FUEL SYSTEM FUEL PUMP 5 A

FUEL SYSTEM FUEL PUMP 5 A

Tle of Contents Pge Identifition............................ 5A - 1 Replement Prts Wrning.............. 5A - 1 Torque Speifitions.................... 5A - 1 Tools/Lurints/Selnts................ 5A - 1 Speifitions........................... 5A - 1 Preutions............................ 5A - 2 Fuel Delivery System.................... 5A - 2 Reommendtions.................... 5A - 2 Desription.......................... 5A - 2 Pge Fuel System Components (Typil)........ 5A - 3 Wter Seprting Fuel Filter.............. 5A - 3 Replement......................... 5A - 3 Fuel Pump Fuel Filter.................... 5A - 4 Replement......................... 5A - 4 Testing Fuel Pump...................... 5A - 4 Fuel Pump Replement................. 5A - 5 Removl............................ 5A - 5 For informtion nd proedures on trouleshooting, refer to SECTION 1C. 5A -- 0 FUEL - FUEL DELIVERY PUMP SYSTEM 90-816462 2-695

Identifition Torque Speifitions Desription L. Ft. N m Fuel Inlet nd Outlet Fittings Fuel Line to Fuel Outlet Fitting Fuel Pump to Blok Tighten finger tight then 1-3/4 to 2-1/4 turns with wrenh. (See Note) Seurely 20 27 NOTE: Apply #592 Lotite Pipe Selnt with Teflon. Do not use Teflon Tpe. Crter Fuel Pump Replement Prts Wrning Eletril, ignition nd fuel system omponents on your MerCruiser re designed nd mnuftured to omply with U.S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosion. Use of replement eletril, ignition or fuel system omponents, whih do not omply with these rules nd regultions, ould result in fire or explosion hzrd nd should e voided. Tools/Lurints/Selnts Desription Prt Numer Fuel Pressure Guge 91-16850A1 Quiksilver Perfet Sel 92-34227-1 Quiksilver Needle Bering Grese 92-42649A1 Otin Lolly Lotite Pipe Selnt with TEFLON Speifitions Type of Fuel Pump Pump Pressure (1800 RPM) Crter 5-1/4-6-1/4 PSI (36-44 kp) Avoid gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel filter se n rk sting nd/or use fuel lek. Apply #592 Lotite Pipe Selnt with Teflon to threds of rss fitting or plug. DO NOT USE TEFLON TAPE. Thred rss fitting or plug into fuel filter se until finger tight. Tighten fitting or plug n dditionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVER-TIGHTEN. Instll fuel line. To prevent over-tightening, hold rss fitting with suitle wrenh nd tighten fuel line onnetors seurely. Chek for fuel leks. 90-816462 2-695 FUEL PUMP - 5A - 1

Preutions Alwys disonnet ttery les from ttery BEFORE working on fuel system to prevent fire or explosion. Be reful when hnging fuel system omponents; gsoline is extremely flmmle nd highly explosive under ertin onditions. Be sure tht ignition key is OFF. DO NOT smoke or llow soures of sprk or flme in the re while hnging fuel filters. Wipe up ny spilled fuel immeditely. Mke sure tht no fuel leks exist efore losing engine hth.! CAUTION DO NOT operte engine without ooling wter eing supplied to sewter pikup pump, or pump impeller will e dmged nd susequent overheting dmge my result. Avoid gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel filter se n rk sting nd/or use fuel lek. Apply #592 Lotite Pipe Selnt with Teflon to threds of rss fitting or plug. DO NOT USE TEFLON TAPE. Thred rss fitting or plug into fuel filter se until finger tight. Tighten fitting or plug n dditionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVER-TIGHTEN. Instll fuel line. To prevent over-tightening, hold rss fitting with suitle wrenh nd tighten fuel line onnetors seurely. Chek for fuel leks. Fuel Delivery System Reommendtions Boting industry stndrds (BIA, ABYC, et.) federl stndrds nd Cost Gurd regultions MUST BE dhered to when instlling fuel delivery system. When designing nd instlling fuel delivery system, the following informtion MUST BE oserved: 1. Fuel tnk should e mounted elow ruretor level, if possile. If tnk is mounted ove ruretor level, grvity feed my use ruretor fuel inlet needle to unset, nd flooding my result. 2. Fuel pikup should e t lest 1 in. (25 mm) from the ottom of the fuel tnk to prevent piking up wter or other impurities. 3. Fuel lines used MUST BE Cost Gurd pproved (USCG type A) nd MUST NOT BE SMALLER THAN 3/8 in. (9.5 mm) I.D. On instlltions where long lines or numerous fittings re required, lrger size lines should e used. 4. Fuel line should e instlled free of stress nd firmly seured to prevent virtion nd/or hfing. 5. Shrp ends in fuel line should e voided. 6. A flexile fuel line must e used to onnet fuel line to engine to sor defletion when engine is running. Desription The fuel system onsists of fuel tnk(s), wter seprting fuel filter, n eletri fuel pump nd ruretor. The fuel is stored in the fuel tnk. When the fuel pump is energized y turning on ignition swith, fuel is drwn from the fuel tnk, through the wter seprting filter, y the eletri fuel pump. The fuel is pushed through the fuel line to the ruretor where it is metered nd supplied to the engine. 5A - 2 - FUEL PUMP 90-816462 2-695

