Engine Controls - Remove/install/overhaul Mercury Topaz II

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a simple tightening specification may be supplied.

DISTRIBUTOR

1. Remove high tension lead and distributor cap. Align timing marks on TDC of compression stroke. Disconnect distributor wiring from harness. Note direction rotor points and mark distributor base for installation reference.
2. Remove distributor hold-down bolt(s) and clamp. Some engines may be equipped with a security-type distributor hold-down bolt.
3. Use Distributor Hold-Down Wrench (T82L-12270-A) to remove bolt. Remove distributor. To install, reverse removal procedure. Set base ignition timing. See appropriate ADJUSTMENTS article. Refer to the following menu: 4-Cylinder models, see: «ADJUSTMENTS - 4-CYL»(ref-22570) V8 models, see: «ADJUSTMENTS - V8»(ref-22589)

DISASSEMBLY

1. Remove 2 TFI-IV module screws. Pull right side of module down distributor mounting flange and back up to disengage module terminals from connector in distributor base. Remove module by pulling toward flange and away from distributor. CAUTION: Attempting to remove ignition module without first moving entire module toward distributor flange will cause module pins to break at connector.
2. On all models, hold gear and loosen armature screws. DO NOT hold armature. Remove screws and armature. Using a felt tip pen, mark armature and gear for installation reference. Remove and discard roll pin in gear.
3. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A). Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly.
4. Remove thrust washer from distributor and save for installation. Remove screw and octane rod assembly. Save octane rod and screw for installation. Remove stator assembly screws and stator.
5. Inspect base bushing, "O" ring, and distributor housing for wear, cracks, or other damage. If necessary, replace "O" ring. If distributor housing or bushings are worn, replace entire distributor assembly.

REASSEMBLY

1. Place stator assembly over bushing and press down to seat. Place stator connector in position. Tab should fit in notch of base and fastening eyelets should align with screw holes. Position wires away from moving parts. Install and tighten stator screws.
2. Install octane rod through distributor base hole. Place end of rod onto same post as original stator. Install and tighten octane rod screw. Lubricate distributor shaft, just below armature, with light oil. DO NOT over lubricate.
3. Install shaft through base bushing. Place a 1/2" deep well socket over shaft, invert assembly and place in arbor press. Place distributor drive gear on shaft. Align marks made during removal.
4. Place a 5/8" deep well socket over shaft and gear. Press gear until holes align with holes in shaft. If holes do not line up, press gear off and try once more. DO NOT try to align holes using a drift or roll pin.
5. Insert new roll pin through gear and shaft. If armature was removed, install armature. Tighten armature screws. Check distributor for freedom of rotation. If armature contacts stator, replace distributor.
6. Wipe back of TFI ignition module and distributor mounting plate clean. Apply Silicone Dielectric Compound (D7AZ-19A331-A) to back of module and spread evenly.
7. Turn distributor base upside-down so that stator connector is in full view. Insert TFI module. Ensure that module pins are inserted into stator connector.
8. Fully seat TFI ignition module into connector and against base. Install and tighten TFI module screws. (Scheme 1)

Scheme 1

OXYGEN SENSOR PRECAUTIONS

O2 sensor is equipped with a permanent pigtail which must be protected when the sensor is removed. Ensure sensor is free of contaminants and avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Always use anti-seize compound on threads prior to installation.

Note. Fuel pressure must first be released before performing work on fuel injection components.

FUEL SYSTEM PRESSURE RELEASE

Remove fuel tank cap. Using Fuel Pressure Gauge (T80L-9974-B), release pressure from system at pressure relief valve (Schrader valve), located on fuel injection manifold rail.

REMOVAL - SPRING LOCK COUPLING

1. Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" or D87L-9280-B for 1/2"), remove clip from coupling. Place remover over coupling so intrusion is positioned on cage opening side of coupling. (Scheme 2)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Pull male and female halves of coupling apart. Remove tool from disconnected spring lock coupling.

