Mercury Optimax 150 User Manual

3
B
DIRECT FUEL INJECTION
90-855347R1 JANUARY 1999 Page 3B-1
FUEL SYSTEM
Section 3B – Direct Fuel Injection
Table of Contents
Specifications 3B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes: 3B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Handler 3B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Handler Components 3B-8. . . . . . . . . . . . . . . . . . . . . .
Vapor Separator Components 3B-10. . . . . . . . . . . . . . . . .
Fuel Rails/Air Compressor Hose Routing 3B-12. . . . . . .
Fuel Rails 3B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Components 3B-16. . . . . . . . . . . . . . . . .
DFI Operation 3B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Induction Through Crankcase 3B-18. . . . . . . . . . .
Air Compressor System 3B-18. . . . . . . . . . . . . . . . . . .
Fuel 3B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil 3B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 3B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 3B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Electric Fuel Pump Pressure Output 3B-20. . . .
Low Pressure Electric Fuel Pump 3B-20. . . . . . . . . . .
High Pressure Electric Fuel Pump 3B-21. . . . . . . . . .
Fuel Management Assembly Removal 3B-22. . . . . . . . .
Reed Block Assembly Removal 3B-25. . . . . . . . . . . .
Reed Block Assembly Installation 3B-25. . . . . . . . . . .
Air Temperature Sensor Removal 3B-25. . . . . . . . . .
Air Temperature Sensor Installation 3B-26. . . . . . . . .
Throttle Plate Assembly Removal 3B-26. . . . . . . . . . .
Throttle Plate Assembly Installation 3B-26. . . . . . . . .
Vapor Separator Disassembly 3B-26. . . . . . . . . . . . . .
Vapor Separator Reassembly 3B-28. . . . . . . . . . . . . .
Air Plenum Installation 3B-29. . . . . . . . . . . . . . . . . . . .
Low Pressure Electric Fuel Pump Installation 3B-29.
Vapor Separator Installation 3B-31. . . . . . . . . . . . . . .
Fuel Rail Removal 3B-33. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Disassembly 3B-34. . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 3B-37. . . . . . . . . . . . . . . . . .
Air Pressure Regulator 3B-39. . . . . . . . . . . . . . . . . . . .
Tracker Valve 3B-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Cleaning 3B-43. . . . . . . . . . . . . . . . . . . . . . . .
Direct Injector Removal 3B-43. . . . . . . . . . . . . . . . . . .
Fuel Rail and Direct Injector Installation 3B-45. . . . .
Air Compressor 3B-46. . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Disassembly/Reassembly 3B-49. . .
Air Compressor Flow Diagram 3B-50. . . . . . . . . . . . .
Air Compressor Pressure Test 3B-51. . . . . . . . . . . . .

Mercury Optimax 150 Specifications

General

Horsepower	150 HP
Engine Type	V6
Alternator Output	60 amp / 756 watt
Starting	Electric
Steering	Remote
Displacement	2.5 L
Fuel Induction System	2-Stage Direct Fuel Injection (DFI)
Shaft Length	20", 25"
Dry Weight	431 lbs (20 in), 439 lbs (25 in)