FUEL SYSTEM. Table of Contents. Section 3B Direct Fuel Injection

Transcription

1 FUEL SYSTEM Section 3B Direct Fuel Injection Tle of Contents DIRECT FUEL INJECTION Specifictions B-2 Specil Tools B-3 Throttle Body B-6 Reed Block B-8 Fuel System B-10 Vpor Seprtor Components B-12 Fuel Ril Components B-14 Vpor Seprtor/Fuel Ril Mounting B-16 Air Hoses B-18 Air Compressor Components B-20 DFI Opertion B-22 Air Induction Through Crnkcse B-22 Air Compressor System B-22 Fuel B-22 Oil B-23 Electricl B-23 Opertion B-23 Testing Electric Fuel Pump Pressure Output 3B-24 Low Pressure Electric Fuel Pump B-24 High Pressure Electric Fuel Pump B-25 Fuel Mngement Assemly Removl B-26 Air Temperture Sensor Removl B-31 Air Temperture Sensor Instlltion B-31 MAP Sensor Removl B-32 MAP Sensor Instlltion B-32 Throttle Plte Assemly Removl B-33 Throttle Plte Assemly Instlltion B-33 Reed Block Assemly Removl B-34 Reed Block Assemly Instlltion B-34 Vpor Seprtor Tnk Disssemly B-37 Fuel Flow Director Components B-40 Vpor Seprtor Tnk Ressemly B-41 Air Plenum Instlltion B-46 Vpor Seprtor Instlltion B-46 Fuel Ril Removl B-48 Fuel Pressure Regultor B-54 Air Pressure Regultor B-59 Air Regultor Trouleshooting B-60 Fuel Ril Clening B-64 Direct Injector Removl B-64 Direct Injector Lek Test B-67 Fuel Ril nd Direct Injector Instlltion. 3B-68 Air Compressor B-69 Notes: B-73 Air Compressor Disssemly/Ressemly 3B-74 Air Compressor End Cp/Crnkshft Removl nd Ressemly B-76 Air Compressor Flow Digrm B-81 Air Compressor Pressure Test B-82 Fuel Injector Test B-84 3 B APRIL 2003 Pge 3B-1

2 Specifictions Fuel Pressure Air Pressure Fuel/Air Differentil High nd Low Pressure Fuel Pump Amperge Drw Low Pressure Electric Fuel Pump Output Fuel System Specifictions ± 13.8 kp (108 ± 2 psi) ± 13.8 kp (94 ± 2 psi) 96.5 kp ± 6.9 kp (14.0 ± 1.0 psi) Amps kp kp (20-30 psi) Fuel Injector Ohm Resistnce 1.8 ± 0.1Ω Direct Injector Ohm Resistnce 1.3 ± 0.3Ω Air Compressor Specifictions Air Compressor Type Compressor Output Reciprocting Piston (1.14 to 1 rtio with engine Idle 655 kp (95 psi) Cylinder Block Displcement 60 cc (3.66 cu. in.) Cylinder Bore Dimeter (Stndrd) Tper/Out of Round/Wer Mximum Bore Type 52.0 mm ( in.) mm (0.001 in.) Cst Iron Stroke Length 27.9 mm (1.100 in.) Piston Piston Type Aluminum Piston Dimeter ± mm ( ±.0004 in.) Dimension A t Right Angle (90 ) to Piston Pin in. Piston Ring End Gp Top Ring Middle Ring Bottom Ring mm ( in.) mm ( in.) mm ( in.) Reeds Reed Stnd Open 0.25 mm (0.010 in.) Pge 3B APRIL 2003

3 Specil Tools DIRECT FUEL INJECTION Duel Fuel/Air Pressure Guge kp (160 psi) A1/A2/A3 Adptors to convert pressure guge A1/A A2 to n A3 c d e NOTE: 2 Adptors A2 re required to convert pressure guge set. -1/2 in. to 1/4 in. Adpter if required -Femle quick disconnect c -Mle quick disconnect d-screw on Schrder e -O-ring Sel/Teflon Ring Instlltion Tool APRIL 2003 Pge 3B-3

4 Sel/Teflon Ring Sizing Tool o56014 DMT 2000 Digitl Tchometer Multi-meter T1 Direct Injector Removl Tool Pge 3B APRIL 2003

5 Clmp Tool Kit A2 o Clmp tool T Gercse Lekge Tester FT-8950 o57714 Regultor Instlltion Tool o APRIL 2003 Pge 3B-5

6 Throttle Body Pge 3B APRIL 2003

7 Throttle Body (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 THROTTLE BODY ASSEMBLY 2 1 PLATE 3 4 SCREW GROMMET 5 1 GROMMET 6 1 CLAMP 7 1 SCREW 8 1 WASHER 9 1 WASHER 10 1 BUSHING 11 1 THROTTLE LEVER KIT 12 1 THROTTLE ROLLER ASSEMBLY 13 1 LOCKWASHER 14 1 WASHER 15 1 WASHER 16 1 SCREW 17 1 ROLLER 18 1 BRACKET 19 3 SCREW (M6 x 16) CABLE 21 1 CAM 22 1 SPACER 23 1 WASHER 24 1 SCREW (M6x 40) COUPLER 26 1 TPI 27 3 SCREW CLAMP Oetiker 29 2 CONDUIT [33 cm (13 in.)] APRIL 2003 Pge 3B-7

8 Reed Block Tue Ref. # 14 Description 2 Cycle Premium Outord Oil Mercury Prt Numer Quicksilver Prt Numer A Q1 25 Liquid Neoprene Pge 3B APRIL 2003

9 Reed Block (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 SHIFT RAIL 2 2 TAB WASHER 3 2 SCREW (M8 x 25) SLIDE 5 1 NUT 6 1 WASHER 7 1 NUT Drive tight; ut joint must e free to pivot 8 1 GASKET 9 1 LOWER END CAP ASSEMBLY 10 1 CHECK VALVE 11 1 OIL SEAL 12 1 O-RING 13 3 SCREW (M10 x 25) 14 1 REED ADAPTOR PLATE 15 1 GASKET 16 1 FITTING 17 1 COVER 18 1 GASKET 19 9 SCREW (M8 x 45) SCREW (M8 x 35) REED BLOCK 22 3 GASKET 23 6 SCREW (M6 x 20) MAP SENSOR 25 1 BRACKET 26 1 SCREW (M6 x 16) TEMPERATURE SENSOR O-RING 29 1 NEGATIVE BATTERY CABLE 30 2 SCREW (M8 x 14) WASHER 32 1 CLAMP APRIL 2003 Pge 3B-9

