632

Scheme 633

Scheme 634

Scheme 635

1. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown in illustration.
2. Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
3. Lubricate the bearing surface of the RH exhaust camshaft bearing thrust cap with clean engine oil and install the bearing thrust cap. Loosely install the bolts.
4. Tighten the RH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
5. Install the RH camshaft phaser and socket. For additional information, refer to «CAMSHAFT PHASER AND SPROCKET»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

SPECIAL TOOLS Compressor, Valve Spring 303-473 (T94P-6565-BH)

Scheme 636

MATERIAL SPECIFICATIONS

Scheme 637

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 LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «VALVE COVER - RH»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the LH and RH spark plugs. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/ignition-system/#engine-ignition-30l-4v) article.
4. Remove the RH splash shield. To install, tighten to 9 Nm (80 lb-in).
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the roller follower.
6. Using the Valve Spring Compressor, remove the roller followers.
7. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

SPECIAL TOOLS Compressor, Valve Spring 303-473 (T94P-6565-BH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 638

Scheme 639

MATERIAL SPECIFICATIONS

Scheme 640

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
2. Pressurize the cylinder using compressed air.
3. Using the Valve Spring Compressor, remove the key, retainer and the valve spring.
4. Remove the valve seal.

Scheme 641

1. Using the Valve Stem Oil Seal Installer, install the valve seal.
2. Using the Valve Spring Compressor, install the valve spring, retainer and key.
3. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

MATERIAL SPECIFICATIONS

Scheme 642

ITEM DESCRIPTION

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

Scheme 643

Scheme 644

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 lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - RH»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
4. Remove the coolant pump housing. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
5. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
6. Verify the RH camshafts are in the neutral position.
7. Remove the 3 bolts and the RH camshaft phaser and sprocket.
8. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
9. Loosen the bolts evenly in the sequence shown in illustration. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
10. Remove the camshaft roller followers.
11. Remove the hydraulic lash adjusters.
12. Remove the bolts in the sequence shown in illustration. Remove the cylinder head. Discard the bolts and gasket.
13. 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.

Scheme 645

Scheme 646

Scheme 647

Scheme 648

Scheme 649

1. Use a plastic scraping tool to remove all traces of the head gasket. Clean all surfaces with metal surface prep.
2. Position a new gasket and the cylinder head.
3. Install the bolts and tighten in 6 stages in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
6. Position the RH camshaft phaser and sprocket onto the intake camshaft. Install the 3 bolts finger-tight.
7. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown in illustration.
8. Install the camshaft bearing caps. Loosely install the bolts.
9. Install the camshaft bearing thrust caps. Loosely install the bolts.
10. Tighten the RH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
11. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
12. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
13. Install the coolant pump housing. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
14. Install the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - RH»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
15. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

SPECIAL TOOLS Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Oil Seal 303-409 (T92C-6700-CH) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455

Scheme 650

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Scheme 657

MATERIAL SPECIFICATIONS

Scheme 658

ITEM DESCRIPTION

Scheme 659

ITEM DESCRIPTION

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

Scheme 660

Scheme 661

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 lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
4. Remove the coolant pump housing. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
5. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
6. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
7. Using the Oil Seal Remover, remove and discard the camshaft oil seal.
8. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
9. Verify the LH camshafts are in the neutral position.
10. Remove the 3 bolts and the LH camshaft phaser and sprocket.
11. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
12. Loosen the bolts evenly in the sequence shown in illustration. Remove the camshaft bearing thrust caps (1L and 5L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
13. Remove the camshaft roller followers.
14. Remove the hydraulic lash adjusters.
15. Remove the 4 upper radiator support bracket bolts.
16. Remove the oil level indicator.
17. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator support and the cooling fan. Remove and discard the O-ring seal.
18. Remove the bolts in the sequence shown in illustration.
19. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
20. 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.

