Mercury 3M6Z-9F593-BA Injector Assembly

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To remove the intake manifold on models through 2004, start by depressurizing the fuel system and disconnecting the negative battery cable. Remove the air cleaner and inlet duct, and disconnect the accelerator cable. For 2.3L and 2005 and later 2.0L models, remove the engine cooling fan and shroud. Disconnect the brake booster vacuum hose from the base of the manifold, remove the engine oil dipstick and its tube. Disconnect the injection harness wiring plug and camshaft position sensor at the rear of the cylinder head. Disconnect all electrical connectors from the throttle body. For models through 2004, disconnect the fuel supply and return lines from the fuel rail. Protect the alternator from fuel spillage. If equipped, disconnect the intake manifold runner control (IMRC) cable. Remove the manifold support bracket (SPI engines) and manifold retaining bolts. Check there is nothing else attached to the manifold and withdraw it from the engine, keeping it as level as possible. Recover the four gaskets - new ones must be used on installation.

For V6 models, in addition to the previous steps, you need to perform the following: a) Remove the upper intake manifold. b) Disconnect the vacuum line from the fuel pulsation damper. c) Disconnect the fuel supply line from the fuel rail. d) Disconnect the electrical connectors from the fuel injectors. e) Remove the fuel rail mounting bolts. f) Disengage the injectors from the lower intake manifold. g) Lift the fuel rail and injectors from the engine as a single assembly.

To start replacing the fuel injectors, first, relieve the fuel system pressure and equalize tank pressure by removing the fuel filler cap. Then, disconnect the cable from the negative battery terminal and remove the air intake duct. After that, disconnect the accelerator cable and cruise control cable (if equipped) from the throttle lever cam.