Engine: Other Mercury Montego III

Material

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233015) .
3. Remove the pin-type retainers and the RH fender splash shield.
4. Use the special tool to hold the crankshaft pulley and remove the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

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1. Lubricate the front cover and 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 special tool, install the crankshaft pulley.
4. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, 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. Position the RH fender splash shield and install the pin-type retainers.
6. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-233015) .

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Scheme 177

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-233006-S23558798672006052400000) .
3. Using the special tools, remove the crankshaft rear oil seal and discard.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-233006-S24589360122006052400000) and «VALVE COVER - RH»(ref-233006-S03276844262006052400000) .
3. Remove the 6 spark plugs. To install, tighten to 15 Nm (11 lb-ft).
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 special tool, remove the roller followers.
7. To install, reverse the removal procedure.

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1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-233006-S25884087122006052400000) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer and the valve spring.
4. Remove the valve seal.

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Note. 6 speed transaxle shown, CVT similar.

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1. Remove the 8 bolts and the flexplate.
2. Using the special tools, remove and discard the crankshaft rear oil seal.
3. Mount the engine on a suitable stand.
4. If equipped, remove the 3 retainers and the A/C compressor pulley shield.
5. Rotate the tensioner counterclockwise and remove the accessory drive belt.
6. Disconnect the A/C compressor electrical connector.
7. Disconnect the LH catalyst monitor sensor electrical connector and detach the wiring retainer.
8. If equipped, remove the 2 nuts, the bolt and the A/C compressor shield.
9. If equipped, remove the bolt and the A/C compressor.
10. Remove the 2 bolts, 2 nuts and the A/C compressor.
11. Remove the 5 bolts and the A/C compressor bracket.
12. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and detach the wiring retainer.
13. Disconnect the oil pressure sensor electrical connector.
14. Remove the 2 nuts, disconnect the camshaft position sensor (CMP) and detach the retainers.
15. Loosen the fittings and remove the exhaust gas recirculation (EGR) system module tube.
16. Disconnect the EGR system module electrical connector.
17. Disconnect the throttle body electrical connector.
18. Disconnect the throttle body coolant hose.
19. Disconnect and remove the positive crankcase ventilation (PCV) tube.
20. Disconnect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
21. Disconnect the fuel charging wiring harness electrical connector.
22. Disconnect the RH HO2S and detach the retainer.
23. Remove the bolt and detach the power steering tube bracket.
24. Remove the bolt and detach the power steering tube bracket.
25. Remove the 2 nuts and detach the power steering fluid reservoir.
26. Remove the power steering fluid reservoir bracket nut.
27. Remove the 3 nuts and the power steering pump, reservoir and tubes.
28. Remove the 8 bolts and the upper and lower intake manifold. Remove and discard the gaskets.
29. Remove the nut and position the wiring conduit aside.
30. Disconnect the RH ignition coil electrical connectors and detach the wiring retainers.
31. Remove the nut and disconnect the generator wiring. Detach the wiring retainer.
32. Remove the nut and detach the ground wire.
33. Disconnect the crankshaft position sensor (CKP) electrical connector and detach the wiring retainer.
34. Disconnect the LH ignition coil electrical connectors and detach the wiring retainers.
35. Disconnect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.
36. Disconnect the bypass and the coolant pump hoses.
37. Remove the engine wiring harness.
38. Remove the stud bolt and the oil level indicator tube. Remove and discard the O-ring seal.
39. Remove and discard the oil filter.
40. Remove the 4 bolts and the oil filter adapter. Remove and discard the O-ring seal from the M22 bolt.
41. Remove the 2 nuts, bolt and the generator.
42. Remove the 4 bolts and the RH engine insulator bracket.
43. Remove and discard the 6 RH exhaust manifold nuts.
44. Remove the RH exhaust manifold. Remove and discard the gasket.
45. Remove and discard the 6 RH exhaust manifold studs.
46. Remove and discard the 6 LH exhaust manifold nuts.
47. Remove the LH exhaust manifold. Remove and discard the gasket.
48. Remove and discard the 6 LH exhaust manifold studs.
49. Remove the 6 bolts and the RH and LH ignition coils.
50. Remove the 6 bolts, 8 stud bolts and the LH valve cover. Remove and discard the gasket.
51. Remove the 9 bolts, 5 stud bolts and the RH valve cover. Remove and discard the gasket.
52. Remove the 2 bolts and the thermostat housing. Remove and discard the O-ring seal.
53. Remove the 4 bolts and the coolant pump.
54. Remove the 2 bolts and the coolant bypass tube.
55. Remove the bolt and the radio interference capacitor.
56. Remove the 15 bolts and the oil pan. Remove and discard the gasket.
57. Remove the 2 bolts and the oil pump screen and pickup tube. Remove and discard the O-ring seal.
58. Remove the 8 nuts and the oil pan baffle.
59. Remove the oil pressure sender.
60. If equipped, remove the block heater.
61. Use the special tool to hold the crankshaft damper and remove the bolt.
62. Using the special tool, remove the crankshaft damper.
63. Using the special tool, remove and discard the crankshaft front seal from the engine front cover.
64. Remove the bolt and the belt tensioner.
65. Remove the stud bolt, 14 bolts and the front cover. Remove and discard the gaskets.
66. Remove the ignition pulse wheel.
67. Install the damper bolt.
68. Remove the LH and RH spark plugs.
69. 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.
70. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
71. Verify that the RH camshafts are in the neutral position.
72. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
73. Remove the 2 bolts, RH timing chain guide and the timing chain.
74. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
75. Verify the LH camshafts are in the neutral position.
76. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
77. Remove the LH timing chain and timing chain guide.
78. Remove the damper bolt and the crankshaft sprockets.
79. Remove the 3 bolts and camshaft oil seal retainer. Remove and discard the press-in-place gasket.
80. Using a suitable press, remove the camshaft oil seal.
81. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
82. Remove the LH and RH camshafts.
83. Remove the LH and RH camshaft roller followers. Mark the location of the roller followers using a permanent-type marker.
84. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Remove and discard the gaskets and the bolts.
85. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
86. Support the cylinder head on a bench with the head gasket side up.
87. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
88. Remove the 3 bolts and the power steering pump bracket.
89. Remove the 2 bolts and the oil separator cover. Remove and discard the gasket.
90. Remove the crankshaft key.