Scheme 662

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Scheme 668

Scheme 669

1. Position a new gasket and the cylinder head.
2. Install the bolts and tighten in 6 stages in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten 90 degrees. Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
3. Guide the oil level indicator tube between the radiator support and the cooling fan and install it in the orifice, install the stud bolt. To install, tighten to 10 Nm (89 lb-in).
4. Install the oil level indicator.
5. Install the 4 upper radiator support bracket bolts. Tighten to 10 Nm (89 lb-in).
6. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
7. Install the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil.
8. Position the camshaft phaser and sprocket onto the intake camshaft. Install the 3 bolts finger-tight.
9. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown in illustration.
10. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
11. Lubricate the bearing surface of the LH exhaust camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
12. Tighten the LH exhaust camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
13. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
14. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
15. Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump Pulley Installer, install the camshaft oil seal.
16. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
17. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
18. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
19. Install the coolant pump housing. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
20. Install the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
21. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

Scheme 670

ITEM DESCRIPTION

Scheme 671

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures 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 may cause engine failure.

Scheme 672

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/mariner/ii-2011-2011/remont/hoistjack/#jacking-lifting) article.
2. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
3. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
4. Remove and discard the oil filter.
5. Remove the access cover.
6. Remove the 2 oil pan-to-transaxle bolts.
7. Remove the 15 bolts and the oil pan. Remove and discard the oil pan gasket.

Scheme 673

1. Use a plastic scraping tool to remove all traces of the oil pan gasket. Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
2. Apply a 10 mm (0.40 in) diameter dot of silicone sealant to the areas indicated.
3. Position the oil pan and loosely install the bolts.
4. Install the 2 oil pan-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
5. Tighten the oil pan-to-engine bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
6. Install the access cover.
7. Install a new oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
8. Install the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
9. Fill the engine with clean engine oil.

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, may cause engine failure.

Scheme 674

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-30l-4v) and «OIL PAN»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the bolts the oil pump screen and pickup tube. Remove and discard the O-ring seal.

Scheme 675

1. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate the O-ring seal with clean engine oil.
2. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the bolts and tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

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

Scheme 676

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 pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «OIL PUMP SCREEN AND PICKUP TUBE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the 8 nuts and the oil pan baffle in the following sequence. To install, tighten the 4 M6 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten an additional 45 degrees. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten an additional 45 degrees.
4. To install, reverse the removal procedure.

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

Scheme 677

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 timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Remove the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «OIL PUMP SCREEN AND PICKUP TUBE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
4. Remove the bolts in the sequence shown in illustration.

Scheme 678

1. Position the oil pump and install the bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Install the oil pump screen and pickup tube. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) and «OIL PUMP SCREEN AND PICKUP TUBE»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-30l-4v) in this service information.

MATERIAL SPECIFICATIONS

Scheme 679

ITEM DESCRIPTION

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 oil filter. To install, tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
4. Remove the EOP switch. To install, tighten to 14 Nm (124 lb-in).
5. To install, reverse the removal procedure. Apply thread sealant to the EOP switch threads.

MATERIAL SPECIFICATIONS

Scheme 680

ITEM DESCRIPTION

Scheme 681

ITEM DESCRIPTION

1. Remove the Air Cleaner (ACL) outlet pipe and the ACL . For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
2. Detach the upper radiator hose from the 2 retaining clips on the cooling fan shroud. Position the hose aside.
3. Remove the 4 upper radiator support bracket bolts. To install, tighten to 10 Nm (89 lb-in).
4. Remove the oil level indicator.
5. Remove the 3 bolts and position aside the heat shield. To install, tighten to 10 Nm (89 lb-in).
6. Detach the wiring harness retainer from the oil level indicator tube.
7. Remove the stud bolt and then remove the oil level indicator tube by guiding it between the radiator support and the cooling fan. Remove and discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
8. To install, reverse the removal procedure.

Scheme 682

ITEM DESCRIPTION

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 3.0L RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
4. Remove the 3 exhaust manifold heat shield bolts and the heat shield.
5. Remove the EGR tube fitting nut from the exhaust manifold.
6. Remove and discard the 6 exhaust manifold nuts.
7. Remove the exhaust manifold and discard the exhaust manifold gasket.
8. Remove and discard the 6 exhaust manifold studs.
9. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/mechanical/#engine-mechanical-system-general-information) article.

Scheme 683

1. Install the 6 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 6 new nuts. Tighten the nuts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
3. Install the EGR tube fitting nut on the exhaust manifold. Tighten to 40 Nm (30 lb-ft).
4. Install the exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
5. Connect the HO2S electrical connector.
6. Install the 3.0L RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.

