Mercury 200 OptiMax Jet Drive

Direct Fuel Injection
90-8M0050731 MAY 2011 Page 3B-1
3
B
Fuel System
Section 3B - Direct Fuel Injection
Table of Contents
Air Compressor Specifications...........................................3B-2
Fuel System Specifications................................................3B-2
Fuel Rail Specifications......................................................3B-3
Vapor Separator Components...........................................3B-6
Air Handler and Flywheel Cover........................................3B-8
Air Handler Components..................................................3B-10
Fuel Rail Components (S/N 0T178500 and Above).........3B-12
Fuel Hose Components...................................................3B-14
Air Hose Components......................................................3B-16
Air Compressor Components...........................................3B-18
DFI Operation..................................................................3B-22
Air Induction..............................................................3B-22
Air Compressor System............................................3B-22
Fuel...........................................................................3B-22
Oil.............................................................................3B-22
Electrical...................................................................3B-22
Operation..................................................................3B-23
200 OptiMax Jet Drive Air/Fuel Schematic...............3B-24
Electric Fuel Pump Pressure Tests..................................3B-25
Low‑Pressure Boost Pump Test...............................3B-25
High‑Pressure Fuel Pump........................................3B-25
Air Compressor Pressure Test.........................................3B-26
Fuel or Air Pressure Not to Specifications ‑ SportJet Models
.....................................................................................3B-27
Fuel Management Assembly Removal............................3B-30
Reed Block Assembly Removal................................3B-33
Throttle Body Assembly Removal.............................3B-33
Air Management Assembly and Installation.....................3B-34
Vapor Separator Tank......................................................3B-38
VST Removal............................................................3B-38
VST Disassembly ....................................................3B-40
VST Assembly..........................................................3B-43
VST Installation.........................................................3B-47
Fuel Rail...........................................................................3B-49
Fuel Pressure Regulator...........................................3B-49
Fuel Pressure Regulator Cutaway............................3B-50
Air Pressure Regulator.............................................3B-51
Tracker Valve............................................................3B-51
Fuel Injectors............................................................3B-53
Fuel Rail Removal....................................................3B-53
Fuel Injector Removal...............................................3B-57
Direct Injector Removal............................................3B-59
Direct Injectors..........................................................3B-59
Direct Injector Tests..................................................3B-60
Fuel Pressure Regulator Removal............................3B-63
Air Pressure Regulator Removal (S/N 0T178500 and
Above)...................................................................3B-64
Tracker Valve Removal............................................3B-64
Fuel Rail Cleaning....................................................3B-65
Fuel Injector Installation ...........................................3B-65
Tracker Valve Installation.........................................3B-66
Air Pressure Regulator Installation (S/N 0T178500 and
Above)...................................................................3B-66
Fuel Pressure Regulator Installation.........................3B-67
Fuel Rail Installation.................................................3B-68
Air Compressor................................................................3B-71
Air Compressor Flow Diagram..................................3B-71
Air Compressor Removal..........................................3B-72
Air Compressor Disassembly...................................3B-74
Air Compressor Assembly........................................3B-75
Air Compressor Installation.......................................3B-78