Direct Injector Removal; Direct Injectors - Mercury 200 OptiMax Jet Drive Service Manual

Direct Injector Removal

1. Remove the direct injector from the cylinder head using a direct injector removal tool.
a
Direct Injector Removal Tool
2. Inspect the cupped washer on the cylinder head for damage.
3. If the cylinder head is to be replaced, ensure the new cylinder head supplies the cupped washers. If the new cylinder head
does not have the cupped washers, remove the cup washers from each direct injector port by prying it out with a flat tip
screwdriver. Reinstall the washers into the new cylinder head. The washers provide tension for the direct injectors between
the cylinder head and fuel rails.
4. Inspect the direct injector white teflon sealing ring for signs of combustion blowby. The teflon ring will be streaked with carbon.
The carbon color can range from light brown to black. If blowby is present, replace the teflon sealing ring.
5. Inspect the O‑rings and teflon ring for cuts or abrasions. Replace the components as necessary.
6. Install the direct injector into the cylinder head.

Direct Injectors

Six direct injectors (one per cylinder) are used to inject a fuel/air mix into the cylinders. Injectors are mounted between the fuel
rails and cylinder heads.
For best results, check the direct injector for continuity to ground when the injector is near operating temperature (engine warmed
up).
90-8M0050731 MAY 2011
a - Direct injector
b - Direct injector removal tool
b
10252
a - Cupped washer
b - Retainer
a
b
10270
Direct Fuel Injection
91‑883521
Page 3B-59