Scheme 684

ITEM DESCRIPTION

Scheme 685

1. Remove the engine support insulator bracket bolt. To install, tighten to 115 Nm (85 lb-ft).
2. Position a floor jack with a block of wood under the front of the oil pan. Using the floor jack, lift the engine 12 mm (0.47 in).
3. Remove the nut and ground wire eyelet from the engine support insulator bracket stud. To install, tighten to 25 Nm (18 lb-ft).
4. Remove the 3 nuts and the engine support insulator bracket. To install, tighten to 55 Nm (41 lb-ft).
5. Remove the 3 bolts and the engine support insulator. To install, tighten to 48 Nm (35 lb-ft).
6. To install, reverse the removal procedure.

SPECIAL TOOLS Disconnect Tool, Transmission Cooler Line 307-569 Engine Lifting Bracket Set 303-1140 Lifting Brackets, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Remover, Halfshaft Oil Seal 308-428 Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

All vehicles

Scheme 693

Scheme 694

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Scheme 700

Scheme 701

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Scheme 737

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Scheme 744

Scheme 745

Scheme 746

Scheme 747

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. Remove the Air Cleaner (ACL) outlet pipe and ACL assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
5. 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.
6. Remove the lower splash shields.
7. Remove the 4 bolts and the lateral support crossmember.
8. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
9. Disconnect the RH CMS electrical connector.
10. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
11. 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.
12. Remove the 2 intermediate shaft bearing retainer nuts.
13. Remove the intermediate shaft. All-Wheel Drive (AWD) vehicles
14. Remove and discard the 6 front driveshaft-to- PTU bolts and washers. Position the driveshaft aside and support with mechanic's wire. All vehicles
15. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
16. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
17. Drain the engine oil and install the drain plug. Tighten to 26 Nm (19 lb-ft).
18. Disconnect the A/C compressor electrical connector.
19. Remove the 3 bolts and position the A/C compressor aside.
20. Disconnect the generator electrical connector.
21. Remove the front roll restrictor bolt and the 2 bolts for the engine support cross brace.
22. Remove the rear nut and the engine support crossmember. Discard the nut.
23. Remove the 2 secondary latches from the transaxle fluid cooler tubes.
24. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown in illustration).
25. Disconnect the 2 transmission electrical connectors and detach the wiring retainer from the stud bolt.
26. Disconnect the upper and lower radiator hoses.
27. Disconnect the 2 heater hoses.
28. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
29. Disconnect the gearshift cable from the transaxle.
30. Remove the 2 shift cable bracket bolts, and position the cable and bracket aside.
31. Detach the shift cable retainer from the bracket.
32. Disconnect the Evaporative Emission (EVAP) canister purge valve tube and disconnect the brake booster vacuum tube from the intake manifold.
33. Disconnect the middle PCM electrical connector and the engine wiring harness electrical connector. Detach the 2 wiring harness retainers.
34. Detach the wiring harness retainer from the battery tray bracket.
35. Remove the bolt and detach the ground wire.
36. Remove the nut and disconnect the cable from the Power Distribution Box (PDB).
37. Disconnect the electrical connector from the PDB.
38. Remove the nut and the ground wire eyelet from the engine mount stud.
39. If equipped, disconnect the engine block heater electrical connector.
40. Remove the access cover.
41. Remove the 4 torque converter nuts.
42. Remove the 2 oil pan-to-transaxle bolts.
43. Remove the 2 nuts and the transaxle-to-engine stud.
44. Remove the 3 bolts and the halfshaft support bracket.
45. Using the Adjustable Grip Arm, secure the engine and transaxle to the Powertrain Lift.
46. Remove the RH transaxle support insulator bolt and the mass damper (if equipped).
47. Remove the bolt, nuts and the RH transaxle support insulator.
48. Remove the rear transaxle support through bolt.
49. Remove the 3 engine support bracket nuts and the bolt. Remove the engine support bracket.
50. Lower the powertrain from the vehicle.
51. Remove the nut and the starter wiring ground.
52. Remove the 2 nuts and the starter wiring.
53. Remove the 2 stud bolts and the starter. AWD vehicles
54. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
55. Remove the 3 bolts and the RH heat shield.
56. Remove the 3 nuts and the RH catalytic converter. Discard the nuts and gasket.
57. Remove the bolts and the Power Transfer Unit (PTU) support bracket.
58. Remove the bolt, detach the pin-type retainer and position the PTU vent tube aside.
59. Remove the 3 PTU bolts.
60. Remove the bolt and the PTU .
61. Remove the 3 bolts and the PTU heat shield.
62. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. All vehicles
63. Install the lower half of the Engine Lifting Bracket Set.
64. Install the upper half of the Engine Lifting Bracket Set.
65. Install the Adjustable Grip Arm and the Engine Lifting Bracket to the front of the RH cylinder head.
66. Install the Adjustable Grip Arm and the Engine Lifting Bracket to the rear of the LH cylinder head.
67. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine and transaxle from the Powertrain Lift.
68. Remove the 5 remaining transaxle-to-engine bolts (3 shown in illustration).
69. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, separate the engine and transaxle.

