Mercury 3.0 Liter Service Manual Page 15
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90-898303 2-10
2.4/2.5L Fuel Flow Component
Description
Pulse Fuel Pump
The pulse fuel pump operates through alternating crankcase pressure to
deliver fuel through the water-separating filter to the vapor separator.
•
Fuel pressure @ Idle – 2-3 psi (Minimum – 1 psi).
•
Fuel Pressure @ Wide-Open-Throttle – 6-8 psi (Minimum – 4 psi).
Water Separating Filter
The water separating filter protects the fuel injectors from water and debris.
The filter contains a sensor probe which monitors water level in the filter. If
water is above the sensor probe, the water detection light will come on and
the warning horn will begin a series of beeps.
Vapor Separator
The vapor separator is a fuel reservoir which continuously blends and
circulates fresh fuel, oil and unused fuel/oil from the fuel rail.
1) Fuel Inlet – Fresh fuel delivered from the water separator by the crankcase
mounted pulse fuel pump. The amount of fuel allowed to enter the vapor
separator is controlled by a needle/seat and float assembly mounted in the
cover of the vapor separator.
2) Oil Inlet – Oil delivered by the crankshaft driven oil pump.
3)
Crankcase Bleed Inlet – Recirculated (unburned) fuel/oil mixture delivered
from the bleed lines through a filter into the vapor separator.
4)
Fuel Pressure Regulator Inlet – Unused fuel/oil mixture being recirculated
from the fuel rail back into the vapor separator.
Bleed System
On carbureted engines, excess fuel which collects in the crankcase is
channeled into the transfer ports to be burned.
On EFI engines, excess crankcase fuel is directed through a filter (to eliminate
contaminates) and emptied into the vapor separator. It mixes with fresh
incoming fuel and is pumped to the fuel rail and fed through the injectors.
A 30 micron filter is installed in the bleed line to prevent contaminants from
entering the vapor separator. If the filter becomes clogged, the engine will load
up at idle and hesitate upon acceleration.
1989–1995 2.4L/2.5L
The bleed system flow is closed off to the vapor separator during off idle
speeds by the bleed shut off valve. The bleed shut off valve is activated by
throttle linkage on the manifold. At idle speeds the flow can be close to
1000cc’s of gasoline per hour.
Notes
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15
- Outboard V6 EFI 1
- Speed/Density System 5
- Ignition 10
- 2.4/2.5L Fuel Flow Component 15
- Fuel Pressure Regulator 17
- Fuel Injectors 17
- 1987–1999 2.4L & 2.5L 18
- 2000–2001 2.5L 18
- EFI Electrical Components 19
- 12 VOLT BATTERY 20
- FUEL INJECTORS 20
- 2.4L & 2.5L (1987–1999) 21
- 2-18 23
- VOLTAGE TEST CHART 24
- 2-20 25
- Ignition Systems 26
- 2-22 27
- 2-24 29
- Idle Stabilizer Shift System 31
- 2-28 33
- Theory of Operation 34
- #1 Cylinder Trigger Circuit 35
- Ignition Coil Circuit 35
- Stop Circuit 35
- Control Module 36
- Bias Circuit 36
- Shift Stabilizer Circuit 36
- Idle Stabilizer Circuit 36
- 2-32 37
- 2.0/2.5 LITRE 6 CYL.: 37
- 2-34 39
- Miscellaneous Checks 41
- Low Battery Voltage 42
- Ignition Spark Check 43
- 2-40 44
- Adjustment 45
- 2-42 46
- 2-46 49
- ECM Injector Driver Test 50
- Marine Diagnostics 51
- 824003 Fuel ECM 52
- Injector Test 53
- Multi Pulse Test 55
- 824003 ECM 56
- 2-56 58
- Programmable - ECM History 59
- 1995-2001 3.0L Fuel Flow 63
- ELECTRIC FUEL PUMP 65
- 3.0L Fuel Pump Test 67
- 3.0L ECM Wiring Diagram 68
- FLYWHEEL 73
- CRANK POSITION SENSOR 73
- THROTTLE POSITION SENSOR 73
- ENGINE TEMPERATURE SENSOR 73
- SHIFT INTERUPT SWITCH 74
- 3.0L LITRE 6 CYLINDER 74
- Operation of Warning Panel 75
- ENGINE OVER-SPEED 76
- 3 Function Gauge Wiring 77
- Injector Test (Cont.) 79
- Single Pulse Test 81
- 3.0L EFI Scan Data Worksheet 82
- Ignition ECM 83
- 3.0L PROM ID Chart 84
- 3.0L PROM ID Chart (Cont.) 85
- Oil Injection Components 94
- Priming The Oil Pump 95
- Priming Procedure – Method 1 96
- Ignition Coil 100
- Electronic Control Module 101
- Flywheel 102
- Crank Position Sensor 102
- 90-898303 103
- VISUAL INSPECTION 105
- SENSOR HEAT TEST 105
- SENSOR PRESSURE TEST 106
- DDT TEST 107
- Air Temperature Sensor 108
- VOLTAGE TEST 110
- Spark Plugs and Wires 113
- Main Power Relay 114
- Stop Switch Circuit 114
- Shift Interrupt Switch 114
- Water Sensing System 115
- 2002 Warning System Signals 118
- Guardian Protection System 119
- Guardian System Activation 120
- Smartcraft Data Worksheet 121
- Description 124
- Overview 127
- SmartCraft System Products 127
- SmartCraft System Rules 128
- System Monitor 130
- Section 5 - Product Changes 131
- Table of Contents 132
- Model Year Changes 133
- 2004 MY 134
- 2004 RUNNING CHANGE 134
- New Model - 200 HP 3.0 Litre 135
- Returnable Engine Carton 136
- Shift Link 3.0 EFI 139
- Starter Motor – 2.5 and 3.0L 140
- Control Harnesses 141
- New Decal Design 144
- Power Trim Rams 144
- Dielectric Grease 145
- Drive Shaft Seal Carrier 145
- Upper Engine Mounts 146
- Thermostat Discharge Fitting 146
- Special Tools 150
- Spark Board - P/N 91-850439T 153
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