10 Fuel System NOTE: A = To Crnkcse NOTE: B = To Vent Fitting Pge 3B APRIL 2003

11 Fuel System (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 HOSE VENT 2 AR CABLE TIE (8 in.) 3 1 HOSE ASSEMBLY 4 1 HOSE ASSEMBLY 5 1 SCHRADER VALVE 6 1 O RING 7 1 CLIP 8 1 SCREW (M6 x 12) TUBING (10-1/2 in.) 10 1 FITTING 11 1 TUBING (28 in.) 12 1 TUBING (4-1/2 in.) 13 1 CLAMP (15.3) 14 1 HOSE 15 1 SEAL APRIL 2003 Pge 3B-11

12 Vpor Seprtor Components A Pge 3B APRIL 2003

13 Vpor Seprtor Components (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 COVER KIT 2 1 SEAT 3 1 BAFFLE PLATE 4 2 SCREW GASKET 6 1 FITTING O-RING 8 1 FITTING PLUG FUEL FILTER 11 1 FLOAT KIT 12 1 FLOAT PIN 13 1 FUEL PUMP HIGH PRESSURE 14 1 SLEEVE 15 1 O-RING 16 1 SEAL 17 1 RETAINER SCREW BOOST PUMP 20 1 GROMMET 21 1 O-RING 22 1 SEAL 23 1 BOWL KIT 24 1 WIRE 25 1 CHECK VALVE 26 2 FITTING 27 1 INLET VALVE KIT 28 2 DRAIN SCREW O-RING 30 1 WATER SENSOR 31 1 ELBOW (90 DEGREE) Note 32 2 O-RING 33 1 INSERT NOTE: Instll elow fitting in to VST 5 turns minimum 7 turns mximum. A Torque retiner screws to 2.5 Nm (22 l. in.) APRIL 2003 Pge 3B-13

14 Fuel Ril Components Pge 3B APRIL 2003

15 Fuel Ril Components (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 FUEL RAIL ASSEMBLY 2 1 FUEL PLUG 3 2 SEAL 4 2 CLAMP 5 9 SCREW (M5 x 10) O-RING 7 1 FITTING 8 1 BRACKET 9 3 INJECTOR 10 1 O-RING KIT 11 1 O-RING KIT 12 3 RETAINER 13 2 VALVE KIT - SCHRADER 14 2 CAP 15 1 O-RING KIT 16 2 CLAMP 17 1 ELBOW 18 1 AIR PLUG 19 1 FITTING 20 1 O-RING 21 2 CLAMP 22 1 O-RING KIT 23 1 O-RING (16 per kit) APRIL 2003 Pge 3B-15

16 Vpor Seprtor/Fuel Ril Mounting Tue Ref. # 110 Description 4 Stroke 10W30 Outord Oil Mercury Prt Numer Quicksilver Prt Numer A Q1 Pge 3B APRIL 2003

17 Vpor Seprtor/Fuel Ril Mounting (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 2 STUD (M10 x 91) Drive Tight 2 2 NUT AIR INJECTOR 4 3 CUPPED WASHER 5 2 SPACER 6 3 GROMMET 7 3 WASHER 8 2 SCREW (M8 x 60) SCREW (M8 x 35) BUSHING APRIL 2003 Pge 3B-17

18 Air Hoses Pge 3B APRIL 2003

19 Air Hoses (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 1 TUBING [20.3 cm (8 in.)] 2 2 CLAMP (15.3) 3 1 HOSE 4 1 HOSE ASSEMBLY 5 2 CABLE TIE [20.3 cm (8 in.)] 6 1 AIR MUFFLER 7 1 HOSE [11.4 cm (4-1/2 in.)] APRIL 2003 Pge 3B-19

20 Air Compressor Components Tue Ref. # Description Mercury Prt Numer Quicksilver Prt Numer Loctite 271 Thredlocker Loctite 567 PST Pipe Selnt 2 Cycle Premium Outord Oil A Q1 Pge 3B APRIL 2003

21 Air Compressor Components (Continued) DIRECT FUEL INJECTION TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 AIR COMPRESSOR 2 1 END CAP 3 1 O RING 4 1 CONNECTING ROD 5 1 PISTON ASSEMBLY (WITH RINGS) 6 2 LOCK RING 7 1 REED PLATE ASSEMBLY 8 1 GASKET 9 1 GASKET 10 1 COMPRESSOR HEAD 11 1 ELBOW (45 Degree) 12 4 SCREW (M8 x 1.25) ELBOW 14 1 FITTING O RING 16 1 TEMPERATURE SENSOR O RING 18 3 CHECK VALVE PIN ELBOW 21 5 CABLE TIE 22 1 HOSE 23 1 CHECK VALVE 24 1 SCREW (M6 x 20) PULLEY 26 3 SCREW (M6 x 12) TENSIONER ARM 28 1 PULLEY 29 1 SCREW (M10 x 25) BEARING 31 1 BUSHING 32 2 TUBING [45.7 cm (18 in.)] 33 1 SPRING 34 1 SCREW (M10 x 45) WASHER 36 1 TUBING [55.8 cm (22 in.)] 37 6 CABLE TIE [20.3 cm (8 in.)] 38 3 SCREW (M8 x 90) APRIL 2003 Pge 3B-21

22 DFI Opertion Air Induction Through Crnkcse Air Compressor System Comustion ir enters the cowl through holes locted in the top ft end of the cowl. The cowl liner directs this ir to the ottom of the powerhed. This limits the exposure of slt ir to the components inside the engine cowl. Once inside the cowl the ir enters the plenum through the throttle shutter which is locted in the plenum ssemly. The ir then continues through the reed vlves nd into the crnkcse. The throttle shutter is ctuted y the throttle shft. Mounted on seprte shft is throttle position sensor (TPS). This sensor tells the propulsion control unit (PCM) the position of the throttle. Fuel Air from inside the engine cowl is drwn into the compressor through n ir filter in the ir ttenutor. This ttenutor cts like muffler to quiet compressor noise nd contins filter to prevent the ingestion of deris into the compressor. The compressor is driven y elt from pulley mounted on the flywheel nd is utomticlly self-djusted using single idler pulley. This ir compressor is single cylinder unit contining connecting rod, piston, rings, erings, reed vlves, nd crnkshft. The compressor is wter cooled to lower the temperture of the ir chrge nd is luricted y oil from the engine oil pump ssemly. As the compressor piston moves downwrd inside the cylinder, ir is pulled through the filter, reed vlves nd into the cylinder. After the compressor piston chnges direction, the intke reeds close nd the exhust reeds open llowing compressed ir into the hose leding to the ir/fuel rils. The ir/fuel rils contin two pssges; one for fuel, the second for ir. The ir pssge is common etween ll the cylinders included in the ril. A hose connects the ril ir pssge to the ir compressor. An ir pressure regultor will limit the mount of pressure developed inside the ir pssges to pproximtely 96.5 kp (14 psi) elow the pressure of the fuel inside the fuel pssges [i.e kp (94 psi) ir vs kp (108 psi) fuel]. Air exiting the pressure regultor is dischrged through muffler into the lower cowling. Fuel for the engine is stored in typicl fuel tnk. A primer ul is instlled into the fuel line to llow priming of the fuel system. A vpor seprtor mounted diphrgm fuel pump drws fuel through the fuel line, primer ul nd fuel pump ssemly. The pump then pushes the fuel through wter seprting fuel filter. This filter removes ny contmintes nd wter efore the fuel reches the vpor seprtor. Fuel vpors re vented through the ottom cowling into the tmosphere. The electric fuel pump is cple of developing fuel pressures in excess of kp (108 psi). Fuel inside the ril must remin pressurized t exctly 96.5 kp (14 psi) over the ir ril pressure or the PCM (mp) clirtions will e incorrect. Fuel from the vpor seprtor is supplied to the top of the fuel ril. Fuel is stored inside the ril until n injector opens. A fuel pressure regultor controls pressure in the fuel ril, nd llows excess fuel to return into the vpor seprtor. The fuel regultor not only regultes fuel pressure ut lso regultes it t 96.5 kp (14 psi) higher thn whtever the ir ril pressure is. The fuel regultor diphrgm is held closed with spring tht requires 96.5 kp (14 psi) to force the diphrgm off the diphrgm set. The ck side of the diphrgm is exposed to ir ril pressure. As the ir ril pressure increses, the fuel pressure needed to open the regultor will eqully increse. Exmple: If there is kp (50 psi) of ir pressure on the ir ril side of the diphrgm, kp (64 psi) of fuel pressure will e required to open the regultor. The fuel ril is wter cooled. Pge 3B APRIL 2003