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1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the oil separator cover, a new gasket and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the power steering pump bracket and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
4. Position the new gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown 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.
5. Install the crankshaft damper bolt and rotate the crankshaft key way to the 11 o'clock position to locate top dead center (TDC).
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
8. Apply clean engine oil to the LH and RH camshafts.
9. Install the LH and RH camshafts. Locate the camshafts as shown.
10. Lubricate the camshaft journal caps with clean engine oil. Position the LH camshaft caps and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
11. Position the RH camshaft caps and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
12. Install the camshaft oil seal retainer and the 3 bolts. Tighten to 10 Nm (89 lb-in).
13. Position the new camshaft oil seal on the special tool.
14. Position the special tool and the camshaft oil seal on the camshaft.
15. Using the special tools, install the camshaft oil seal.
16. Remove the crankshaft damper bolt.
17. Install the crankshaft sprocket with the timing marks facing outward.
18. Position the chain tensioner in a soft-jawed vise.
19. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
20. Slowly compress the timing chain tensioner.
21. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
22. 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.
23. Verify that the LH camshafts are correctly positioned.
24. Position the LH timing chain and guide and install the 2 bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
25. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
26. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
27. Verify that the RH camshafts are correctly positioned.
28. Install the RH timing chain and chain guide and install the 2 bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
29. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
30. Remove the LH and RH timing chain tensioner piston retaining wires.
31. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
32. 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.
33. Remove the crankshaft damper bolt.
34. Install the ignition pulse wheel.
35. Install the LH and RH spark plugs. Tighten to 15 Nm (11 lb-ft).
36. Install 3 new gaskets in the engine front cover.
37. 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.
38. Position the engine front cover. Install the 14 bolts and the stud bolt. Tighten in the sequence shown to 25 Nm (18 lb-ft).
39. Install the belt tensioner and the bolt. Tighten to 45 Nm (33 lb-ft).
40. Using the special tool, install a new crankshaft front seal.
41. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
42. Using the special tools, install the crankshaft pulley.
43. Using the special tool to hold the crankshaft pulley, install the bolt and washer and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn (360 degrees). Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten to 90 Nm (66 lb-ft).
44. If equipped, install the block heater. Tighten to 14 Nm (10 lb-ft).
45. Install the oil pressure sender. Tighten to 14 Nm (10 lb-ft).
46. Install the oil pan baffle and the 8 nuts. Tighten the M8 nuts to 15 Nm (11 lb-ft) and then rotate 45 degrees. Tighten the M6 nuts to 5 Nm (44 lb-in) and then rotate 45 degrees.
47. Position the oil pump screen and pickup tube and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
48. Install the radio interference capacitor and the bolt. Tighten to 8 Nm (71 lb-in).
49. Install the coolant bypass tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
50. Install the coolant pump and the 4 bolts. Tighten in 4 stages: Stage 1: Tighten the coolant pump center bolt to 4 Nm (35 lb-in). Stage 2: Loosely install the 3 coolant pump outer bolts. Stage 3: Tighten the coolant pump center bolt to 25 Nm (18 lb-ft). Stage 4: Tighten the 3 coolant pump outer bolts to 10 Nm (89 lb-in).
51. Install the thermostat housing and the 2 bolts. Tighten to 10 Nm (89 lb-in).
52. Clean the LH and RH valve cover sealing surfaces.
53. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-RH cylinder head joints.
54. Position the RH valve cover. Install the 9 bolts and 5 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
55. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-LH cylinder head joints.
56. Position the LH valve cover. Install the 6 bolts and 8 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
57. Install the RH and LH ignition coils and the 6 bolts. Tighten to 6 Nm (53 lb-in).
58. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
59. Position a new gasket and the LH exhaust manifold and converter. Install the 6 new nuts. Tighten to 20 Nm (15 lb-ft).
60. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
61. Position a new gasket and the RH exhaust manifold and converter. Install the 6 new nuts. Tighten to 20 Nm (15 lb-ft).
62. Install the RH engine insulator bracket and the 4 bolts. Tighten to 55 Nm (41 lb-ft).
63. Install the generator, nuts and the bolt. Tighten to 48 Nm (35 lb-ft).
64. Position the oil filter adapter and loosely install the bolts. Tighten in 3 stages: Stage 1: Tighten the M22 bolt to 25 Nm (18 lb-ft). Stage 2: Tighten the M8 bolt to 25 Nm (18 lb-ft). Stage 3: Tighten the M22 bolt to 155 Nm (111 lb-ft).
65. Install a new oil filter. Tighten to 16 Nm (12 lb-ft).
66. Install the oil level indicator tube and the stud bolt. Tighten to 9 Nm (80 lb-in).
67. Position the engine wiring harness.
68. Connect the bypass and the coolant pump hoses.
69. Connect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.
70. Connect the LH ignition coil electrical connectors and attach the wiring retainers.
71. Connect the crankshaft position sensor (CKP) electrical connector and attach the wiring retainer.
72. Attach the ground wire and install the nut. Tighten to 20 Nm (15 lb-ft).
73. Connect the generator wiring and install the nut. Attach the wiring retainer. Tighten to 8 Nm (71 lb-in).
74. Connect the RH ignition coil electrical connectors and attach the wiring retainers.
75. Position the wiring conduit on the valve cover studs and install the nut. Tighten to 6 Nm (53 lb-in).
76. Position the new gaskets and the upper and lower intake manifold. Install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
77. Position the power steering pump, reservoir bracket and tubes. Install the 3 nuts. Tighten to 25 Nm (18 lb-ft).
78. Install the power steering fluid reservoir bracket nut. Tighten to 9 Nm (80 lb-in).
79. Position the power steering fluid reservoir and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
80. Position the power steering tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
81. Position the power steering tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
82. Connect the RH HO2S and attach the retainer.
83. Connect the fuel charging wiring harness electrical connector.
84. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
85. Install and connect the positive crankcase ventilation (PCV) tube.
86. Connect the throttle body coolant hose.
87. Connect the throttle body electrical connector.
88. Connect the exhaust gas recirculation (EGR) system module electrical connector.
89. Position the EGR system module tube. Tighten to 40 Nm (30 lb-ft).
90. Connect the camshaft position sensor (CMP) electrical connector, attach the wiring retainers and install the 2 wiring conduit nuts. Tighten to 6 Nm (53 lb-in).
91. Connect the oil pressure sensor electrical connector.
92. Connect the LH heated oxygen sensor (HO2S) electrical connector and attach the wiring retainer.
93. Install the A/C compressor bracket and the 5 bolts. Tighten to 25 Nm (18 lb-ft).
94. Install the A/C compressor, 2 nuts and 2 bolts. Tighten to 25 Nm (18 lb-ft).
95. If equipped, install the A/C compressor and the bolt. Tighten to 25 Nm (18 lb-ft).
96. If equipped, install the A/C compressor shield, 2 nuts and the bolt. Tighten to 25 Nm (18 lb-ft).
97. Connect the LH catalyst monitor sensor electrical connector and attach the wiring retainer.
98. Connect the A/C compressor electrical connector.
99. Rotate the tensioner counterclockwise and install the accessory drive belt.
100. If equipped, install the A/C compressor pulley shield and the 3 retainers.
101. Install the special tool to the RH cylinder head.
102. Install the special tool to the LH cylinder head.
103. Install the lower half of the special tool.
104. Install the upper half of the special tool.
105. Using the special tools and a suitable engine crane, remove the engine from the engine stand.
106. Using the special tools, install the crankshaft rear oil seal.
107. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).

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