Mercury 200 EFI User Manual

3
B
FUEL INJECTION
90-883728 JULY 2001 Page 3B-1
FUEL SYSTEM
Section 3B - Fuel Injection
Table of Contents
Specifications 3B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes: 3B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Management System 3B-6. . . . . . . . . . . . . . . .
Vapor Separator Components 3B-8. . . . . . . . . . . . .
Electronic Fuel Injection (EFl) System 3B-10. . . . . .
Introduction 3B-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Test Procedures 3B-10. . . . . . . . . . . . .
EFI System Tests 3B-10. . . . . . . . . . . . . . . . . . . . .
Safety Precautions 3B-10. . . . . . . . . . . . . . . . . . .
Fuel Injection System Function 3B-11. . . . . . . . .
Preliminary Checks 3B-11. . . . . . . . . . . . . . . . . . . . . .
Ignition Spark Check 3B-11. . . . . . . . . . . . . . . . . .
Electronic Fuel Injection Set Up 3B-12. . . . . . . .
Fresh Quality Fuel 3B-12. . . . . . . . . . . . . . . . . . . .
Low Battery Voltage 3B-12. . . . . . . . . . . . . . . . . .
Fuel Flow Diagram 3B-13. . . . . . . . . . . . . . . . . . . . . .
Fuel Flow Component Description 3B-14. . . . . . . . .
Pulse Fuel Pump (d) 3B-14. . . . . . . . . . . . . . . . . .
Water Separating Filter (e) 3B-14. . . . . . . . . . . . .
Vapor Separator (h) 3B-14. . . . . . . . . . . . . . . . . . .
Final Filter (n) 3B-14. . . . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
(Inside Vapor Separator) (j) 3B-14. . . . . . . . . . . .
Fuel Injectors (c) 3B-14. . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator (p) 3B-14. . . . . . . . . . .
EFI Electrical Components 3B-15. . . . . . . . . . . .
EFI Fuel Management
(Low Pressure Fuel Route) 3B-17. . . . . . . . . . . . . . .
EFI Fuel Management
(High Pressure Fuel Route) 3B-18. . . . . . . . . . . . . . .
Fuel Rail Electrical/Fuel Determination 3B-19. . . . .
EFI System Test Procedures 3B-20. . . . . . . . . . . . . .
Fuel Gauge Connection/Pressure Test 3B-20. .
Vapor Separator Fuel Delivery Test 3B-21. . . . .
Pulse Fuel Pump Delivery Test 3B-22. . . . . . . . .
Water Separating Filter Inspection 3B-23. . . . . .
Vapor Separator Float Test 3B-24. . . . . . . . . . . .
Electric Fuel Pump Inlet Filter Check and
De-Pressurizing EFI System Procedures 3B-25
Pressure Regulator Test 3B-27. . . . . . . . . . . . . . .
Electric Fuel Pump Voltage/Pressure Test 3B-28
Injector Electrical Harness Test 3B-29. . . . . . . . .
Injector Load Test 3B-30. . . . . . . . . . . . . . . . . . . .
Fuel Rail Assembly Leakage Test 3B-30. . . . . . .
Air Temperature Sensor and Head
Temperature Sensor Test 3B-31. . . . . . . . . . . . . .
Detonation Control System Test
(200 Models Only) 3B-32. . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Test 3B-33. . . . . . . . . . .
MAP Sensor Test 3B-34. . . . . . . . . . . . . . . . . . . . .
Problem Diagnosis 3B-35. . . . . . . . . . . . . . . . . . .
Engine Head Temperature Sensor Removal 3B-38
Engine Head Temperature Sensor Installation 3B-38
Fuel Management Assembly Removal 3B-39. . . . .
Fuel Rail Removal 3B-43. . . . . . . . . . . . . . . . . . . .
Fuel Rail Installation 3B-45. . . . . . . . . . . . . . . . . .
Reed Block Assembly Removal 3B-47. . . . . . . .
Reed Block Assembly Installation 3B-47. . . . . . .
Air Temperature Sensor Removal 3B-48. . . . . .
Air Temperature Sensor Installation 3B-48. . . . .
Manifold Absolute Pressure (MAP)
Sensor Removal 3B-48. . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP)
Sensor Installation 3B-48. . . . . . . . . . . . . . . . . . . .
Throttle Plate Assembly Removal 3B-49. . . . . . .
Throttle Plate Assembly Installation 3B-49. . . . .
Vapor Separator Disassembly 3B-49. . . . . . . . . .
Vapor Separator Reassembly 3B-50. . . . . . . . . .
Air Plenum Installation 3B-52. . . . . . . . . . . . . . . .
Vapor Separator (VST) Installation 3B-53. . . . . .
Water Separating Filter Assembly
Removal 3B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Separating Filter Assembly
Installation 3B-54. . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Removal 3B-55. . . . . .
Throttle Position Sensor Installation 3B-55. . . . .
Oil Reservoir Removal 3B-56. . . . . . . . . . . . . . . .
Oil Reservoir Installation 3B-56. . . . . . . . . . . . . .
Fuel Pressure Regulator Removal 3B-57. . . . . .
Fuel Pressure Regulator Disassembly 3B-58. .
Fuel Pressure Regulator Reassembly 3B-58. . .
EFI System Cleaning and Inspection 3B-59. . . . . . .
Cleaning 3B-59. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3B-59. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury 200 EFI Specifications

General

Brand	Mercury
Model	200 EFI
Category	Engine
Language	English