23 Oil Electricl Opertion DIRECT FUEL INJECTION Oil in this engine is not mixed with the fuel efore entering the comustion chmer. Oil is stored inside n engine mounted reservoir. A remote oil tnk is ville s n option. Crnkcse pressure will force oil from the remote oil tnk into the oil reservoir on the front of the powerhed. Oil will flow from the oil reservoir into the oil pump. The oil pump is solenoid design. It is ctivted y the PCM nd includes 7 pistons with corresponding dischrge ports. The oil pump is mounted on the electricl plte. Ech cylinder is luricted y one of the dischrge ports. The oil is dischrged into the crnkcse. The seventh pssge connects to the hose tht leds to the ir compressor for luriction. Excess oil from the compressor returns into the cylinder ores. The PCM will chnge the dischrge rte of the oil pump, depending upon engine demnd. The PCM will lso pulse the pump on initil strt up to fill the oil pssges eliminting the need to leed the oil system. The PCM provides dditionl oil for rek-in, s determined y its internl clock. The oil rtio vries with engine RPM nd lod. The electricl system consists of the PCM, crnk position sensor (flywheel speed & crnkshft position), throttle position sensor (TPS), MAP sensor, engine temperture sensor, ignition coils nd injectors (fuel & direct). The engine requires ttery to strt (i.e. the ignition nd injection will not occur if the ttery is ded). The system will run off of the lterntor. The opertion of the system hppens in milliseconds (ms). Exct timing is criticl for engine performnce. As the crnkshft rottes, ir is drwn into the crnkcse through the throttle shutter, into the plenum nd through the reed vlves. As the piston ners ottom ded center, ir from the crnkcse is forced through the trnsfer system into the cylinder. As the crnkshft continues to rotte the exhust nd intke ports close. With these ports closed, fuel cn e injected into the cylinder. The PCM will receive signl from the throttle position sensor (TPS), engine temperture sensor (TS) nd the crnk position sensor (flywheel speed nd position sensor). With this informtion, the PCM refers to the fuel clirtion (mps) to determine when to ctivte (open nd close) the injectors nd fire the ignition coils. With the piston in the correct position, the PCM opens the fuel injector, kp (108 psi) fuel is dischrged into mchined cvity inside the ir chmer of the ir/fuel ril. This mixes the fuel with the ir chrge. Next the direct injector will open, dischrging the ir/fuel mixture into the comustion chmer. The direct injector directs the mixture t the owl locted in top of the piston. The piston s owl directs the ir/fuel mixture into the center of the comustion chmer. This ir fuel mixture is then ignited y the sprk plug. Compressor Notes: To id in strting when the ir ril pressure is low nd efore the compressor hs time to uild pressure, some direct injectors re held open y the PCM. This llows the compression from inside the cylinders to pressurize the ir ril fster (1 or 2 strokes, or 60 of crnkshft rottion). Idle Notes: Idle qulity is controlled y fuel volume nd fuel timing. The throttle shutter will e open t idle speed. The shift switch is mounted on the exhust dptor plte nd is ctivted y cm/notch in the upper shift shft. The switch hs closed circuit when the engine is in ger (forwrd or reverse) nd n open circuit when the engine is in neutrl. The switch is monitored y the PCM. The PCM will chnge fueling, timing nd RPM limit ccording to whether the engine is in ger or in neutrl. The TPS signls the PCM to chnge the fuel nd sprk without movement of the throttle shutters. The throttle cm is mnufctured to llow the TPS sensor shft to move efore opening the throttle shutter APRIL 2003 Pge 3B-23

24 Testing Electric Fuel Pump Pressure Output Low Pressure Electric Fuel Pump 1. Connect Dul Fuel/Air Pressure Guge [ A1/A2/A3] to Schrder vlve on VST. Guge should indicte kp (20 30 psi). o Low pressure electric fuel pump Schrder vlve o59586 Pge 3B APRIL 2003

25 High Pressure Electric Fuel Pump DIRECT FUEL INJECTION 1. Instll Pressure Guge Assemly A1/A2/A3 to fuel ril pressure test vlve. NOTE: After 15 seconds of crnking engine with strter motor, fuel pressure guge should indicte ± 13.8 kp (108 ± 2 psi) A1/A2/A3 o Fuel pressure guge [should indicte ± 13.8 kp (108 ± 2 psi)] -Fuel pressure test vlve (ottom of fuel ril) APRIL 2003 Pge 3B-25

26 Fuel Mngement Assemly Removl CAUTION Fuel system must e led off prior to removl of fuel system components. WARNING Drin fuel from vpor seprtor tnk (VST) into suitle continer. Even though VST hs een drined, fuel my still remin in fuel rils nd hoses. Norml precutionry procedures should e dhered to while working with the fuel system. Avoid sprks, smoking nd open flme while in the presence of liquid fuel or fuel vpors. NOTE: Use Fuel/Air Pressure Guge or A1/A2/A3 to de-pressurize ir hose first nd then fuel hose. 1. De-pressurize fuel system. e c -Air pressure guge -Fuel pressure guge c -Air pressure port d o59594 d-fuel pressure port (Design 1) e -Fuel pressure port (Design 2) Pge 3B APRIL 2003

