Home ReviewsRefund Car not listed?
Home/Mercury/Monterey/Mercury Monterey VIII (2003-2007)/Repair manual/Fuel System/Fuel System & Engine Control System: Removal & Installation
Contents Wiring diagrams Section: Fuel System All sections

Fuel System & Engine Control System: Removal & Installation Mercury Monterey VIII

Fuel System 4 illustrations ~420 words

Removal and Installation

CAUTIONThrottle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body can occur.
  1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-234493) .
  2. Detach the harness retainer from the cable bracket stud bolt.
  3. Disconnect the TP sensor electrical connector.
  4. Disconnect the throttle return spring from the throttle body.
  5. Disconnect the speed control cable from the throttle body.
  6. Disconnect the accelerator cable from the throttle body.
  7. Remove the 2 cable bracket bolts and position the bracket and cables aside. To install, tighten to 15 Nm (11 lb-ft).
  8. Remove the 4 throttle body-to-upper intake manifold bolts and the throttle body. To install, tighten to 10 Nm (89 lb-in).
  9. Remove the throttle body gasket. Inspect the gasket and install new if necessary.
  10. To install, reverse the removal procedure.

Scheme 1

Scheme 1: Fuel Charging Wiring Harness
Scheme 1: Fuel Charging Wiring Harness
WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.

Scheme 2

Scheme 2
Scheme 2
  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) .
  2. Remove the upper intake manifold. For additional information, refer to «ENGINE - 3.9L AND 4.2L»(ref-234492) .
  3. Disconnect the fuel injector electrical connectors.
  4. Disconnect the fuel pressure and temperature sensor electrical connector.
  5. Disconnect the fuel charging-to-engine wiring harness electrical connector.
  6. Detach the fuel charging wiring harness retaining pins.
  7. Cut the nylon tie-straps and remove the fuel charging wire harness. Install new nylon tie-straps.
  8. To install, reverse the removal procedure.

Scheme 3

Scheme 3: Fuel Rail and Injector - Exploded View
Scheme 3: Fuel Rail and Injector - Exploded View

For additional information, refer to the Fuel Rail and Fuel Pump Driver Module removal and installation procedures.

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.
  1. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-234535) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) .
  3. Remove the fuel charging wiring harness. For additional information, refer to «FUEL CHARGING WIRING HARNESS»(ref-234496-S07134227052006061000000) .
  4. Disconnect the fuel pressure and temperature sensor vacuum connector.
  5. Remove the fuel tube retaining clip.
  6. Disconnect the tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-234535) .
  7. Remove the fuel injection supply manifold bolts. To install, tighten to 10 Nm (89 lb-in).
  8. Remove the fuel injection supply manifold.
  9. Remove the fuel injector clips.
  10. Remove the fuel injectors.
  11. Remove and discard the fuel injector O-ring seals.
  12. To install, reverse the removal procedure. Lubricate the new O-ring seals with clean engine oil before installing.

Scheme 4

Scheme 4: Fuel Pump Driver Module (FPDM)
Scheme 4: Fuel Pump Driver Module (FPDM)
  1. Remove the LH lower B-pillar trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-234524) .
  2. Disconnect the fuel pump driver module electrical connector.
  3. Remove the fuel pump driver module nuts. To install, tighten to 5 Nm (44 lb-in).
  4. Remove the fuel pump driver module.
  5. To install, reverse the removal procedure.

More articles — Fuel System & Engine Control System