SPECIAL TOOLS 3 Jaw Puller 303-D121 (or equivalent) Installer, Connecting Rod 303-462 (T94P-6136-AH) Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, Stretchy Belt 303-1419 Slide Hammer 307-005 (T59L-100-B)

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

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 may cause engine failure.

Note. For additional information, refer to the exploded view under the Assembly procedure in this service information.

All vehicles

Scheme 755

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Scheme 833

1. Remove the bolts and the flexplate.
2. Remove the engine-to-transaxle separator plate.
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
4. Mount the engine on a suitable stand.
5. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
6. Disconnect the electronic throttle control electrical connector.
7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
9. Detach the wiring harness retainer from the upper intake manifold.
10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
11. Disconnect the RH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers. Front Wheel Drive (FWD) vehicles
12. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
13. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
14. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
15. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
16. Disconnect the fuel injector wiring harness electrical connector.
17. Disconnect the LH VCT electrical connector.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
19. Disconnect the LH HO2S electrical connector.
20. Disconnect the 3 LH coil-on-plug electrical connectors. Detach the 2 wiring harness retainers.
21. Remove the nut and the B+ wire from the generator.
22. Detach the 2 wiring harness retainers. Remove the B+ harness from the engine.
23. Remove the EGR tube fitting from the EGR valve.
24. Remove the 2 upper intake manifold bracket bolts (1 shown in illustration).
25. Remove the 7 bolts and the upper intake manifold. Remove and discard the gaskets.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 8 lower intake manifold bolts and the lower intake manifold. Remove and discard the gaskets.
28. Remove the 6 bolts and the 6 coil-on-plugs. FWD vehicles
29. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
30. Remove the 3 bolts and the RH heat shield.
31. Remove the 3 nuts and the RH catalytic converter. Discard the nuts and gasket. All vehicles
32. Remove the 6 RH exhaust manifold nuts and the manifold. Discard the nuts and gasket.
33. Remove and discard the 6 RH exhaust manifold studs.
34. Remove the bolt, 2 nuts and the generator.
35. Remove the 3 bolts and the A/C compressor bracket.
36. Remove the 3 bolts and the LH heat shield.
37. Remove the stud bolt and the oil level indicator and tube. Remove and discard the O-ring seal.
38. Remove the 6 nuts, the LH catalytic converter and the gasket. Discard the gasket and nuts.
39. Remove and discard the 6 LH exhaust manifold studs.
40. Remove the EOP switch and, if equipped, the block heater.
41. Remove and discard the oil filter.
42. Position the Stretchy Belt Remover under the coolant pump belt as shown in illustration.
43. With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown in illustration.
44. Remove the coolant pump belt. Fold the Stretchy Belt Remover over the top of the coolant pump belt. In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
45. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
46. Remove the 5 coolant pump housing bolts.
47. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
48. Remove the nut and the radio interference capacitor.
49. Remove the bolts and the RH valve cover. Discard the gasket.
50. Remove the bolts and the LH valve cover. Discard the gasket.
51. Remove the 15 bolts and the oil pan. Discard the gasket.
52. Remove the 2 bolts and the oil pump screen and pickup tube.
53. Remove and discard the O-ring seal.
54. Remove the oil pan baffle. Remove the 4 M6 oil pan baffle nuts. Remove the 4 M8 oil pan baffle nuts.
55. Remove the 3 bolts and the accessory drive belt tensioner.
56. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
57. Using the 3 Jaw Puller, remove the crankshaft pulley.
58. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
59. Remove the 2 bolts and the LH VCT .
60. Remove the 2 bolts and the RH VCT .
61. Remove the 14 bolts, 2 stud bolts and the engine front cover. Discard the gaskets.
62. Remove the LH and RH spark plugs.
63. Remove the ignition pulse wheel.