27 2. Cut cle tie securing VST vent hose. 3. Plce suitle continer underneth vpor seprtor drin fittings. Turn respective relese screw to llow fuel to drin from fitting. Use ruer hose connecting drin fittings to direct fuel into suitle continer. After fuel is drined from VST, close off ech relese screw nd rettch hose to ech drin fitting. 4. Disconnect wter seprtor sensor connector. e c d o Cle ties -Relese screws c -Wter seprtor sensor led d-ruer hose e -Drin fittings 5. Disconnect electric fuel pump hrness connector. o Electric fuel pump connector APRIL 2003 Pge 3B-27

28 6. Remove the inlet fuel hose from the pulse fuel pump. 7. Remove pulse fuel pump vcuum hoses (2 ech). 8. Remove the fuel outlet hose nd fuel return hose on vpor seprtor tnk (VST). 9. Remove 3 mounting olts nd remove seprtor. e d e c -Fuel inlet hose to pulse pump -Fuel outlet hose (disconnect t fuel ril) o00883 c -Fuel return hose d-mounting olts e -Pulse pump vcuum hoses Pge 3B APRIL 2003

29 10. Remove throttle rm screw nd throttle cle pltform screw. 11. Disconnect MAP sensor, ir temperture sensor nd throttle position sensor hrness connectors. o00712 c e d -Throttle rm screw -Throttle cle pltform screw c -MAP sensor connector o00694 d-air temperture sensor connector e -Throttle position sensor connector APRIL 2003 Pge 3B-29

30 12. Remove 9 screws securing ir plenum nd remove plenum/throttle ody ssemly. o Screws Pge 3B APRIL 2003

31 Air Temperture Sensor Removl 1. Disconnect sensor hrness. 2. Unscrew sensor from ir plenum. DIRECT FUEL INJECTION o Air temperture sensor hrness connector -Air temperture sensor Air Temperture Sensor Instlltion 1. Screw sensor into ir plenum. 2. Reconnect sensor hrness. TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 TEMPERATURE SENSOR APRIL 2003 Pge 3B-31

32 MAP Sensor Removl 1. Disconnect wiring hrness. 2. Remove screw securing MAP sensor retiner nd remove sensor. c o59575 MAP Sensor Instlltion -MAP sensor -Screw c -Hrness connector 1. Instll sensor into ir plenum. 2. Reconnect sensor hrness connector. TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 SCREW (M6 x 16) Pge 3B APRIL 2003

33 Throttle Plte Assemly Removl DIRECT FUEL INJECTION NOTE: The throttle plte ssemly is clirted nd preset for proper running chrcteristics nd emissions t the fctory. Other thn complete ssemly removl from the ir plenum, no further disssemly should e mde. 1. Remove 4 olts securing throttle plte ssemly to ir plenum nd remove ssemly. -Screws (4) o Throttle plte ssemly Throttle Plte Assemly Instlltion 1. Secure throttle plte ssemly to ir plenum with 4 screws. TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 4 SCREW APRIL 2003 Pge 3B-33

34 Reed Block Assemly Removl 1. Remove 9 screws securing cover to reed lock dptor plte. 2. Remove 15 screws securing reed lock dptor plte to crnkcse cover. 3. Remove 2 screws securing ech reed lock to dptor plte. d c e f g -Screws (9 ech) (M8 x 45) -Cover c -Adptor Plte d-screws (6 ech) (M6 x 20) e -Crnkcse Cover f -Reed Block (3 ech) g-screws (15 ech) (M8 x 35) Reed Block Assemly Instlltion NOTE: Replce ll gskets for lsting repir. 1. Secure ech reed lock with 2 screws to dptor plte. TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. d 6 SCREW (M6 x 20) Pge 3B APRIL 2003

35 2. Secure dptor plte to crnkcse cover with 15 screws. Torque screws in following sequence. o00792 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 15 SCREW (M8 x 35) APRIL 2003 Pge 3B-35

36 3. Reinstll cover with 9 screws. Torque screws in following sequence o00820 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 9 SCREW (M8 x 45) Pge 3B APRIL 2003

37 Vpor Seprtor Tnk Disssemly DIRECT FUEL INJECTION 1. Remove 2 screws securing pulse fuel pump to VST nd remove pump. Refer to Section 3A for disssemly, inspection nd ressemly of pulse fuel pump. -Pulse fuel pump o Screws 2. Remove fuel/wter seprtor filter from VST. Inspect filter O-rings for cuts or risions. Replce O-rings s required. Inspect filter element for deris. Remove deris or replce element s required. c o59372 o Fuel/wter seprtor filter -O-rings c -Filter element APRIL 2003 Pge 3B-37

38 3. Remove wter sensor from VST nd inspect for deris or corrosion. Clen or replce s required. Inspect sensor O-ring for cuts or rsions. Replce s required. o59370 o Wter sensor -O-ring 4. Remove 9 screws securing VST cover nd remove cover. Inspect cover seling ring for cuts or risions. Replce s required. o59374 o Screws (9) -Seling ring Pge 3B APRIL 2003

39 5. Loosen screw securing flot ssemly nd remove flot. Inspect flot for deteriortion or fuel retention. Replce flot s required. Inspect flot needle nd set for wer, deris or corrosion. Replce needle nd set s required. -Flot -Screw c o59342 c -Flot needle 6. Remove 2 screws securing low pressure fuel pump. 7. Remove low nd high pressure pumps from VST. Disconnect electricl connectors from ech pump. Inspect O-rings on ech pump nd on hrness for cuts or risions. Replce s required. c e e o59378 d e d c o Screws -Low pressure pump c -High pressure pump d-electricl connectors e -O-rings APRIL 2003 Pge 3B-39

40 Fuel Flow Director Components COMPONENTS c o Fuel director insert -Sel c -Sel ASSEMBLY VIEW d c e o High pressure fuel pump -Sel c -Fuel director insert d-check vlve e -Sel (instll on fitting) Pge 3B APRIL 2003

41 Vpor Seprtor Tnk Ressemly DIRECT FUEL INJECTION 1. Apply light oil to fuel pump elow O-rings to id instlltion into vpor seprtor. 2. Align gsket etween fuel pump nd VST. Secure fuel pump to VST with 2 screws. 3. Retorque ssemly screws. e c d c o Elow -Fuel pump c -Assemly screws d-attching screws e -Gsket (hidden) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. c/d 4 SCREW Apply light oil to wter sensor O-ring nd reinstll sensor in VST. o59371 o Wter sensor -O-ring APRIL 2003 Pge 3B-41

