Mercury 200 OptiMax Jet Drive Service Manual page 211

Direct Fuel Injection
5. Secure the fuse holder, low‑pressure fuel boost pump, and the lift pump connectors fuel pump with a cable tie.
6. Secure the low‑pressure fuel pump connector and the fuse holder to the boost pump with a cable tie.
a
d
7. Install 18.3 mm hose clamps onto the high‑pressure fuel hose and low‑pressure fuel return hose.
8. Install the fuel hoses and crimp the 18.3 mm hose clamps with the hose clamp tool.
IMPORTANT: Use tool 91‑803146T or Snap‑On equivalent YA3080 to crimp the full circle hose clamp. Using a different tool
could result in a crimp that is too loose or too tight. Do not use a screw type hose clamp as it may damage the hose.
9. Secure the high‑pressure fuel hose and the low‑pressure fuel return hose together with a cable tie. Do not overtighten the
cable tie.
10. Install the air vent hose to the VST. Secure the hose with a cable tie.
11. Install the fuel hose to the lift pump inlet. Secure with a hose clamp.
12. Connect the high‑pressure fuel pump connector to the engine harness connector. Secure the fuel pump harness connectors
to the high‑pressure fuel hose with a cable tie.
a
b
c
Page 3B-48
a -
b -
c -
d -
b
c
45817
d
f
e
g
Lift pump connector
Low‑pressure fuel boost pump connector
Fuse holder
Cable tie
45812
3924
a - High‑pressure fuel outlet
hose (18.3 mm hose clamp)
b - Fuel return hose (from fuel
regulator) (18.3 mm hose
clamp)
c - Drain plug
d - Air vent hose (to fuel tank)
(cable tie)
e - Lift pump fuel inlet
f - High‑pressure fuel pump
electrical connector
g - Cable tie
90-8M0050731 MAY 2011