64. Install the crankshaft pulley bolt and washer.
65. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
66. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
67. Verify that the RH camshafts are in the neutral position.
68. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
69. Remove the 2 bolts and the RH timing chain guide. Remove the RH timing chain from the engine.
70. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
71. Verify the LH camshafts are in the neutral position.
72. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
73. Remove the 2 bolts and the LH timing chain guide. Remove the LH timing chain from the engine.
74. Remove the crankshaft pulley bolt and the crankshaft sprocket.
75. Remove the 4 bolts in the sequence shown in illustration. Remove the oil pump.
76. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
77. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
78. Verify the LH camshafts are in the neutral position.
79. Remove the 3 bolts and the LH camshaft phaser and sprocket.
80. Remove and discard the VCT system oil filter screen from the LH camshaft.
81. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
82. Loosen the bolts evenly in the sequence shown in illustration. Remove the camshaft bearing thrust caps (1L and 5L). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
83. Verify the RH camshafts are in the neutral position.
84. Remove the 3 bolts and the RH camshaft phaser and sprocket.
85. Remove and discard the VCT system oil filter screen from the RH camshaft.
86. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
87. Loosen the bolts evenly in the sequence shown in illustration. Remove the camshaft bearing thrust caps (5R and 1R). Remove the remaining camshaft bearing caps. Remove the camshafts from the cylinder head.
88. Remove the LH and RH camshaft roller followers. Mark the location of the roller followers, using a permanent-type marker.
89. Remove the hydraulic lash adjusters.
90. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the bolts and the gaskets.
91. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
92. 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.
93. Remove the bolts and the oil separator cover. Discard the gasket.
94. Remove the crankshaft key.
95. 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.
96. Remove the connecting rod cap bolts and cap. Discard the connecting rod cap bolts.
97. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
98. Repeat the previous 2 steps until all of the piston/rod assemblies are removed from the engine block.
99. Remove the engine block from the stand and place on a workbench.
100. Remove the bolts and studs in the indicated sequence. Discard the lower cylinder block bolts. Remove the lower cylinder block.
101. Remove the crankshaft rear main seal. Remove the crankshaft.
102. Remove the crankshaft thrust bearing from the cylinder block.
103. Remove the bearings from the lower cylinder block.
104. Remove the crankshaft main bearings from the cylinder block.
105. Inspect the cylinder block, lower cylinder block, 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 303-1418 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 834

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Scheme 838

ITEM DESCRIPTION

Disassembly

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations. If not reassembled in their original positions, severe engine damage may occur.

Scheme 839

1. Using the Valve Spring Compressors, remove the keys, retainer and spring.
2. Remove the valve from the cylinder head.
3. Remove the valve stem seal.

Scheme 840

Scheme 841

1. Using the Valve Stem Oil Seal Installer, install the valve stem seal.
2. Install the valve.
3. Using the Valve Spring Compressors, install the valve spring, retainer and keys.

MATERIAL SPECIFICATIONS

Scheme 842

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 843

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. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location

SPECIAL TOOLS Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Connecting Rod 303-462 (T94P-6136-AH) Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Lifting Bracket, Engine 303-050 (T70P-6000) Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Scheme 844

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Scheme 853

MATERIAL SPECIFICATIONS

Scheme 854

ITEM DESCRIPTION

Scheme 855

ITEM DESCRIPTION

Scheme 856

ITEM DESCRIPTION

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. If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