42 NOTE: If the fuel pump hrness must e replced, the new hrness must e routed through the VST csting efore instlling the RED nd BLACK wire pins into the hrness connector. To ensure correct electricl polrity, the RED wire pin must e instlled into the (A) pin receptcle nd the BLACK wire pin must e instlled into the (B) pin receptcle. After oth pins re instlled nd locked into the connector, slide the pin retiner over the hrness nd lock in plce on the connector. c d e f o (A) pin receptcle -Pin retiner c -RED wire d-black wire e -(B) pin receptcle f -Connector Pge 3B APRIL 2003

43 5. Apply light oil to electric fuel pump O-rings nd pump hrness O-rings. 6. Attch electricl hrnesses to ech fuel pump. Secure high pressure pump hrness to pump with cle tie. c o O-rings -Electricl hrness c -Cle tie 7. Instll oth fuel pumps into VST. Secure low pressure pump with retiner nd 2 screws. -Screws -Retiner c -Low pressure pump d-high pressure pump c d o59378 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 2 SCREW APRIL 2003 Pge 3B-43

44 8. Secure flot, needle nd pivot pin ssemly to seprtor cover with screw. d c o Flot -Needle c -Pivot pin d-screw TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. d 1 SCREW Instll cover seling ring on VST. Secure cover to VST with 9 screws. o Seling ring -Screws o59374 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 9 SCREW Pge 3B APRIL 2003

45 10. Apply 2-4-C with Teflon to fuel/wter seprtor filter O-rings. Thred filter into VST cover until filter sets. 95 o59372 o Fuel/Wter seprtor filter -O-rings Tue Ref. # Description Mercury Prt Numer Quicksilver Prt Numer C with Teflon A Q APRIL 2003 Pge 3B-45

46 Air Plenum Instlltion Secure plenum to crnkcse with 9 screws. Torque olts in sequence shown. -Air plenum o Screws Vpor Seprtor Instlltion TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 9 SCREW (M8 x 45) Secure vpor seprtor to ir plenum with 3 olts. 2. Reconnect pulse fuel pump vcuum hose. 3. Connect fuel inlet hose to pulse pump. IMPORTANT: Only use tool T (or Snp-On equivlent YA3080) to crimp full circle clmps. Using different tool could result in crimp tht is too loose, or too tight. Do not use screw type metl hose clmp s it my dmge hose. 4. Secure fuel outlet hose with 15.3 mm full circle clmp ( ) using crimping tool T. Pge 3B APRIL 2003

47 5. Connect fuel return hose to vpor seprtor. Secure hose with retiner nd screw g d c f e d d -Screws -Pulse pump vcuum hoses c -Inlet fuel hose d-fuel return hose e -Retiner f -Screw g-outlet fuel hose o00882 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 3 SCREW (M8 x 60) f 1 SCREW (M6 x 12) APRIL 2003 Pge 3B-47

48 Fuel Ril Removl CAUTION Fuel system must e led off prior to removl of fuel system components. NOTE: Use Fuel/Air Pressure Guge or A1/A2 to de-pressurize ir hose first nd then fuel hose. 1. De-pressurize fuel system. 2. Remove fuel injector hrness from ech injector y compressing spring clip with flt tip screw driver while pulling on connector. c e d f o Fuel pressure port (ottom of fuel ril)(design 1) -Air pressure port c -Fuel injector o59586 d-hrness connector e -Spring clip f -Fuel pressure port (Design 2) Pge 3B APRIL 2003

49 NOTE: Alwys remove fuel/ir hose nd fitting together y removing fitting retiner rther thn cutting clmps. IMPORTANT: If ir hose is removed from red fitting, replce hose, s interior surfce of hose will e dmged during removl. 3. Remove llen screws securing ir nd fuel hose retiners. 4. Remove fuel, wter nd ir hoses from fuel ril. c o59609 e o59592 d o Fuel hose -Wter hose c -Fuel hose retiner llen screws d-air hose retiner llen screws (ottom of ril) e -Air hose APRIL 2003 Pge 3B-49

50 NOTE: It is recommended tht direct injectors remin in the cylinder hed (if they re not to e replced) while removing the fuel ril. The direct injectors hve teflon sel which my expnd if the injector is removed from the hed. This expnsion my cuse reinstlltion difficulty or require the replcement of the sel. 5. Remove 2 nuts securing fuel ril. -Nuts o As fuel ril is removed, use flt tip screw driver to hold direct injectors in cylinder hed. -Fuel ril o Direct injectors NOTE: The fuel ril contins 3 fuel injectors, 1 fuel fuel regultor, nd 1 ir regultor. Pge 3B APRIL 2003

51 NOTE: Ech fuel/ir inlet or outlet hose dptor hs 2 O-ring sels. These O-rings should e inspected for cuts or risions nd replced s required when fuel ril is disssemled for clening. f i l e j g c d k h o Fuel injector -Fuel regultor c -Air regultor d-coolnt outlet to tell-tle e -Excess fuel return to VST f -Wter inlet for cooling fuel ril g-excess ir to muffler h kp (109 psi) fuel i -655 kp (95 psi) ir j -Air pressure Schrder vlve k -Fuel pressure Schrder vlve (Design 1) l -Fuel pressure Schrder vlve (Design 2) APRIL 2003 Pge 3B-51

52 FUEL INJECTOR REMOVAL 1. Remove 2 screws securing injector. NOTE: Use cotter pin extrctor tool in pry holes to remove injectors. 2. Gently pry up on injector to loosen O-ring dhesion nd remove injector. o57970 o Screws -Pry holes 3. Inspect fuel injector orifices for foreign deris, O-rings for cuts or risions, nd plstic components for het dmge. Replce components s required. 4. An ohm test of the fuel injector my e mde y connecting test leds to injector terminls. Ohm reding should e 1.8 ± 0.1 ohm. c o56124 o Fuel injector -Fuel nozzle c -O-rings Pge 3B APRIL 2003

53 FUEL INJECTOR INSTALLATION DIRECT FUEL INJECTION NOTE: Apply nti-seize grese (otin loclly) or 2-4-C with Teflon to fuel injector ttching screw threds. 1. Insert fuel injector into fuel ril with connector pins fcing (inwrds) towrds center of engine. NOTE: Turn injector ck nd forth slightly to set injector O-rings in fuel ril while securing injector with retiner nd 2 screws Injector -Retiner o57970 c -Screws Tue Ref. # Description Mercury Prt Numer Quicksilver Prt Numer C with Teflon A Q1 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. c 2 SCREW APRIL 2003 Pge 3B-53

