25 Sep 08 Ford Merkur Fuel Injector Change DIY
1. Disconnect battery ground cable.
2. On vehicles equipped with automatic transmission, disconnect kickdown cable from throttle linkage.
3. On all models, disconnect accelerator cable from throttle linkage.
4. Remove screws attaching accelerator cable bracket to upper intake manifold , then position bracket, accelerator cable and the automatic transmission kickdown cable, if equipped, out of way.
5. Disconnect fuel pressure regulator vacuum hose from fuel pressure regulator and the upper intake manifold fitting.
6. Disconnect positive crankcase ventilation (PCV ) hose at upper intake manifold fitting.
7. Disconnect coil wire from distributor cap and position out of way.
8. Remove distributor cap attaching screws and the cap, positioning out of way.
9. Using suitable vacuum pump, depressurize fuel system. Connect pump hose to fuel system pressure regulator and apply at least 25 inches of vacuum. Fuel supply lines will remain pressurized for some period of time after engine is shut off. System pressure must be relieved before disconnecting any fuel lines.
10. Disconnect vacuum pump from fuel pressure regulator.
11. Disconnect fuel supply line from fuel supply manifold.
12. Using tool T822-9500-AH or equivalent, disconnect fuel return line.
13. Remove fuel pulse damper to mounting bracket attaching nut.
14. Cut fuel injection wiring harness routing strap at fuel pulse damper bracket, if necessary.
15. Disconnect fuel injector wiring harness connector.
16. Disconnect electrical connector from coolant temperature sender at cylinder block.
17. Remove fuel supply manifold assembly front retaining bolt,
18. Remove fuel supply manifold assembly rear attaching bolt,
19. Remove fuel supply manifold assembly by disengaging each fuel injector from lower intake manifold, then carefully pulling the whole assembly out from under the upper intake manifold toward front of engine.
20. Remove three Allen head attaching screws and the fuel pressure regulator from the fuel supply manifold.
21. Remove each injector from fuel supply manifold.
22. Disconnect electrical connector at each injector.
23. Reverse procedure to install, torquing fuel supply manifold attaching bolts to 15-22 ft. lbs.
Tags: Fuel
15 Sep 08 Merkur Fuel Pump Change
CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.
NOTE: The low-pressure pump is not serviced separately. It and the fuel sending unit are replaced as an assembly.
Removal
1. Remove the fuel tank . If necessary.
2. Remove the sending unit/ fuel pump lock ring using Lock Ring Tool D84P-9275-A, or
equivalent. Turn the lock ring counterclockwise to release from the tank.
3. Remove the lock ring, seal ring and sending unit/ fuel pump from the fuel tank .
Installation
1. Clean the fuel tank seal ring groove.
2. Put a light coating of C1AZ-19590-B, or equivalent heavy-duty grease, on a new seal
ring to prevent the lock ring from dragging on the seal during installation.
3. Position the new seal ring in the fuel tank groove.
4. Position the sending unit/ fuel pump in the fuel tank.
5. Hold the assembly in position and install the lock ring fingertight. Make sure that all
locking tabs are under the tank lock ring tabs.
6. Tighten the lock ring using Lock Ring Tool D84P-9275-A, or equivalent.
Tags: Fuel
