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Engine - 3.9L and 4.2L: Component Locations Mercury Monterey VIII

Mechanical 26 illustrations ~1502 words

Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Remover, Spark Plug Wire 303-106 (T74P-6666-A)

Scheme 89

Scheme 89: Special Tool(s)
Scheme 89: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Crankshaft Vibration Damper 303-176 (T82L-6316-B) Installer, Crankshaft Vibration Damper 303-175 (T82L-6316-A)

Scheme 90

Scheme 90: Special Tool(s)
Scheme 90: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Remover, Oil Seal 303-409 (T92C-6700-CH) Installer, Crankshaft Front Oil Seal 303-335 (T82L-6316-A) Installer, Crankshaft Front Oil Seal 303-474 (T94P-6701-AH)

Scheme 91

Scheme 91: Special Tool(s)
Scheme 91: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Impact Slide Hammer 100-001 (T50T-100-A) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH) Replacer, Rear Crankshaft Seal 303-516 (T95P-6701-BH) Spacer, Rear Crank Seal Replacer 303-561 (T96T-6701-B) Adapter, Crankshaft Rear Seal (Use only the adapter retaining bolts) 303-518 (T95P-6701-DH) Adapter, Crankshaft Rear Seal (Use only the adapter retaining bolts) 303-S560 (T96T-6701-A)

Scheme 92

Scheme 92: Special Tool(s)
Scheme 92: Special Tool(s)

Scheme 93

Scheme 93
Scheme 93

Scheme 94

Scheme 94
Scheme 94

SPECIAL TOOL SPECIFICATIONS Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Crankshaft Vibration Damper 303-176 (T82L-6316-B) Installer, Crankshaft Vibration Damper 303-175 (T82L-6316-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Installer, Crankshaft Front Oil Seal 303-335 (T82L-6316-A) Installer, Crankshaft Front Oil Seal 303-474 (T94P-6701-AH)

SPECIAL TOOL SPECIFICATIONS Compressor, Valve Spring 303-163 (T81P-6513-A)

Scheme 95

Scheme 95: Special Tool(s)
Scheme 95: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Engine Lift Bracket Set 303-D095 (D94L-6001-A)

Scheme 96

Scheme 96: Special Tool(s)
Scheme 96: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Support Bar, Engine 303-290A Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Spreader Bar) 303-290A-10 Adapter for 303-290A (Strut) 303-290A-09 Lifting Bracket Set, Engine 303-D095 (D94L-6001A) or equivalent

Scheme 97

Scheme 97: Special Tool(s)
Scheme 97: Special Tool(s)

Scheme 98

Scheme 98
Scheme 98

Scheme 99

Scheme 99
Scheme 99

Scheme 100

Scheme 100: Removal and Installation
Scheme 100: Removal and Installation
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the hood.
  3. Remove the wiper motor and pivot assembly. For additional information, refer to WIPERS AND WASHERS .
  4. Remove the 2 engine roll restrictor bolts and the engine roll restrictor. To install, tighten to 63 Nm (46 lb-ft).
  5. Remove the transaxle support insulator nut. To install, tighten to 90 Nm (66 lb-ft).
  6. Remove the LH engine mount nut. To install, tighten to 90 Nm (66 lb-ft).
  7. Remove the RH engine mount nut. To install, tighten to 90 Nm (66 lb-ft).
  8. Using the special tools, raise the engine.
  9. Remove the RH engine mount bolt. To install, tighten to 90 Nm (66 lb-ft).
  10. Remove the RH engine mount.
  11. To install, reverse the removal procedure.

SPECIAL TOOL SPECIFICATIONS Support Bar, Engine 303-290A Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Spreader Bar) 303-290A-10 Adapter for 303-290A (Strut) 303-290A-09 Lifting Bracket Set, Engine 303-D095 (D94L-6001A) or equivalent

SPECIAL TOOL SPECIFICATIONS Powertrain Lift (014-00765) Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Scheme 101

Scheme 101: Special Tool(s)
Scheme 101: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Impact Slide Hammer 100-001 (T50T-100-A) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover, Oil Seal 303-409 (T92C-6700-CH) Remover, Crankshaft Vibration Damper 303-176 (T82L-6316-B)

SPECIAL TOOL SPECIFICATIONS Compressor, Valve Spring 303-163 (T81P-6513-A)

SPECIAL TOOL SPECIFICATIONS Pin Remover/Replacer 303-S024 (T68P-6135-A)

Scheme 102

Scheme 102: Special Tool(s)
Scheme 102: Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Service Set, Camshaft 303-017 (T65L-6250-A) Installer, Crankshaft Front Oil Seal 303-335 (T82L-6316-A) Installer, Crankshaft Front Oil Seal 303-474 (T94P-6701-AH) Installer, Crankshaft Vibration Damper 303-175 (T82L-6316-A) Replacer, Rear Crankshaft Seal 303-516 (T95P-6701-BH) Spacer, Rear Crank Seal Replacer 303-561 (T96T-6701-B) Adapter, Crankshaft Rear Seal (Use only the adapter retaining bolts) 303-518 (T95P-6701-DH) Adapter, Crankshaft Rear Seal (Use only the adapter and the center jack screw) 303-S560 (T96T-6701-A) Engine Lifting Brackets 303-D095 (D94L-6001-A) Synchronizer Alignment Gauge 303-630

Scheme 103

Scheme 103: Special Tool(s)
Scheme 103: Special Tool(s)

Scheme 104

Scheme 104
Scheme 104

Scheme 105

Scheme 105
Scheme 105

SPECIAL TOOL SPECIFICATIONS Powertrain Lift (014-00765) Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Scheme 106

