Fuel Management Assembly Removal - Mercury 200 OptiMax Jet Drive Service Manual

Direct Fuel Injection
Component or Problem
Air and fuel pressure differential
out of range
Normal differential is103.5 kPa
(15 psi)

Fuel Management Assembly Removal

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank (VST). To avoid a possible fire or explosion,
follow normal precautionary procedures while working with the fuel system. Use a suitable container when draining fuel from
the VST and avoid sparks, smoking, and open flame while in the presence of liquid fuel or fuel vapors.
Page 3B-30
Possible Causes
Tracker valve
Fuel regulator
Failed fuel injector
Injector stuck open
Fuel rail damaged
WARNING
!
CAUTION
!
WARNING
!
Corrective Action
Remove/inspect the tracker valve diaphragm for cuts, tears, or
abrasions.
Check the diaphragm seat and rail for damage. Replace
components as necessary.
Remove/inspect the fuel regulator diaphragm for cuts, tears, or
abrasions.
Inspect the fuel regulator hole for blockage. Clean or correct as
necessary.
Inspect the diaphragm seat and rail for damage. If the fuel
regulator is faulty, replace the port fuel rail.
Check the air system for fuel contamination.
Inspect the injector O‑ring for nicks, cuts, or abrasions.
Replace the injector as necessary.
Perform a fuel injector leak test.
Replace components as necessary.
Check for fuel in the air system.
Inspect the offending rail valves and regulators. If all
components check out, replace the rail.
90-8M0050731 MAY 2011