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Fuel System & Engine Control System - 3.5L: Removal & Installation Mercury Sable V

Fuel System 1 illustration ~294 words

REMOVAL AND INSTALLATION

CAUTIONThe throttle body must be removed from the vehicle to be cleaned. Do not hold the throttle plate open with any object that could scratch the bore or plate while servicing or cleaning the throttle body.
  1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-293503) article.
  2. Disconnect the electronic throttle control electrical connector.
  3. Remove the 4 bolts and the throttle body (TB). Discard the TB gasket. To install, tighten to 10 Nm (89 lb-in).
  4. To install, reverse the removal procedure.

Scheme 1

Scheme 1: Fuel Rail and Fuel Injector - Exploded View
ItemPart NumberDescription
1Fuel tube-to-fuel rail spring lock coupling (part of 9J280)
214A464Fuel injector electrical connector (6 required) (part of 12A581)
3W503279Fuel rail bolt (4 required)
49F792Fuel rail
59C995Fuel injector clip (6 required)
69F593Fuel injector
79229Upper fuel injector O-ring seal (6 required)
89229Lower fuel injector O-ring seal (6 required)
9Fuel tube routing clip (2 required) (part of 9J280)
  1. For additional information, refer to the procedures.

REMOVAL

WARNINGDo not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNINGBefore working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
  1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.
  3. Remove the upper intake manifold. For additional information, refer to «ENGINE - 3.5L»(ref-293494) article.
  4. Detach the fuel tube routing clips from the fuel rail.
  5. Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
  6. Disconnect the 6 fuel injector electrical connectors.
  7. Remove the 4 fuel rail bolts.
  8. Remove the fuel rail and injectors as an assembly.
  9. Remove the 6 fuel injector clips and the 6 fuel injectors. Remove and discard the 12 fuel injector O-ring seals.

INSTALLATION

  1. Install the 6 fuel injectors and the 6 fuel injector clips into the fuel rail.
  2. Install the fuel rail and fuel injectors as an assembly.
  3. Install the 4 fuel rail bolts. Tighten to 10 Nm (89 lb-in).
  4. Connect the 6 fuel injector electrical connectors.
  5. Connect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-293502) article.
  6. Attach the fuel tube routing clips to the fuel rail.
  7. Install the upper intake manifold. For additional information, refer to «ENGINE - 3.5L»(ref-293494) article.
  8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-293478) article.