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

All vehicles

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1. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block rear face. The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2. The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
6. Install the crankshaft key.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.
9. Apply gasket and sealant to the cylinder block as shown in illustration.
10. Position the lower cylinder block and install the new bolts and new studs. Tighten the bolts and studs in the sequence shown in 4 stages. Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees. Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
11. 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 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
13. Install the engine-to-transaxle separator plate.
14. Position the flexplate and install the bolts. Tighten to 80 Nm (59 lb-ft).
15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores. Measure the cylinder block bore diameter. Mark the outside of the block with the appropriate number(s) to identify bore grade size. Choose the correct piston grade size for the cylinder bore.
17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
18. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft).
19. Install the crankcase cover, a new gasket and the bolts. Tighten to 10 Nm (89 lb-in).
20. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence in illustration in 6 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten to 90 Nm (66 lb-ft). Stage 3: Loosen one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten 90 degrees. Stage 6: Tighten 90 degrees.
21. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).
22. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
23. Apply clean engine oil to the LH and RH camshaft roller followers.
24. Install the LH and RH camshaft roller followers.
25. Install the new LH and RH oil filter screens in the intake camshafts.
26. Position the camshaft phaser and sprockets onto the intake camshafts. Install the 3 bolts finger-tight.
27. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the LH camshafts as shown in illustration.
28. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
29. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
30. Tighten the LH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
31. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
32. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 10 Nm (89 lb-in).
33. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
34. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head. Align the RH camshafts as shown in illustration.
35. Install the camshaft bearing caps. Loosely install the bolts.
36. Install the camshaft bearing thrust caps. Loosely install the bolts.
37. Tighten the RH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
38. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
39. Position the oil pump and install the bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
40. Remove the crankshaft pulley bolt.
41. Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
42. Position the chain tensioner in a soft-jawed vise.
43. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
44. Slowly compress the timing chain tensioner.
45. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
46. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
47. Position the LH timing chain and guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
48. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
49. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
50. Verify that the RH camshafts are correctly positioned.
51. Install the RH timing chain and chain guide and install the bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
52. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts. Tighten to 25 Nm (18 lb-ft).
53. Remove the LH and RH timing chain tensioner piston retaining wires.
54. Rotate the crankshaft counterclockwise 120 degrees to TDC.
55. Verify the timing with the following steps. There should be 12 chain links between the camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
56. Remove the crankshaft pulley bolt and washer.
57. Install the ignition pulse wheel.
58. Install the LH and RH spark plugs. Tighten to 15 Nm (133 lb-in).
59. Use a plastic scraping tool to remove all traces of sealant. Clean all sealing surfaces with metal surface prep and install new gaskets.
60. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
61. Position the front cover and install the bolts and stud bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
62. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid. Tighten to 10 Nm (89 lb-in).
63. Install the 2 bolts and the RH VCT solenoid. Tighten to 10 Nm (89 lb-in).
64. Apply clean engine oil to the seal lip and seal bore before installing the seal.
65. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
66. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
68. Install the bolt and washer. Tighten the bolt in 4 stages: Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
