856036 1 Mercury SPRING, Return

This service procedure requires the valve cover to be removed. This will expose the service technician to to moving parts which may case pinch or entanglement hazards. The hazards could result in personal injury or death. Keep all body parts, loose clothing, hair, and other items which could become entangled away from the moving parts.
Electrical Shock Hazard. The unit injector system uses 90 - 120 volts. The ECM sends this signal to the unit injectors. Do not come in contact with the unit injector harness connector while the engine is operating. Failure to follow this instruction could resulting in personal injury or death.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
This service procedure requires removal of the valve cover. This will expose moving parts. Be sure to keep all tools and other objects away from the moving parts. Failure to do so may result in damage to engine components.
Start the engine. Allow the engine to operate at low idle.Note: Do not raise the engine speed above low idle.
Use a 1U-5566 Ultraviolet Lamp Gp in order to determine if fuel is leaking from the area around each injector.
If there is no indication of fuel, perform this test step. Remove each quill assembly and each injector. Inspect the following items on each quill assembly and each injector. Carefully inspect the O-ring seals for cuts and for other damage. Inspect the mating surfaces of the quill assembly and the injector. Look for signs of uneven wear. Uneven wear indicates that the quill assembly was not seated correctly.If a problem is found, perform the following procedure. If there is a damaged O-ring seal, replace the damaged O-ring seal. Replace the quill assembly and the injector if there is uneven wear at the mating surfaces. Run the engine at low idle after the new parts are installed. Verify that the problem is resolved. Install the valve cover. Proceed to "Service the Oil System".If all of the parts are OK, install the valve cover. Replace the high pressure fuel pump. Refer to the engine's Disassembly and Assembly Manual for the correct procedure. Perform a "Fuel System Functional Test" after the new high pressure fuel pump is installed. Proceed to "Service the Oil System".
If there is an indication of fuel, perform this test step. Remove the appropriate injector. Inspect the O-ring seals for cuts and for other damage.If there is a damaged O-ring seal, replace the damaged O-ring seal. Install the injector. Run the engine at low idle after the injector is installed. Verify that the problem is resolved. Install the valve cover. Proceed to "Service the Oil System".If the O-ring seals are OK, replace the injector. Flash program the injector's trim file into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary. Run the engine at low idle after the new injector is installed. Verify that the problem is resolved. Install the valve cover. Perform the "Fuel System Verification Test". Proceed to "Service the Oil System".Service the Oil System
Replace the engine oil and replace the engine oil filter. Refer to the engine's Operation and Maintenance Manual for the appropriate procedure. Verify that the oil level is correct. Return the vehicle to service.