Mercury OptiMax 250 Manual

3
B
DIRECT FUEL INJECTION
Page 3B-1
90-888438 JUNE 2002
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. . . . . . . . . . . . . . . . .
Air Handler Components 3B-10. . . . . . . . . . . . . . . . .
Vapor Separator Components 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-26. . . . . .
Air Temperature Sensor Installation 3B-26. . . . .
Throttle Plate Assembly Removal 3B-26. . . . . . .
Throttle Plate Assembly Installation 3B-26. . . . .
Vapor Separator Disassembly 3B-27. . . . . . . . . .
Vapor Separator Reassembly 3B-29. . . . . . . . . .
Air Plenum Installation 3B-30. . . . . . . . . . . . . . . .
Low Pressure Electric Fuel Pump Installation . . .
3B-30
Vapor Separator Installation 3B-33. . . . . . . . . . .
Fuel Rail Removal 3B-35. . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 3B-40. . . . . . . . . . . . . .
Air Pressure Regulator 3B-43. . . . . . . . . . . . . . . .
Air Regulator Troubleshooting 3B-43. . . . . . . . . .
3B-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tracker Valve 3B-46. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Cleaning 3B-49. . . . . . . . . . . . . . . . . . . .
Direct Injector Removal 3B-49. . . . . . . . . . . . . . .
Direct Injector Leak Test 3B-50. . . . . . . . . . . . . . .
Fuel Rail and Direct Injector Installation 3B-51.
Air Compressor 3B-52. . . . . . . . . . . . . . . . . . . . . .
Air Compressor Disassembly/Reassembly 3B-55
Air Compressor End Cap/Crankshaft Removal and
Reassembly 3B-56. . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Flow Diagram 3B-59. . . . . . . . .
Air Compressor Pressure Test 3B-60. . . . . . . . .

Mercury OptiMax 250 Specifications

General

Brand	Mercury
Model	OptiMax 250
Category	Outboard Motor
Language	English