54 Fuel Pressure Regultor The fuel regultor is locted on the port fuel ril. o Fuel pressure regultor The fuel pump is cple of delivering more fuel thn the engine cn consume. Excess fuel flows through the fuel pressure regultor, interconnecting pssges/hoses, fuel cooler, nd ck to the vpor seprtor tnk. This constnt flow of fuel mens tht the fuel system is lwys supplied with cool fuel, therey preventing the formtion of fuel vpor ules nd minimizing the chnces of vpor lock. The fuel pressure regultor is clirted to rise the fuel pressure to 96.5 kp (14 psi) ove the ir pressure. The fuel regultor is mounted on the fuel ril, ner the top. This regultor relies on oth ir nd spring pressure to control the fuel pressure. Inside the regultor ssemly is 14 l. spring, this spring holds the diphrgm ginst the diphrgm set. The contct etween the diphrgm nd diphrgm set closes the pssge etween the incoming fuel [from the electric fuel pump] nd the fuel return pssge. When the engine is not running (no ir pressure on the spring side of the diphrgm) the fuel pressure required to move the diphrgm is 96.5 kp (14 psi). When the engine is running, ir pressure from the ir compressor kp (94 psi) is routed through the ir pssges, to the spring side of the fuel pressure regultor diphrgm. The ir pressure kp (94 psi) nd spring pressure 96.5 kp (14 psi) comine to regulte system fuel pressure to kp (108 psi) - or 96.5 kp (14 psi) higher thn the ir pressure in the DFI system fuel/ir rils. Pge 3B APRIL 2003

55 FUEL PRESSURE REGULATOR CUTAWAY Regultor Closed DIRECT FUEL INJECTION Regultor Open Top cover 2 -Expnsion plug 3 -O-ring 4 -Spring retiner 5 -Spring 6 -O-ring 7 -Diphrgm set 8 -Air ril 9 -Air pssge (from ir compressor) 10 - Fuel return pssge (to vpor seprtor) 11 - Fuel inlet pssge (from electric fuel pump) 12 - Diphrgm ssemly 13 - Clirtion screw (do not turn) APRIL 2003 Pge 3B-55

56 FUEL REGULATOR REMOVAL 1. Remove 4 screws securing regultor nd remove regultor. 2. Inspect regultor diphrgm for cuts or ters. 3. Inspect regultor housing O-ring for cuts nd risions. Replce components s required. c e d f o57968 o Screws -Fuel regultor c -Diphrgm d-spring e -Cup f -O-Ring Pge 3B APRIL 2003

57 FUEL REGULATOR INSTALLATION DIRECT FUEL INJECTION NOTE: Apply light cot of 2-4-C with Teflon to diphrgm surfce nd O-ring to id in the retention of diphrgm nd O-ring on fuel ril during ressemly. c e e d o Diphrgm -O-ring c -Spring o57975 d-cup e -Screws Tue Ref. No. Description Mercury Prt Numer Quicksilver Prt Numer C with Teflon A Q1 1. Position diphrgm on fuel ril. 2. Position O-ring on fuel ril. 3. Position spring nd cup onto diphrgm. NOTE: Apply nti-seize grese (otin loclly) or 2-4-C with Teflon to regultor ttching screw threds. 4. Plce cover over spring/cup/diphrgm ssemly. Plce the lignment pins from the specil tool ( ) through two of the regultor cover mounting holes nd thred them into the corresponding threded holes in the fuel ril. o Alignment Pins APRIL 2003 Pge 3B-57

58 5. Push the regultor cover ginst the fuel ril. While holding the cover down instll two cover retining screws through the open holes in the cover. Thred the two screws down until the hed of the screw mkes contct with the cover. Do not torque screws t this time. o Screw 6. Remove the lignment pins nd instll the two remining screws. -Screws o56126 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1st torque 5.6 Nm e 4 SCREW (50 l. in.); 2nd torque 7.9 Nm (70 l. in.) Pge 3B APRIL 2003

59 Air Pressure Regultor The ir pressure regultor is locted on the fuel ril. DIRECT FUEL INJECTION -Air pressure regultor o59585 The ir pressure regultor is designed to limit the ir pressure inside the rils to pproximtely kp (94 psi). The ir regultor uses spring (pressure) to control the ir pressure. This spring kp (94 psi) holds the diphrgm ginst the diphrgm set. The contct re locks (closes) the ir inlet pssge from the excess ir, return pssge. As the ir pressure rises (elow the diphrgm), it must rech pressure equl to or greter thn the spring pressure holding the diphrgm closed. Once this pressure is chieved, the spring compresses, llowing the diphrgm to move. The diphrgm moves wy from the diphrgm set, llowing ir to exit through the diphrgm set, into the excess ir pssge leding to the ir plenum APRIL 2003 Pge 3B-59

60 Air Regultor Trouleshooting Correct ir pressure nd volume is criticl to proper opertion. Although ir pressure guge my show correct pressure, it does not confirm good volume. Air pressure should e mesured t the ir schrder vlve locted ner the middle of the fuel ril ssemly. Is ir pressure within [ kp (93 97 psi)] rnge t neutrl idle position? No Yes Momentrily pinch off ir dischrge hose. Does pressure rise very quickly to pproximtely kp (108 psi) or higher? Momentrily pinch off ir dischrge hose. Does pressure rise very quickly to pproximtely kp (108 psi) or higher? No Yes No Yes Ostruction t compressor inlet or outlet or filed compressor. Air regultor OK. Compressor output low. Check compressor. Air compressor output nd volume OK. Air regultor fulty. Inspect regultor diphrgm, spring nd cup. Air compressor output nd volume OK. Regultor OK. Regultor Closed Regultor Open Top cover 2 -Expnsion plug 3 -Spring retiner 4 -Vent 5 -Spring 6 -Diphrgm set 7 -Air ril 8 -Air pssge (from ir compressor) 9 -Excess ir pssge (to exhust dptor) 10 - Fuel inlet pssge (from electric fuel pump) 11 - Diphrgm ssemly 12 - Clirtion screw (do not turn) Pge 3B APRIL 2003

61 AIR REGULATOR REMOVAL DIRECT FUEL INJECTION NOTE: Due to the stiffness of the regultor spring, it is recommended tht Regultor Instlltion Tool e utilized when removing the ir regultor cover. Clen re re round regultor prior to disssemly to keep deris out of fuel system. 1. Remove two opposing screws from regultor cover nd instll regultor instlltion tool. o With instlltion tool pplying pressure to regultor cover, remove remining cover screws. 3. Loosen instlltion tool nd remove cover. o59357 o APRIL 2003 Pge 3B-61

62 4. Inspect regultor diphrgm for cuts or ters. Replce s required. c d e -Screws -Air regultor cover c -Diphrgm AIR REGULATOR INSTALLATION o57974 d-spring e -Cup NOTE: Apply light cot of 2-4-C with Teflon to diphrgm surfce to id in the retention of diphrgm on fuel ril during ressemly. 1. Remove fuel ril from engine nd plce ril in horizontl position when ssemling ir regultor to ril to prevent dmge to diphrgm. NOTE: Mount fuel ril in vice to keep ril stle while ressemling. 2. Position diphrgm, spring nd cup onto fuel ril with fuel ril in horizontl position. NOTE: Apply nti-seize grese (otin loclly) or 2-4-C with Teflon to regultor ttching screw threds. NOTE: Due to the stiffness of the regultor spring, it is recommended tht Regultor Instlltion Tool e utilized when instlling the ir regultor cover. c -Cup -Spring c -Diphrgm Pge 3B APRIL 2003

