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Mercury OptiMax 250 Manual
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DIRECT FUEL INJECTION
Page 3B-47
90-888438 JUNE 2002
Engine Off (No Pressure)
Engine at Operating Pressures
1
2
3
4
5
6
7
8
1
2
3
4
5
6
8
9
9
1
2
3
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5
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9
1
2
3
4
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6
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9
1-
T
op Cover
2-
Spring Retainer (not shown)
3-
Spring
4-
O-ring
5-
Diaphragm (at rest) Seat
6-
Air Rail
7-
Air Passage (from Air Compressor)
8-
Fuel Inlet Passage (from Electric
Fuel Pump)
9-
Diaphragm Assembly
46
48
Table of Contents
Table of Contents
1
Specifications
2
Special Tools
3
Notes
5
Air Handler
6
Air Handler Components
8
Air Handler Components
9
Vapor Separator Components
12
Fuel Rails
14
Air Compressor Components
16
DFI Operation
18
Air Induction through Crankcase
18
Air Compressor System
18
Fuel
18
Oil
19
Electrical
19
Operation
19
Testing Electric Fuel Pump Pressure Output 3B-20
20
Low Pressure Electric Fuel Pump
20
High Pressure Electric Fuel Pump
21
Fuel Management Assembly Removal
22
Reed Block Assembly Removal
25
Reed Block Assembly Installation
25
Air Temperature Sensor Removal
26
Air Temperature Sensor Installation
26
Throttle Plate Assembly Removal
26
Throttle Plate Assembly Installation
26
Vapor Separator Disassembly
27
Vapor Separator Reassembly
29
Air Plenum Installation
30
Low Pressure Electric Fuel Pump Installation
30
Vapor Separator Installation
33
Fuel Rail Removal
35
Fuel Pressure Regulator
40
Air Pressure Regulator
43
Air Regulator Troubleshooting
43
Tracker Valve
46
Fuel Rail Cleaning
49
Direct Injector Removal
49
Direct Injector Leak Test
50
Fuel Rail and Direct Injector Installation
51
Air Compressor
52
Air Compressor Disassembly/Reassembly 3B-55
55
Air Compressor End Cap/Crankshaft Removal and Reassembly
56
Air Compressor Flow Diagram
59
Air Compressor Pressure Test
60
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Mercury OptiMax 250 Specifications
General
Engine Type
V6
Horsepower
250 hp
Gear Ratio
1.75:1
Starting System
Electric Start
Alternator
60 Amp
Shaft Length
20", 25"
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