Mercury 1L2Z-9D280-ED Fuel Rail

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For the above procedures involving the removal of upper intake manifold and throttle body, the following are the steps required for sohc four cylinder engines, The air cleaner housing and the splash shield for the accelerator linkage should be taken off; the accelerator cable should as well be disconnected from the throttle body. Then, remove the connection of the electrical wires coming from the throttle position sensor, idle air control valve and EGR vacuum regulator control if present, and the ground wire of the engine if exist. Remove the PCV hose and mark the vacuum hoses from manifold vacuum tee. Disconnect the transducer hoses for the EGR and the EGR valve and take out the upper intake manifold bolts and studs. Remove any old gasket material from the surfaces, fit a new gasket on the lower intake manifold, place the upper manifold in position and tighten the bolts in a star pattern to the recommended torque. The process of installation is done in a opposite way whereby the removal process was done. To expose the bug, remove the throttle body splash shield disconnecting also the accelerator cable and the electrical connector of the Throttle Position Sensor. The air inlet duct; free the clips or bolts and disconnect the air inlet duct and then remove the bolts that are holding the throttle body and remove the throttle body. Scrub that mating surfaces and set in a new gasket before repositioning the throttle body and fastening the screws. When dealing with fuel rail and injectors, steam clean the engine if required, then refer to the fuel system pressure relief procedure, next remove the negative battery cable and finally the air inlet tube. Remove the fuel supply hose and the return hose from the fuel injectors, then remove the bolts holding the fuel rail then disconnect the electrical connectors from the injectors. Delicately raise the fuel rail and its injectors, if necessary disconnecting the injectors. For installation, the injector O-rings must be checked for damage, if so, it must be replaced and lubed with the engine oil then the injectors must be fitted to the fuel rail. At last, rotate the key ON/OFF to pressurise the fuel system and look for any signs of leakage.

Relieve the system fuel pressure and disconnect the cable from the negative battery terminal. Remove the strut tower cross brace mounting nuts and brace, if equipped, followed by the upper intake manifold. Disconnect the fuel supply line spring-lock coupling from the fuel rail, then remove the fuel rail insulators. Disconnect the electrical connectors from all six fuel injectors, remove the four fuel rail bolts, and take out the fuel rail and injectors as a single assembly. Release the fuel injector retaining clip and remove each injector from its bore in the fuel rail, discarding the upper and lower injector O-rings. It's advisable to replace all O-rings at the same time, even if only one injector is being replaced. Coat the new upper and lower O-rings with clean engine oil and install them on the injectors, then insert each injector into its bore in the fuel rail and secure them with the retaining clips. For the 4.0L V6 engine, disconnect the fuel supply line spring-lock coupling, remove the mounting bracket bolts, and detach the fuel rail supply tube. Remove the fuel rail flange O-rings and disconnect the vacuum hose and electrical connector from the Fuel Rail Pressure and Temperature sensor. Remove the injector wiring harness and the fuel rail and injectors as a single assembly, pulling each injector out firmly. Replace the old O-rings with new ones and ensure proper installation of the new O-rings on the fuel injectors and at the mounting flanges. For V8 engines, disconnect the fuel supply line spring-lock coupling, detach the wiring harness retainer clips, and disconnect the electrical connectors from all eight fuel injectors. Remove the fuel rail mounting bolts and take out the fuel rail and injectors as a single assembly. Remove the injector retainer clips and the old O-rings from each injector, replacing them with new ones. Coat the O-rings with clean engine oil before installing the injectors back into the fuel rail and securing them with the retainer clips. Finally, install the fuel rail and injector assembly, ensuring that the installation is otherwise the reverse of removal.

During installation, the new O-rings are lubricated with light-grade oil, two are installed on each injector, and the injectors are installed into the lower intake manifold using a light twisting motion.