Scheme 2

1. Ensure garter spring in cage of male fitting is not damaged, replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage and replace using proper fuel resistant "O" rings, (if necessary).
2. Lubricate "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over the coupling. (Scheme 3) DO NOT install retaining clip over rubber fuel line.

Scheme 3

REMOVAL - HAIRPIN CLIP COUPLING

Remove hairpin clip from fitting. Spread each clip leg about 1/8" to disengage body. Push legs into fitting. While pulling lightly on triangular end of clip. Work it clear of tube and fitting. Pull fitting and steel line in axial direction. Use twisting motion while pulling fitting loose.

INSTALLATION

Insert clip into any 2 adjacent openings with triangular portion pointing away from fitting opening. Install clip to fully engage the body. Clean end of fitting. Align fitting and tube axially and push fitting onto tube end. When fitting is engaged, a definite click will be heard.

REMOVAL - 2.3L

1. Disconnect air cleaner outlet tube from air intake throttle body. Disconnect throttle position sensor and air by-pass valve from wire harness. Mark and disconnect vacuum lines from upper manifold. Disconnect EGR tube at manifold connection.
2. Remove accelerator cables and speed control cable (if equipped). Remove top bolt from manifold upper support bracket. Remove fuel supply manifold shield. Remove 4 retaining bolts and shoulder stud from upper manifold. Remove upper manifold assembly. Remove gasket.

Clean all gasket surfaces. Install new gasket on lower manifold assembly. Mount upper intake manifold to lower. Install manifold bolts and tighten to 15-22 ft. lbs. (20-30 N.m). Reconnect EGR tube. Tighten to 31-45 ft. lbs. (41-56 N.m). To complete installation, reverse removal procedure.

REMOVAL - 5.0L

1. Disconnect wiring from air by-pass valve, TPS and EGR position sensor. Disconnect throttle and transmission linkages from throttle body. Remove cable bracket with cables attached and position out of way. Identify and disconnect all lines to upper intake manifold.
2. Disconnect PCV system from fitting at rear of upper manifold. Remove 2 EGR coolant lines from fittings on EGR spacer.
3. Remove nut retaining alternator bracket to upper intake manifold. Remove 2 bolts retaining alternator bracket to water pump and alternator. Remove bolts holding upper intake manifold to lower manifold. Remove upper intake as an assembly.

Ensure mounting faces are clean and flat. Position new gasket and install upper manifold with throttle body onto lower manifold. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

REMOVAL

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove the fuel supply and fuel return lines. Refer to «FUEL LINE CONNECTOR»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Remove negative battery cable. Remove wiring harness from injectors.
2. Remove injector retaining bolts. Carefully disengage fuel rail from injectors. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove fuel supply and return lines. See «FUEL LINE CONNECTOR»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Remove negative battery cable. Remove wiring harness from injectors.
2. Remove upper intake manifold. Refer to removal procedures under «UPPER INTAKE MANIFOLD»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Remove injector retaining bolts. Carefully disengage fuel rail from injectors. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure.

INJECTOR - PORT FUEL INJECTION (PFI) SYSTEMS

Injectors may be removed after fuel rail has been removed from intake manifold. See appropriate FUEL RAILS heading above. Refer to the following menu. Install new "O" rings on injectors. Inspect injector "plastic hat" (covering the injector pintle) and washer for signs of deterioration. Replace as necessary.

1. «FUEL RAIL - 2.3L EXCEPT MUSTANG & 5.0L»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul)
2. «FUEL RAIL - 2.3L MUSTANG»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul)

Remove nuts and bolts from throttle body. Label and disconnect electrical connectors interfering with throttle body removal. Disconnect air cleaner outlet tube. Label and disconnect vacuum hoses. Disconnect throttle and speed control cables. Remove throttle bracket. Carefully separate throttle body from upper intake manifold. Remove and discard gasket.

Clean all gasket surfaces. Install new gasket. Secure throttle body to upper intake manifold with 4 retaining bolts. Tighten to specification. To complete installation, reverse removal procedure.