Fuel System Components FUEL SYSTEM Filter should e repled when fuel flow is restrited or filter flow is questionle. DO NOT ttempt to flush out filter. g Typil f - Fuel Tnk - Anti Siphon Vlve - Wter Seprting Fuel Filter d - Fuel Pump e - Cruretor f - Fuel Filter g - Vent Hose h - Fuel Line i - Sight Tue i d h e 50830 Replement Refer to Preutions, in this setion, BE- FORE proeeding. 1. Disonnet ttery les from ttery. 2. Remove fuel filter from se. A filter wrenh my e needed to loosen element. 3. Lurite seling ring(s) of new filter with SAE engine oil. 4. Instll new filter, tightening seurely y hnd. 5. Reonnet ttery les. Mke sure wter is supplied to ooling system nd strt engine. Chek for fuel leks. Wter Seprting Fuel Filter (If So Equipped) The fuel filter onsists of the fuel filter se nd filter element. 72678 - Filter Bse/Mounting Brket - Filter Element - Seling Ring 72678 - Filter Mounting Brket - Filter Element - Seling Ring 90-816462 2-695 FUEL PUMP - 5A - 3

Fuel Pump Fuel Filter Refer to Preutions, in this setion, BE- FORE proeeding. Replement INSPECTION Fuel pumps re equipped with sight tue. Any evidene of fuel in the sight tue indites ruptured diphrgm nd fuel pump must e repled immeditely. 9. Chek for gsoline leks. 10. If leks exist, STOP ENGINE nd rehek onnetions. Testing Fuel Pump Refer to Preutions, in this setion, BE- FORE proeeding. 1. Disonnet ttery les from ttery. 2. Remove fuel line from ruretor or outlet side of fuel pump. 3. Instll Fuel Pressure Connetor (91-18078) to ruretor or fuel pump nd reinstll fuel line. Tighten onnetor nd fuel line seurely. 4. Connet fuel pressure test guge to onnetor. 50738 - Sight Tue - Fuel Fitting NOTE: This fuel pump must e repled s n ssemly; it is not repirle with diphrgm kit. 1. Disonnet ttery les from ttery.! CAUTION Plug fuel supply hose fter removl to prevent fuel from leking into ot. 2. Remove sfety wire. 3. Loosen srew from filter owl il nd relese il from fuel pump housing. 4. Remove owl, filter element, spring, nd gsket from fuel pump. 5. Instll new filter. 6. Tighten retining srew seurely. 7. Instll sfety wire nd tighten seurely. 8. Strt nd run engine. 71561 Fits into Cruretor - Fuel Line Connetion - Fuel Guge Br 5. Reonnet ttery les, strt engine, nd run t idle, mking sure wter is supplied to the ooling system. 6. Fuel pressure should e within speifitions. If not, reple fuel pump. 7. Remove fuel pressure guge nd onnetor tool. Reonnet fuel line to fuel pump. 5A - 4 - FUEL PUMP 90-816462 2-695

Fuel Pump Replement Removl 1. Remove fuel inlet nd outlet lines t fuel pump. 2. Remove sight tue. Chek for fuel leks. 5. Instll fuel outlet fitting (from old pump) into fuel pump. 6. Instll fuel line to fuel outlet fitting. Tighten seurely. 7. Instll fuel inlet fitting to fuel pump. 8. Instll sight tue nd fuel supply line. 9. Strt engine nd hek for fuel leks. 50738 - Sight Tue - Fuel Fitting 3. Remove 2 fuel pump mounting olts nd lokwshers, pump nd gsket.! CAUTION Plug fuel lines fter disonneting from fuel pump to eliminte ny hne of fuel siphoning into ilge. 4. Instll new gsket (ot oth sides with Perfet Sel) on fuel pump. Instll pump, nd torque mounting olts to speifitions. Avoid gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel filter se n rk sting nd/or use fuel lek. Apply #592 Lotite Pipe Selnt with Teflon to threds of rss fitting or plug. DO NOT USE TEFLON TAPE. Thred rss fitting or plug into fuel filter se until finger tight. Tighten fitting or plug n dditionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVER-TIGHTEN. Instll fuel line. To prevent over-tightening, hold rss fitting with suitle wrenh nd tighten fuel line onnetors seurely. 90-816462 2-695 FUEL PUMP - 5A - 5