69. Install the belt tensioner and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
70. Install the 8 nuts and the oil pan baffle in the following sequence. Tighten the 4 M6 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten an additional 45 degrees. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten an additional 45 degrees.
71. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate the O-ring seal with clean engine oil.
72. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the 2 bolts and tighten to 10 Nm (89 lb-in).
73. Install the new gasket in the LH valve cover in the following sequence. Install the gasket at waffle pads and then the corners. Install the gasket around bolt holes. Install the remaining part of the gasket.
74. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
75. Position the LH valve cover and install the bolts and stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
76. Install the new gasket in the RH valve cover in the following sequence. Install the gasket at waffle pads and then the corners. Install the gasket around bolt holes. Install the remaining part of the gasket.
77. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
78. Position the RH valve cover and install the bolts and stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
79. Install the radio interference capacitor and the nut. Tighten to 6 Nm (53 lb-in).
80. Position the coolant pump housing and attach the coolant hose. Tighten the clamp to 7 Nm (62 lb-in).
81. Install the 5 coolant pump housing bolts. Tighten to 10 Nm (89 lb-in).
82. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
83. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration. Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
84. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
85. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
86. Lubricate the O-ring seal with clean engine oil and install the oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
87. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater. Tighten the EOP switch to 14 Nm (124 lb-in). Tighten the block heater to 21 Nm (15 lb-ft).
88. Install 6 new LH catalytic converter studs. Tighten to 12 Nm (106 lb-in).
89. Install a new gasket and the LH catalytic converter and 6 new nuts. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
90. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
91. Position the oil level indicator and tube and install the stud bolt. Tighten to 10 Nm (89 lb-in).
92. Install the 3 bolts and the LH heat shield. Tighten to 10 Nm (89 lb-in).
93. Install the 3 bolts and the A/C compressor bracket. Tighten to 25 Nm (18 lb-ft).
94. Position the generator and install the bolt and 2 nuts. Tighten to 47 Nm (35 lb-ft).
95. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
96. Install a new gasket and the RH exhaust manifold and new nuts. Tighten the nuts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in). FWD vehicles
97. Install a new gasket and the RH catalytic converter and the 3 new nuts. Tighten to 40 Nm (30 lb-ft).
98. Install the 3 bolts and the RH heat shield. Tighten to 10 Nm (89 lb-in).
99. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
100. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. Install the 6 coil-on-plugs and the bolts. Tighten to 6 Nm (53 lb-in).
101. Position the lower intake manifold and install the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
102. 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.
103. Install the 4 bolts and the fuel rail and injectors assembly. Tighten to 10 Nm (89 lb-in).
104. Position the upper intake manifold and install the 7 bolts. Tighten the bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
105. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown in illustration), then tighten all the bolts. Tighten to 10 Nm (89 lb-in).
106. Install the EGR tube fitting in the EGR valve. Tighten to 40 Nm (30 lb-ft).
107. Position and attach the 3 B+ wiring harness retainers.
108. Install the B+ wire and nut on the generator. Tighten to 8 Nm (71 lb-in).
109. Connect the 3 LH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers.
110. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
111. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
112. Connect the LH VCT electrical connector.
113. Connect the fuel injector wiring harness electrical connector.
114. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
115. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
116. Connect the RH VCT electrical connector.
117. Connect the RH coil-on-plug electrical connectors. Attach the 2 wiring harness retainers. FWD vehicles
118. Connect the RH HO2S electrical connector. All vehicles
119. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
120. Attach the wiring harness retainer to the upper intake manifold.
121. Connect the EGR regulator electrical connector and attach the wiring retainer.
122. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
123. Connect the electronic throttle control electrical connector.
124. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
125. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.