5.0L PFI & MA PFI THROTTLE BODY ASSEMBL

Disconnect throttle position sensor and throttle air by-pass valve connectors. Remove PCV hose (if equipped) from throttle body. Remove throttle body retaining nuts. Remove throttle body and discard gasket. To install, clean all gasket surfaces. Install new gasket on studs. To complete installation, reverse removal procedure.

FUEL PRESSURE REGULATOR - PFI ENGINES

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove vacuum line at pressure regulator. Remove 3 Allen retaining screws from regulator housing.
2. Remove pressure regulator assembly, gasket and "O" ring. Make sure gasket surfaces are clean. Lubricate "O" ring with clean engine oil. Install new "O" ring and gasket on regulator. Install fuel pressure regulator on fuel rail assembly and tighten screws.

THROTTLE POSITION SENSOR (TPS) - ALL MODELS

1. Disconnect TPS from wiring harness. Scribe marks on throttle body and TPS for reassembly reference. Remove mounting screws and TPS. Slide rotary tangs of TPS into position over throttle shaft blade with wires pointing down. Rotate TPS clockwise to installed position.
2. Failure to install TPS in this manner may result in excessive idle speeds. Align scribe marks on throttle body and TPS. Secure TPS to throttle assembly with retaining screws. Reconnect wiring.

1. Place vehicle on hoist, do not raise. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Drain fuel from tank. Raise vehicle on hoist. Disconnect and remove fuel filler tube.
2. On All Wheel Drive (AWD) models, remove exhaust system. Remove rear axle assembly. See «DRIVE AXLE - REAR (AWD)»(/mercury/topaz/ii-1987-1994/remont/differentials-drive-axles/#drive-axle-rear-awd) article in the DRIVE AXLES section. On all models, support fuel tank and remove fuel tank support straps. Lower tank partially and remove fuel lines, electrical connectors and vent lines.
3. Remove fuel tank. Remove any dirt that has accumulated around fuel pump retaining flange area. Using Fuel Tank Sender Wrench (D84P-9257-A) in a counterclockwise motion, remove fuel pump locking ring. Remove fuel pump and bracket assembly. Remove seal gasket.
4. On AWD models, partially lift up sender unit. Disconnect jet pump line and electrical connector to resistor. Remove fuel pump and bracket assembly. Remove jet pump assembly retaining screw and pump.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. To hold New seal ring in place during assembly, put a light coat of Long Life Lubricant (C1AZ-19590-BA) on seal ring. Install seal ring in fuel ring groove.
2. On AWD models, install jet pump assembly and retaining screw. Tighten screw to 10-15 ft. lbs. (14-20 N.m). On all models, install fuel pump and sender assembly taking care not to damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. On AWD models, connect jet pump line and electrical connector to resistor. Ensure locating keyways and seal ring remain in place. On all models, hold assembly in place and install locking ring finger tight.
4. Ensure all locking tabs are under tank lock ring tabs. Tighten lock ring by rotating ring clockwise using Fuel Tank Sender Wrench (D84P-9257-A) until ring stops against stops. To complete installation, reverse removal procedure. Fill tank with fuel and check for leaks.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Drain fuel from tank. Raise vehicle on hoist. Remove exhaust pipe and shield. Remove fuel hoses and tubes.
2. See «FUEL LINE CONNECTOR»(/mercury/topaz/ii-1987-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Disconnect vapor crossover hose and filler hose. Support fuel tank. Remove fuel tank strap bolts. Partially lower fuel tank. Disconnect fuel lines and electrical connector from fuel gauge sender. Remove fuel tank.
3. Remove any dirt that has accumulated around fuel pump retaining flange area. Using Fuel Tank Sender Wrench (D84P-9257-A) remove fuel pump locking ring. Remove fuel pump.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. to hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (C1AZ-19590-BA) on seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump and sender assembly taking care not to damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Tighten locking ring by rotating ring clockwise using Fuel Tank Sender Wrench (D84P-9257-A) until ring stops against stops. To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• DRIVE AXLE - REAR (AWD)
• TORQUE SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE
• FUEL LINE CONNECTOR