63 3. Position cover over diphrgm spring nd instll Regultor Instlltion Tool Regultor Instlltion Tool ( ) o Gently pply pressure to cover with instlltion tool until cover is just seted ginst fuel ril. Do not over tighten center screw during instlltion or dmge to regultor cover my occur. o Instll two retining screws. Remove instlltion tool. Instll remining two screws o Screws NOTE: After instlltion of ril on engine, verify function of regultor with pressure guge nd check for ir leks using sopy wter. Tue Ref. No. Description Mercury Prt Numer Quicksilver Prt Numer C with Teflon A Q1 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 4 SCREW APRIL 2003 Pge 3B-63

64 Fuel Ril Clening Direct Injector Removl After ll fuel injectors, ir regultor, fuel regultor, inlet hoses nd outlet hoses hve een removed, the fuel rils my e flushed out with suitle prts clening solvent. Use compressed ir to remove ny remining solvent. IMPORTANT: If mechnicl filure should occur in the ir compressor or direct injector ssemlies, the fuel ril nd ttched hoses should e removed nd flushed with suitle prts clening solvent to remove ny metl deris. 1. Remove hrness connectors from direct injectors. 2. Remove direct injector from cylinder hed using Direct Injector (3 ech) -Direct Injector Removl Tool o00783 Pge 3B APRIL 2003

65 3. Inspect injector teflon seling ring (white) for signs of comustion lowy (teflon ring will e streked rownish lck). If lowy is present, replce teflon seling ring. If lowy is not present, seling ring my e reused. 4. Inspect O-rings nd teflon ring for cuts or risions. Replce components s required. 5. If teflon sel requires replcement, use Teflon Sel Instlltion Tool to slide new sel onto injector. Following instlltion of teflon ring, the Teflon Ring Sizing Tool cn e used to compress the teflon sel to id in the instlltion of the injector into the cylinder hed. c d e e o Teflon seling ring -O-ring c -Teflon sel d-sel Instlltion Tool ( ) e -O-ring f -Teflon Ring Sizing Tool ( ) f APRIL 2003 Pge 3B-65

66 NOTE: It is recommended tht digitl ohm meter e used due to it s improved ccurcy when mesuring smll ohm redings inherit with direct injectors. 6. An ohm test of the direct injector my e mde y connecting test leds to injector terminls. Ohm reding should e 1.3 ± 0.3 ohm. 7. An ohm test to determine if direct injector windings re shorted to ground cn e mde y connecting one ohm led to either injector pin while touching the other ohm led to the injector metl cse. There should e no continuity. If there is continuity, the internl windings re shorted nd the injector must e replced. o00051 o Direct injector ohm test (1.3 ± 0.3 ohm) -Direct injector short to ground ohm test (no continuity) Pge 3B APRIL 2003

67 Direct Injector Lek Test 1. Attch Gercse Lekge Tool to dischrge side of injector. DIRECT FUEL INJECTION -Gercse Lekge Tool (FT-8950) -Direct injector o Pump up lekge tool to indicte kp (25-30 psi). 3. Direct injector should not lek down more thn 3.5 kp (1/2 psi) in 1 minute. 4. If injector does not meet the ove specifictions, replce injector. NOTE: If cylinder lock is going to e replced, remove cup wshers from ech direct injector port y prying out with flt tip screwdriver. Reinstll wshers with retiners into new cylinder lock. Wshers provide tension etween direct injectors, cylinder hed nd fuel rils. -Cup wsher -Retiner o APRIL 2003 Pge 3B-67

68 Fuel Ril nd Direct Injector Instlltion 1. Use Teflon Ring Sizing Tool ( ) to compress new teflon seling rings prior to instlltion of injector into cylinder hed. 2. Crefully slide fuel ril over mounting studs nd onto direct injectors. IMPORTANT: ALL fuel nd ir hoses ttched to the fuel rils MUST e secured with stinless steel hose clmps. 3. Secure ech fuel ril with 2 nuts. 4. Reinstll direct injector hrness connectors. -Nuts -Direct injector hrness connectors o59608 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 2 NUT Pge 3B APRIL 2003

69 Air Compressor DIRECT FUEL INJECTION Air compressor is single cylinder, wter cooled nd luricted y the outord oil pump. Air Compressor Specifictions Air Compressor Type Compressor Output Reciprocting Piston (1.14 to 1 rtio with engine Idle kp (94 psi) Cylinder Block Displcement 60 cc (3.66 cu. in.) Cylinder Bore Dimeter (Stndrd) Tper/Out of Round/Wer Mximum Bore Type 52.0 mm ( in.) mm (0.001 in.) Cst Iron Stroke Length 27.9 mm (1.100 in.) Piston Piston Type Aluminum Piston Dimeter ± mm ( ±.0004 in.) Dimension A t Right Angle (90 ) to Piston Pin in. Piston Ring End Gp Top Ring Middle Ring Bottom Ring mm ( in.) mm ( in.) mm ( in.) Reeds Reed Stnd Open 0.25 mm (0.010 in.) APRIL 2003 Pge 3B-69

70 COMPRESSOR REMOVAL 1. Disconnect ttery cles from ttery terminls. 2. Remove top cowling. 3. Remove flywheel cover. 4. Use 3/8 inch drive on elt tensioner rm to relieve elt tension. Remove elt. o Belt tensioner -3/8 in. drive Pge 3B APRIL 2003

71 CAUTION DIRECT FUEL INJECTION If engine hs een recently run, ir pressure outlet hose fittings my e extremely hot. Allow components to cool off efore eginning disssemly. NOTE: Remove 2 screws securing retiner plte to remove ir pressure outlet hose. Inspect O-rings on ir pressure hose fitting for cuts or risions. Replce O-rings s required. 5. Remove ir pressure outlet hose. -Air pressure outlet hose -Screws 6. Remove ir compressor wter outlet hose. 7. Disconnect ir compressor temperture sensor connector. 8. Disconnect compressor ir inlet hose. o59605 o59611 c o Compressor wter outlet hose -Compressor temperture sensor connector c -Compressor ir inlet hose APRIL 2003 Pge 3B-71

72 9. Disconnect ir compressor oil inlet hose. 10. Disconnect wter outlet hose (to fuel ril). 11. Disconnect excess oil return hoses. c d -Air compressor oil inlet hose -Wter inlet hose c -Excess oil return hoses d-oil return check vlves (3) o Remove 3 screws securing ir compressor to outord nd remove compressor. -Screws o00772 Pge 3B APRIL 2003

