Engine Controls - Remove/install/overhaul Mercury Capri III

INTRODUCTION

Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal

Disconnect negative battery cable. On Capri, disconnect vacuum hose from vacuum control unit. Disconnect coil wire from distributor cap. Remove retaining screws and distributor cap. Unplug electrical connectors. Mark distributor housing and cylinder head for reassembly reference. Remove mounting bolts and distributor.

Installation

To install, reverse removal procedure. Install new "O" ring if damaged or worn. Insert and rotate distributor until drive tangs engage camshaft slots. (Scheme 1), (Scheme 2), or 3. Check and adjust timing as required.

Note. On Festiva, only rotor, inner and outer covers, and "O" ring are individually replaceable. DO NOT disassemble distributor. Entire unit is serviced only by replacement.

Scheme 1

Scheme 2

Scheme 3

Removal & Installation

Disconnect negative battery cable. On Festiva, remove heater duct from under instrument panel. On Capri, disengage push-pin retainers by pulling back on front edges of both center carpet panels. Remove carpet panel retaining screws and panels. Unplug ECA wire harness connector. Remove mounting bolts and ECA. To install, reverse removal procedure. On Festiva, ensure mounting clip is inserted into bulkhead recess.

FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE

Remove rear seat assembly. With engine running, unplug fuel pump connector. Run engine until it stalls to relieve fuel line pressure.

Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel tank sending unit. Remove fuel filter from pump. Remove fuel pump wires from sending unit. Remove retaining clamp screw and clamp. Remove rubber retaining band (if equipped). Remove fuel pump from sending unit.

To install, reverse removal procedure. Check system for leaks.

Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. On Capri, remove throttle body. See THROTTLE BODY. On Festiva, remove intake plenum. See INTAKE PLENUM. Disconnect fuel inlet and return lines from fuel rail. Unplug electrical connectors from injectors. Remove pressure regulator. (Scheme 4) Remove retaining bolts and fuel rail. Remove fuel injectors.

Lubricate NEW "O" rings with gasoline, and install onto fuel injectors. Install fuel injectors into cylinder head. Install fuel rail and retaining bolts. To complete installation, reverse removal procedure. Check system for leaks.

Scheme 4

Drain radiator. Remove negative battery cable. Disconnect throttle cable. Remove air duct from throttle body. Unplug throttle position sensor/switch connector. Mark coolant and vacuum hoses for reassembly reference. Disconnect hoses from throttle body. Remove retaining bolts and intake plenum. (Scheme 4)

Note. To prevent dust and dirt from entering intake manifold ports, cover ports with clean cloth after removing intake plenum.

To install, reverse removal procedure. Use NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article.

O2 sensor is mounted in exhaust pipe just below exhaust header. It is equipped with a permanent pigtail which must be protected from damage when sensor is removed. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120° (48°C). Always use anti-seize compound on threads before installation.

THROTTLE BODY

Note. Clean throttle body exterior before removal.

Drain radiator. Disconnect negative battery cable. Remove resonance chamber. Disconnect throttle cable. Remove air duct. Mark coolant and vacuum hoses for reassembly reference. Disconnect hoses from throttle body. Disconnect throttle position sensor/switch connector. Remove retaining bolts and throttle body. Install NEW throttle body gasket. To complete installation, reverse removal procedure.

Disconnect negative battery cable. Unplug throttle position sensor/switch connector. Remove retaining bolts and sensor/switch. To install, reverse removal procedure.

1. Drain cooling system. Disconnect negative battery cable. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger assembly. Disconnect O2 sensor. Remove retaining bolts and lower heat shield from turbocharger. Remove retaining bolts and upper heat shield from exhaust manifold.
2. Guide O2 sensor wire through upper heat shield. Remove retaining bolts and side heat shield from turbocharger. Remove power steering belt. Remove power steering pump fasteners, leaving hoses connected. Disconnect lower radiator hose from water pump.
3. Move power steering pump aside to gain access to mounting bracket. Remove mounting bracket. Remove air cleaner duct retaining screws. Loosen clamp at turbocharger. Move duct aside. Disconnect coolant supply hose at turbocharger.
4. Disconnect oil supply line at engine block. Raise and support vehicle. Remove nuts and washers from exhaust pipe flange. Disconnect exhaust hanger at engine block. Slide rubber exhaust hangers from catalytic converter. Pull exhaust pipe downward and to left side of vehicle. Disconnect oil return and coolant return hoses from turbocharger.
5. Remove turbocharger support bracket bolts. Remove coolant by-pass tube outlet bolts at water pump. Lower vehicle. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove exhaust manifold retaining nuts. Position coolant by-pass tube aside after pulling bracket from stud.
6. Pull exhaust manifold from studs. Move assembly toward right side of engine compartment, clearing cooling fan. With assembly removed from vehicle, separate turbocharger from exhaust manifold. Remove all gaskets and sealant.

1. Install turbocharger onto exhaust manifold, using NEW gasket. Remove oil supply line from turbocharger. Install turbocharger and exhaust manifold assembly onto cylinder head, using NEW gasket. Install coolant by-pass tube bracket. Install exhaust manifold nuts.
2. Tighten heater tube clamp bolt. Raise and support vehicle. Install coolant by-pass tube bolts. Install turbocharger support bracket retaining bolts. Connect coolant return and oil return hoses to turbocharger. Install exhaust pipe onto turbocharger; tighten nuts and washers by hand. Install exhaust hanger.
3. Slide rubber exhaust hangers onto catalytic converter. Tighten exhaust pipe nuts and washers. Lower vehicle. Connect oil supply line to engine block. Connect oil supply line to turbocharger. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS at end of article. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. On Capri, disconnect primary and secondary wires from coil. On Festiva, disconnect VAF wire harness connector. Remove air duct.
2. On Capri, remove retaining bolt and ground wire from air cleaner cover. Remove air cleaner cover bolts and air cleaner cover. From inside air cleaner cover, remove VAF meter retaining nuts. On Festiva, remove attaching bolt and nuts. Remove vane airflow meter.

To install, reverse removal procedure. Position NEW gasket over VAF mounting studs. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS table.

Note. For all on-vehicle adjustments not covered in this article, see ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS