Engine System-General Information: Component Locations Mercury Montego III

Special Tool(s)

SPECIAL TOOL SPECIFICATION Quick Disconnect Compression Tester 134-R0212 or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Engine Cylinder Leak Detection/Air Pressurization Kit 014-00708 or equivalent Oil Pressure Gauge 303-088 (T73L-6600-A) 12 Volt Master UV Diagnostic Inspection Kit 164-R0756 or equivalent (Leak Detector) Vacuum/Pressure Tester 164-R0253 or equivalent

Scheme 280

Scheme 281

Scheme 282

Scheme 283

SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 284

1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the indicator.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install new camshaft and recheck end play. Refer to the appropriate engine article for the procedure. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Refer to the appropriate engine for the procedure.

Scheme 285

1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. If excessive pitting or damage is present, install new components as necessary. Refer to the appropriate engine article for the procedure.

SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 286

1. Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. For additional information, refer to the «SPECIFICATION»(ref-233008-S32263808752006052400000) chart in the appropriate engine section. If out of specification, install new components as necessary. Refer to the appropriate engine article for the procedure.

SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 287

1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the indicator.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Refer to the appropriate engine article for the procedure.

Scheme 288

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Refer to the appropriate engine article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate engine article for the procedure.

Scheme 289

1. Inspect the following valve areas: The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

Scheme 290

1. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer. Refer to the appropriate engine article for the specification.
3. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide.

Scheme 291

1. Measure the free length of each valve spring. Refer to the appropriate engine article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate engine article for the procedure.

Scheme 292

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Refer to the appropriate engine article for the procedure.

SPECIAL TOOL SPECIFICATION Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent

Scheme 293

Scheme 294

1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. Refer to the appropriate engine article for the procedure. If out of specification, install new components as necessary. Refer to the appropriate engine article for the procedure.

SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent Straight Edge 303-D039 (D83L-4201-a) or equivalent

Scheme 295

Scheme 296

1. Using a straight edge and a feeler gauge, inspect the cylinder head for flatness in the sequence shown. If the cylinder head is distorted, install a new cylinder head.

SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent Straight Edge 303-D039 (D83L-4201-A) or equivalent

Scheme 297

1. Use a straight edge and a feeler gauge to inspect the cylinder block for flatness. If the cylinder block is distorted, install a new short block assembly.

SPECIAL TOOL SPECIFICATION Straight Edge 303-D039 (D83L-4201-A) or equivalent

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
2. Using the special tool (or a precision straight edge) and a feeler gauge, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.

SPECIAL TOOL SPECIFICATION Slide Hammer 100-001 (T50T-100-A)