Mercury Repair Questions? Ask a Mechanic for Answers ASAP
Hi, I am Mike, welcome. I'm reviewing your question.
I don't see a by pass pulley and Dorman sells them. I believe you will have to repair what you got.
It appears the last by pass pulley available was for the 2005 Mercury shown here, http://www.dormanproducts.com/p-85708-34274.aspx?year=2005&make=Mercury&origin=keyword
They also appear to be for the 4.0
I was looking at the diagram and it looked to me as though if you also bypassed the other pulley, maybe. Let me get that belt routing diagram back.
here, if you also bypassed #4.
I don't know what belt would fit though, but I suppose you could just measure it with a clothing tape measure.
Yes, it looks like it to me as though it will just miss the bottom of that tensioner.
Check it right now, Remove the tension from the belt and slip it off, than run it like you want right now, leaving everything on, just bypass it then pull on the belt to tighten it up and see if it will hit.
Sounds like a plan.