Mercury 200 OptiMax Jet Drive, Service Manual, Page: 287 / 391

Powerhead
Page 4A-22 90-8M0050731 MAY 2011
• Electronic control module
• Ignition coils
2. Refer to
Section 2B - Charging and Starting System
to remove the following components:
• Flywheel
• Alternator
• Starter motor
• Starter solenoid
3. Refer to
Section 3A - Fuel Pump
to remove the following components:
• Fuel lift pump
4. Refer to
Section 3B - Direct Fuel Injection
to remove the following components:
• Air plenum
• Oil pump
Vapor Separator Tank Removal
!
WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.
!
CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
!
WARNING
Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank (VST). To avoid a possible fire or explosion,
follow normal precautionary procedures while working with the fuel system. Use a suitable container when draining fuel from
the VST and avoid sparks, smoking, and open flame while in the presence of liquid fuel or fuel vapors.
1. Disconnect both battery cables from the battery.
2. Install the fuel/air pressure gauge kit to the fuel pressure test port and release the fuel pressure into an appropriate container.
a - Port fuel rail
b - Fuel pressure test port
c - Air pressure test port
Fuel Pressure Gauge Kit 91‑881833A03
3. Place a suitable container underneath the vapor separator drain plug and remove the plug.
4. Disconnect the water separator sensor lead.
a
c
a
b
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