MATERIAL SPECIFICATIONS Engine Lifting Bracket Set 303-1140 Handle 205-153 (T80T-4000-W) Installer, PTO Driven Gear Oil Seal 308-429 Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 954

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Scheme 960

MATERIAL SPECIFICATIONS

Note. If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

All vehicles

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1. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the engine with the transaxle.
2. Install the 5 transaxle-to-engine bolts (3 shown in illustration). Tighten to 48 Nm (35 lb-ft).
3. Using the Adjustable Grip Arm, secure the engine and transaxle to the Powertrain Lift. All-Wheel Drive (AWD) vehicles
4. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
5. Install the Power Transfer Unit (PTU) heat shield and the 3 bolts. Tighten to 11 Nm (97 lb-in).
6. Position the PTU and install the bolt. Tighten to 45 Nm (33 lb-ft).
7. Install the 3 PTU bolts. Tighten to 45 Nm (33 lb-ft).
8. Install the PTU vent tube, the pin-type retainer and the bolt. Tighten to 14 Nm (124 lb-in).
9. Install the PTU support bracket and bolts. Tighten to 55 Nm (41 lb-ft).
10. Install a new gasket and the RH catalytic converter and the 3 new nuts. Tighten to 40 Nm (30 lb-ft).
11. Install the 3 bolts and the RH heat shield. Tighten to 10 Nm (89 lb-in).
12. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector. All vehicles
13. Install the 2 stud bolts and the starter. Tighten to 27 Nm (20 lb-ft).
14. Install the 2 nuts and the starter wiring. Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in). Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
15. Install the nut and the starter wiring ground. Tighten to 18 Nm (159 lb-in).
16. Position the powertrain into the vehicle.
17. Install the engine support bracket, the bolt and the 3 nuts. Tighten the nuts to 55 Nm (41 lb-ft). Tighten the bolt to 90 Nm (66 lb-ft).
18. Install the rear transaxle support through bolt. Tighten to 103 Nm (76 lb-ft).
19. Position the RH transaxle support insulator and install the bolt and nuts. Tighten to 80 Nm (59 lb-ft).
20. Install the RH transaxle support insulator through bolt and mass damper (if equipped). Tighten to 115 Nm (85 lb-ft).
21. Install the 3 bolts and the halfshaft support bracket. Tighten to 48 Nm (35 lb-ft).
22. Install the transaxle-to-engine stud and 2 nuts. Tighten to 48 Nm (35 lb-ft).
23. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
24. Position the oil pan and gasket and loosely install the bolts and stud bolts.
25. Install the 2 oil pan-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
26. Tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
27. Install the 4 torque converter nuts. Tighten to 40 Nm (30 lb-ft).
28. Install the access cover.
29. If equipped, connect the engine block heater electrical connector.
30. Install the ground wire eyelet and nut to the engine mount stud. Tighten to 25 Nm (18 lb-ft).
31. Connect the electrical connector to the Power Distribution Box (PDB).
32. Install the cable and the nut to the PDB. Tighten to 12 Nm (106 lb-in).
33. Attach the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
34. Attach the wiring harness retainer to the battery tray bracket.
35. Connect the middle PCM electrical connector and the engine wiring harness electrical connector. Attach the 2 wiring harness retainers.
36. Connect the Evaporative Emission (EVAP) canister purge valve tube and the brake booster vacuum tube to the intake manifold.
37. Attach the shift cable retainer to the bracket.
38. Position the shift cable and bracket in place, install the bolts. Tighten to 23 Nm (17 lb-ft).
39. Connect the gearshift cable to the transaxle.
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/mariner/ii-2011-2011/remont/fuel-system/#fuel-system-general-information) article.
41. Connect the 2 heater hoses.
42. Connect the upper and lower radiator hoses.
43. Connect the 2 transmission electrical connectors and attach the wiring retainer to the stud bolt.
44. Connect the 2 transaxle fluid cooler tubes.
45. Install the 2 secondary latches to the transaxle fluid cooler tubes.
46. Install the cross brace and the new nut finger-tight.
47. Install the 2 bolts for the cross brace and the bolt for the front roll restrictor. Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft). Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
48. Tighten the cross brace nut to 175 Nm (129 lb-ft).
49. Connect the generator electrical connector.
50. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
51. Connect the A/C compressor electrical connector.
52. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. AWD vehicles
53. Align the index-marks made during removal and install 6 new front driveshaft-to- PTU bolts and washers. Tighten to 37 Nm (27 lb-ft). All vehicles
54. Install the intermediate shaft.
55. Install the 2 intermediate shaft bearing retainer nuts. Tighten to 27 Nm (20 lb-ft).
56. Install the RH and LH halfshaft and the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/mercury/mariner/ii-2011-2011/remont/axle-shafts/#front-drive-halfshafts) article.
57. Install the exhaust-Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-434503) article.
58. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
59. Connect the LH CMS electrical connector.
60. Install the lateral support crossmember and the 4 bolts. Tighten to 115 Nm (85 lb-ft).
61. Install the lower splash shields and bolts. Tighten to 9 Nm (80 lb-in).
62. 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.
63. Install the Air Cleaner (ACL) outlet pipe and ACL . For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(/mercury/mariner/ii-2011-2011/remont/removal-installation/#intake-air-distribution-and-filtering-30l-4v) article.
64. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(ref-434539) article.
65. Fill the engine with clean engine oil.
66. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/mariner/ii-2011-2011/remont/cooling-system-mechanical/#engine-cooling-except-hybrid) article.
67. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

See also:
• IDENTIFICATION CODES
• INTRODUCTION
• ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION
• INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)
• FUEL SYSTEM - GENERAL INFORMATION
• FUEL CHARGING AND CONTROLS - 3.0L (4V)
• ENGINE IGNITION - 3.0L (4V)
• JACKING & LIFTING
• ACCESSORY DRIVE - 3.0L (4V)
• AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35
• ELECTRONIC ENGINE CONTROLS - 3.0L (4V)
• ENGINE COOLING
• TIRES & WHEELS
• FRONT DRIVE HALFSHAFTS
• UPPER INTAKE MANIFOLD