Fuel Rail Cleaning; Direct Injector Removal - Mercury Optimax 250 Manual

Fuel Rail Cleaning

After all fuel injectors, air regulator, tracker valve, fuel regulator, inlet hoses and outlet
hoses have been removed, the fuel rails may be flushed out with a suitable parts cleaning
solvent. Use compressed air to remove any remaining solvent.

Direct Injector Removal

1. Remove harness connectors from direct injectors.
2. Remove direct injector from cylinder head
a -
b -
3. Inspect injector teflon sealing ring (white) for signs of combustion blowby (teflon ring
will be streaked brownish black). If blowby is present, replace teflon sealing ring. If
blowby is not present, sealing ring may be reused.
4. Inspect o-rings and teflon ring for cuts or abraisions. Replace components as re-
quired.
5. If teflon seal requires replacement, use teflon ring installation tool 91-851980 to slide
new seal onto injector. Following installation of teflon ring, the teflon ring sizing tool
(91-851980-1) can be used to compress the teflon seal to aid in the installation of the
injector into the cylinder head.
57983
a -
b -
c -
90-888438 JUNE 2002
b
Direct Injector (3 each cylinder head)
Harness Connector
b
f
Teflon Sealing Ring
O-Ring
Teflon Seal
a
d
c
a
91-851980-1
d - Seal Installation Tool (91-851980)
e - O-Ring
f - Teflon Ring Sizing Tool (91-851980-1)
DIRECT FUEL INJECTION
57985
e
e
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