Testing Mechanical Fuel
1. Disconnect battery cables from battery.
Pump
!
CAUTION
NOTICE
Plug fuel supply hose after removal to prevent
fuel from leaking into boat.
Refer to “Precautions,” in this section,
BEFORE proceeding.
2.
Use a wrench to stabilize brass coupling at fuel
filterinletfitting,loosenfuellinefitting,disconnect
and suitably plug fuel line to prevent fuel in tank
from leaking into bilge.
1.
2.
Disconnect battery cables from battery.
Remove fuel line from carburetor or outlet side of
fuel pump.
3. Remove fuel filter.
4.
Using wrench to stabilize brass couplings on fuel
pump, loosen fuel line fittings and disconnect
from fuel pump.
3.
Install Fuel Pressure Connector (91-18078) to
carburetor and reinstall fuel line. Tighten connec-
tor and fuel line securely.
5.
6.
Clean gasket from seawater pump.
4.
5.
Connect fuel pressure test gauge to connector.
Apply Quicksilver Perfect Seal to both sides of
fuel pump gasket and install on fuel pump.
Reconnect battery cables, start engine, and run
at 1800 RPM.
7.
8.
Install fuel pump. Torque bolts to 25 lb. ft.
(34 N·m).
6.
Fuel pressure should be within specifications. If
not, replace fuel pump.
Install fuel inlet and outlet fittings to fuel pump
as outlined next:
Mechanical Fuel Pump
!
WARNING
NOTICE
Avoid gasoline fire or explosion. Improper instal-
lation of brass fittings or plugs into fuel pump or
fuel filter base can crack casting and/or cause a
fuel leak.
Refer to “Precautions,” in this section,
BEFORE proceeding.
•
Apply #592 Loctite Pipe Sealant with Teflon to
threads of brass fitting or plug. DO NOT USE
TEFLON TAPE.
Replacement
IMPORTANT: The fuel pump cannot be repaired.
If pump fails, it must be replaced.
•
•
Thread brass fitting or plug into fuel pump or
fuel filter base until finger tight.
Tighten fitting or plug an additional 1-3/4 to
2-1/4
turns using a wrench. DO NOT
OVER-TIGHTEN.
•
Install fuel line. To prevent over-tightening,
hold brass fitting with suitable wrench and
tighten fuel line connectors securely.
•
Check for fuel leaks.
Install sight tube.
9.
10.
11.
12.
Install fuel line and fuel filter.
Reconnect battery cables.
Make sure water is supplied to cooling system
and start engine. Check for fuel leaks.
72677
Index
5A-8 - FUEL DELIVERY SYSTEMS AND FUEL PUMPS
90-823224--2 796
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 454 CID, Mercury MerCruiser 502 CID |
| Model Year | 1993, 1994, 1995, 1996, 1997 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
(4 votes, average: 4.5 out of 5)
Marine readers have rated 1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16 4.5 out of 5.0 based on 4 product reviews. Hugely helpful service manual! Perfect. Thank you!
Manuals are all Important for Technician
This book is invaluable if you do your own repairs. Great book.
Could not find a copy until a search brought me here.
Excellent print.
Thank you