Rajan Wilcox
The Mercury Optimax fuel system is a finely tuned direct fuel injection system that uses a combination of high-pressure fuel and air to inject an atomized mixture of gas directly into the combustion chamber. This system is very different from conventional 2-stroke engines. The fuel injectors can be removed with a screwdriver or cotter pin tool, while Mercury also makes a tool for air injector removal. It is recommended to have the fuel injectors professionally cleaned and diagnosed for any problems.
| Characteristics | Values |
|---|---|
| Fuel Injector System | Finely tuned direct fuel injection system |
| Injector Type | Air and Fuel Injectors |
| Fuel Pumps | 3 (a pulse-operated lift pump and 2 electric pumps inside the VST or vapor separating tank) |
| Fuel Flow | From the fuel rail to the fuel injectors |
| Fuel Rail | Held to the cylinder head by two nuts |
| Injector Removal | Remove the two nuts, pull the fuel rail off the head, and remove the 6 direct injectors |
| Injector Cleaning | Ultrasonic cleaning, flushing with specially formulated cleaning fluid |
| Fuel/Air System | Sensitive, prone to corrosion |
| Fuel Pressure Regulator | Installed on the fuel rail to relieve excess pressure |
| Fuel Rail and Injector Maintenance | Recommended to be serviced at a Mercury Marine Certified repair center or dealer |
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What You'll Learn
Use a screwdriver or cotter pin tool to remove fuel injectors
To remove the fuel injectors from your Mercury Optimax engine, you will need a screwdriver or a cotter pin tool. Before starting, it is recommended to have the official Mercury Service Manual for your specific engine, as well as small wire cutters, an autobody trim tool, a torque wrench, and either Oetiker pliers or end nippers.
First, depressurize the fuel and air systems via the Schrader valves on the fuel rails, starting with the air side. Then, unhook the electrical connections and remove the two Allen bolts holding the injectors in place. You can then use your screwdriver or cotter pin tool to remove the fuel injectors. Be sure to pull the fuel injectors straight out of their housing to avoid damage.
After removing the fuel injectors, it is important to plug or cap any open fuel/air line connections. Apply duct tape or another suitable plug to the direct injector openings to prevent any debris or contaminants from entering the fuel system.
It is also recommended to have replacement seals available in case any are damaged during the removal process. Additionally, a little outboard 2-stroke oil can be applied to the O-rings to help with lubrication during reinstallation.
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Depressurise fuel and air systems via Schrader valves
Depressurising the fuel and air systems via the Schrader valves on the fuel rails of a Mercury Optimax engine is an important step in removing fuel injectors. This is because the Optimax engine uses a combination of high-pressure fuel and high-pressure air to inject an atomised mixture of gas directly into the combustion chamber.
To start the process of depressurisation, it is recommended to begin with the air side. There is an air connection on top of each rail, similar to a car or bike tire. Push the centre pin down, just like you would for a car or bike tire, and you will be good to go.
It is also important to relieve the air that is trapped on the fuel side of the system, from the Schrader valve on the fuel side. This ensures that liquid fuel reaches all the fuel injectors, and the engine will run much more smoothly.
After depressurising the fuel and air systems, you can proceed with the removal of the fuel injectors. It is important to note that the Mercury Optimax fuel and air injection system is fairly complicated, and it is recommended to have a service manual or seek professional help if you are unsure about any steps.
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Remove the two nuts holding the rail to the cylinder head
To remove the two nuts holding the rail to the cylinder head, you will need a couple of basic tools. First, ensure you have a safe, well-lit workspace and that the engine is switched off and cooled down before you begin. Then, gather a 10mm socket with a short extension and a ratchet spanner.
Begin by locating the two nuts; they are positioned on either side of the fuel injector, holding the rail firmly to the cylinder head. Place your ratchet spanner on one of the nuts and hold it firmly in place. With your other hand, use the socket and extension to turn the nut in a counter-clockwise direction. It is important to apply steady pressure to both tools to avoid slipping. Continue turning the nut until it is completely loose and can be removed by hand.
Repeat this process for the second nut. It is important to take your time and ensure that you are applying steady, firm pressure to both tools. Once both nuts are removed, the rail will be free from the cylinder head. It is important to place the nuts and rail somewhere safe and clean to avoid any confusion when reassembling the engine.
This process is a delicate one, and it is important to take your time and ensure that you do not lose or misplace any parts. When removing the nuts, be cautious of any debris or fuel that may be present, and always wear appropriate safety gear, including gloves and eye protection.
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Pull the fuel rail off the head and remove the 6 direct injectors
To remove the fuel injectors, first, you need to relieve the pressure in the fuel system. This is done by removing the Schrader valve cap from the fuel rail and depressing the valve stem with a small screwdriver. This will release any built-up pressure and allow for safe disassembly. Once the pressure is released, proceed to disconnect the fuel lines from the fuel rail. You may need specialized tools for this step, such as fuel line disconnect tools, to ensure that the connectors are not damaged. Be prepared to catch any residual fuel that may spill from the lines.
After the fuel lines are disconnected, it's important to seal or plug the open end of the fuel lines to prevent dirt, debris, or contaminants from entering the system. Use clean rags or suitable plugs for this purpose. Next, you'll need to remove the electrical connectors from the injectors. These connectors provide power and signaling to the injectors, and they should be carefully detached. Again, specialized tools like a connector release tool may be required to safely release the connectors without causing damage.
Now, it's time to remove the fuel rail itself. The rail is secured to the head with bolts, and you'll need to remove these bolts to lift off the rail. Make sure you have a suitable size socket or wrench to remove these bolts. Once the bolts are removed, carefully lift the fuel rail straight up and off the head. Be aware that there may still be some residual fuel in the rail, so have rags ready to catch any spills. With the fuel rail removed, you now have access to the six direct injectors.
To remove each injector, first, identify any clips, brackets, or other retention mechanisms that hold the injector in place. Carefully release or remove these retention components, making sure not to damage the injector or the surrounding engine components. Once the injector is free, gently pull it straight out of its bore. If necessary, use an injector puller tool to ensure even pressure and avoid damage during removal. Repeat this process for all six injectors, and your Mercury Optimax fuel injectors will be successfully removed, allowing you to access and replace the filters as needed.
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Plug or cap any open fuel/air line connections
To plug or cap any open fuel/air line connections, you can use duct tape or any other suitable plugging material. This is a crucial step in the process of removing fuel injector filters on a Mercury Optimax engine, as it helps prevent any potential fuel or air leaks that could occur during the disassembly and servicing of the fuel injectors.
It is important to ensure that all open connections are securely plugged or capped to avoid any leakage that could potentially cause safety hazards or damage to the engine. This step should be done after the fuel and air systems have been depressurized via the Schrader valves on the fuel rails, starting with the air side first.
By following these recommendations, you can help ensure that the fuel and air lines remain sealed during the removal and servicing process, reducing the risk of any complications or issues.
Once the fuel injector filters have been successfully removed and serviced, it is important to remember to remove the plugs or caps from the fuel/air line connections to restore the normal flow of fuel and air to the engine.
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Frequently asked questions
It is recommended to have a Mercury Service Manual for your engine before starting this procedure. First, depressurize the fuel and air systems via Schrader valves on the fuel rails, starting with the air side. Then, remove the two nuts that hold the rail to the cylinder head, and pull the fuel rail off the head. Remove the six direct injectors.
You will need small wire cutters, an autobody trim tool, a torque wrench, and either Oetiker pliers or a pair of end nippers.
Plug or cap any open fuel/air line connections. Apply duct tape or plug the direct injector openings after disassembly.
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