Scheme 106
Scheme 106

Scheme 107

Scheme 107
Scheme 107

Scheme 108

Scheme 108
Scheme 108

Scheme 109

Scheme 109
Scheme 109

Scheme 110

Scheme 110
Scheme 110

Scheme 111

Scheme 111
Scheme 111

Scheme 112

Scheme 112
Scheme 112

Scheme 113

Scheme 113
Scheme 113

Scheme 114

Scheme 114
Scheme 114
  1. Position the engine onto the transaxle and subframe assembly.
  2. Install the engine mount bracket-to-transaxle bolts. Tighten to 63 Nm (46 lb-ft).
  3. Install the oil pan-to-transaxle bolt. Tighten to 45 Nm (33 lb-ft).
  4. Install the RH engine mount and bolt. Tighten to 90 Nm (66 lb-ft).
  5. Install the LH engine mount and bolt. Tighten to 90 Nm (66 lb-ft).
  6. Install the bellhousing bolts. Tighten to 50 Nm (37 lb-ft).
  7. Install the transaxle fluid level indicator and tube and bolt. Tighten to 10 Nm (89 lb-in).
  8. Attach the electrical connector to the subframe.
  9. Attach the 2 electrical connectors to the wiring harness bracket.
  10. Connect the electrical connectors.
  11. Install the wiring harness pin-type retainer.
  12. Connect the turbine shaft speed (TSS) sensor.
  13. Connect the transaxle electrical connectors.
  14. Install the wiring harness pin-type retainer.
  15. Position the engine roll restrictor bracket and install the bolts. Tighten to 50 Nm (37 lb-ft).
  16. Install the engine wiring harness into the retainers.
  17. Attach the electrical connector to the subframe.
  18. Install the engine wiring harness into the retainer.
  19. Position the A/C compressor and install the bolts. Tighten to 25 Nm (18 lb-ft).
  20. Connect the A/C compressor electrical connector.
  21. Install the generator brace bolt. Tighten to 47 Nm (35 lb-ft).
  22. Using a 19-mm (0.76-in) dowel, check the front subframe alignment. The dowel should slide directly through the front subframe and body without tilting.
  23. Using the powertrain lift, raise the engine, transaxle and subframe assembly in the vehicle.
  24. Install the 4 subframe bolts (3 shown in illustration). Tighten to 90 Nm (66 lb-ft).
  25. Install the RH and LH strut bolts. Tighten to 124 Nm (91 lb-ft).
  26. Connect the RH and LH front stabilizer links and install the nuts. Tighten to 95 Nm (70 lb-ft).
  27. Connect the RH and LH anti-lock brake sensor (ABS) electrical connectors.
  28. Install the RH and LH ABS sensor wiring harness retainers.
  29. Install the RH and LH brake calipers and install the bolts. Tighten to 35 Nm (26 lb-ft).
  30. Install the 4 torque converter nuts. Tighten to 36 Nm (27 lb-ft).
  31. Install the inspection cover bolt. Tighten to 10 Nm (89 lb-in).
  32. Install the oil pan-to-transaxle bolts. Tighten to 45 Nm (33 lb-ft).
  33. Install the RH and LH lower engine mount nuts. Tighten to 80 Nm (59 lb-ft).
  34. Connect the lower radiator hose. Position the clamp.
  35. Connect the steering column. Slide the joint downward. Install the bolt and tighten to 40 Nm (30 lb-ft).
  36. Install the transaxle cooler tubes. Connect the tubes. Install the clips.
  37. Install the power steering cooling hose into the retaining clip.
  38. Connect the power steering oil cooler hose. Position the clamp.
  39. Position the A/C compressor manifold and install the bolt. Tighten to 20 Nm (15 lb-ft).
  40. Connect the A/C electrical connector.
  41. Connect the heater hose.
  42. Install the ground cable. Tighten to 10 Nm (89 lb-in).
  43. Install the ground cable. Tighten to 10 Nm (89 lb-in).
  44. Position the engine roll restrictor and install the bolts. Tighten to 63 Nm (46 lb-ft).
  45. Install the 2 engine harness retainers.
  46. Install the sight shield. Install the pin-type retainers.
  47. Connect the degas bottle hose. Position the clamp.
  48. Connect the PCM and tighten the bolt. Tighten to 10 Nm (89 lb-in).
  49. Position the engine wire harness ground and install the bolt. Tighten to 10 Nm (89 lb-in).
  50. Install the engine wiring harness pin-type retainer.
  51. Connect the EVAP canister purge valve electrical connector and vacuum hose.
  52. Connect the brake booster vacuum hose. Position the clamp.
  53. Install the engine wiring harness into the retainer.
  54. Connect the EVAP emission return tube.
  55. Install the shift cable in the shift cable bracket.
  56. Connect the shift cable.
  57. Connect the 16-pin electrical connector.
  58. Install the engine wiring harness into the retainer.
  59. Install the engine wiring harness into the retainer.
  60. Install the 68-pin connector into the power distribution box. Connect the 68-pin connector to the power distribution box. Install the bolt and tighten to 10 Nm (89 lb-in). Attach the power distribution box to the bracket.
  61. Connect the B+ terminal to the power distribution box. Tighten to 10 Nm (89 lb-in).
  62. Install the power distribution box cover.
  63. Connect the upper radiator hose and heater hoses.
  64. Install the accelerator bracket. Position the bracket. Install the stud bolts and tighten to 10 Nm (89 lb-in). Attach the engine wiring harness retainer.
  65. Connect the accelerator cable end and the speed control actuator cable end. Install the throttle return spring.
  66. Install the dual converter Y-pipe. For additional information, refer to EXHAUST SYSTEM .
  67. Install the starter. For additional information, refer to STARTING SYSTEM .
  68. Install the power steering pump. For additional information, refer to POWER STEERING .
  69. If equipped, install the oil cooler coolant tubes and the bolt. Connect the upper quick disconnect oil cooler coolant tubes. Tighten to 25 Nm (18 lb-ft).
  70. If equipped, connect the 2 lower quick disconnect oil cooler coolant tubes.
  71. Connect the fuel supply manifold spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  72. Install the engine air cleaner and engine air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  73. Install the cowl top panel and bolts. Tighten to 6 Nm (53 lb-in).
  74. Connect the windshield wiper motor electrical connector.
  75. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  76. Connect the battery ground and positive cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  77. Fill the engine with clean engine oil.
  78. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  79. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  80. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .

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