Fuel Rail And Direct Injector Installation - Mercury Optimax 115 Service Manual

NOTE: If cylinder head is going to be replaced, remove cup washers from each direct in-
jector port by prying out with a flat tip screwdriver. Reinstall washers with retainers into
new cylinder head. Washers provide tension between direct injectors, cylinder head and
fuel rails.
a -
b -

Fuel Rail and Direct Injector Installation

1. Use Teflon Ring Sizing Tool (91-851980-1) to compress new teflon sealing rings prior
to installation of injector into cylinder head.
2. Carefully slide fuel rail over mounting studs and onto direct injectors.
IMPORTANT: ALL fuel and air hoses attached to the fuel rails MUST be secured with
stainless steel hose clamps.
3. Secure each fuel rail with 2 nuts. Torque nuts to 33 lb. ft. (44 Nm).
4. Reinstall direct injector harness connectors.
a -
b -
90-855347R1 JANUARY 1999
b
b
Cup Washer
Retainer
b
b
a
a
a
a
Nuts [Torque to 33 lb.ft. (44 Nm)]
Direct Injector Harness Connectors
a
a
56148
b b
a a
a
a
56141
DIRECT FUEL INJECTION
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