73 Notes: DIRECT FUEL INJECTION APRIL 2003 Pge 3B-73

74 Air Compressor Disssemly/Ressemly c IMPORTANT: If n internl filure of the ir compressor hs occurred, ll ir hoses, excess oil return hose check vlves, fuel rils nd injectors should e disssemled nd inspected for metl deris. Filure to remove ll metl deris will result in poor performnce nd/or powerhed filure. NOTE: If cylinder ore is scored, ir compressor must e replced s n ssemly. NOTE: Piston Instlltion use metl hose clmp for piston ring compressor. Stgger piston ring openings. NOTE: The piston nd rings re not sold seprtely. They must e replced s n ssemly. The connecting rod nd erings re not sold seprtely. They must e replced s n ssemly. End cp ering nd sel re not sold seprtely. End cp must e replced s n ssemly. 7 c 7 7 d e f 9 9 i 9 h g -Screw (pulley) -Screw (tensioner) c -Screw (end cp) d-end cp ssemly (inspect ering for roughness) e -O-ring (inspect for cuts or risions) f -Reed plte (inspect for roken or chipped reeds/stops) mximum reed stnd-open mm (0.010 in.) g-screw (4 ech) h-temperture sensor i -Fitting (outlet) Pge 3B APRIL 2003

75 Tue Ref. # Description Loctite 271 Thred Locker Loctite 567 PST Pipe Selnt 2 Cycle Premium Outord Oil Mercury Prt Numer DIRECT FUEL INJECTION Quicksilver Prt Numer A Q1 TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 3 SCREW SCREW c 1 SCREW d 3 SCREW h 4 SCREW i 1 TEMPERATURE SENSOR j 1 FITTING APRIL 2003 Pge 3B-75

76 Air Compressor End Cp/Crnkshft Removl nd Ressemly DISASSEMBLY 1. Remove flywheel cover. 2. Use 3/8-inch drive on elt tensioner rm to relieve elt tension, nd remove elt. 3. Remove the 3 olts tht retin the pulley to the pulley flnge. c -Pulley retining olts (3) -Tensioner c -3/8 in. squre drive o00397 Pge 3B APRIL 2003

77 4. Remove the 4 olts tht retin the end cp to the compressor ody. DIRECT FUEL INJECTION -End cp retining olts (4) o While rotting the pulley flnge lterntely clockwise nd counterclockwise out 1/8 to 1/4 turn, pull outwrd on the pulley flnge. Continue rotting until the end cp ssemly hs een removed from the compressor ody APRIL 2003 Pge 3B-77

78 REASSEMBLY 1. Luricte end cp O-ring nd O-ring contct re in compressor ody with two cycle oil. 2. Slide the new end cp ssemly into the compressor ody, keeping the connecting rod journl lined up with the open end of the connecting rod, until the crnkshft just enters the open end of the connecting rod. -Connecting rod open end -Crnkshft connecting rod journl 3. While rotting the pulley flnge clockwise nd counterclockwise, push the end cp into the compressor. Continue rotting the flnge until the end cp is ll the wy down ginst the compressor ody. 4. To confirm tht the connecting rod journl hs properly engged with the connecting rod, rotte the flnge until you feel resistnce from the piston trying to compress ir in the cylinder. Pge 3B APRIL 2003

79 5. Apply Loctite 271 to the threds of the end cp retining screws nd torque to specifiction. 7 -End cp retining screws (4) o57809 Tue Ref. # 7 Description Loctite 271 Thred Locker Mercury Prt Numer Quicksilver Prt Numer TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 4 SCREW APRIL 2003 Pge 3B-79

80 6. Apply Loctite 271 to the pulley retining screws. Torque screws to specifiction. 7 -Screws Tue Ref. # 7 Description Loctite 271 Thred Locker Mercury Prt Numer o00397 Quicksilver Prt Numer TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 3 SCREW Instll compressor/lterntor elt. 8. Run engine to confirm tht compressor is functioning correctly. Pge 3B APRIL 2003

81 Air Compressor Flow Digrm DIRECT FUEL INJECTION j l f k g m p e c d n i o h o Excess ir return to dptor plte -Air muffler c -Wter outlet from fuel ril d-air regultor ± 13.8 kp (94 ± 2 psi) e -Fuel regultor ± 13.8 kp (108 ± 2 psi) f -Fuel ril g-fuel inlet to fuel ril ± 13.8 kp (108 ± 2 psi) h-excess fuel return to VST i -Air pressure test vlve (hidden) j -Wter inlet hose to ir compressor k -High pressure ir to fuel ril ± 13.8 kp (94 ± 2 psi) l -Air compressor m-compressor ir inlet n-air filter o-air inlet p-oil tnk/ir ttenutor APRIL 2003 Pge 3B-81

82 Air Compressor Pressure Test 1. Instll Pressure Guge Assemly A1/A2/A3 to fuel ril pressure test vlves. NOTE: After 15 seconds of crnking engine with strter motor, ir pressure guge should indicte ± 13.8 kp (94 ± 2 psi) nd fuel pressure guge should indicte ± 13.8 kp (108 ± 2 psi). e c d o Air pressure guge should indicte ± 13.8 kp (94 ± 2 psi) -Fuel pressure guge should indicte ± 13.8 kp (108 ± 2 psi) c -Air pressure test vlve d-fuel pressure test vlve (Design 1) e -Fuel pressure test vlve (Design 2) Fuel/Air pressures within the ove listed rnges re importnt, ut the difference etween the two pressures is even more importnt. There should e 96.5 ± 6.9 kp (14 ± 1 psi) difference. If the pressure difference is outside this rnge, confirm guge ccurcy. Reversing the dul pressure guge connections is good wy to confirm guge ccurcy. Pge 3B APRIL 2003

83 NOTE: Proper pressure does not necessrily confirm good fuel/ir volumes. DIRECT FUEL INJECTION To confirm good ir volume, momentrily pinch off the ir dischrge hose on the port side of the engine. Pressure should rise very quickly to out kp (120 psi) or higher. -Air dischrge hose pinched off to rise pressure If ir pressure does not rise quickly to kp (120 psi), the following items should e checked: Dirty ir compressor ir filter. Leking ir hoses. Broken ir compressor reed vlves. Scuffed ir compressor piston. Defective direct injector. To confirm good fuel volume, momentrily pinch off the fuel return hose on the port side of the engine. Pressure should rise very quickly to out kp (120 psi) or higher. -Fuel dischrge hose pinched off to rise pressure If fuel pressure does not rise quickly to kp (120 psi), the following items should e checked: Proper fuel level in vpor seprtor tnk. Check low pressure fuel pump output APRIL 2003 Pge 3B-83