Sylvie Willis
If you're experiencing low fuel pressure woes caused by failed fuel pumps from EPA-mandated ethanol gasoline, you'll need to replace your fuel pump. This guide will take you through the process of replacing the fuel pump on a Mercruiser, including disconnecting the fuel hose and electrical connection, unbolting the pump, and installing a new fuel pressure regulator.
| Characteristics | Values |
|---|---|
| Step 1 | Disconnect water inlet and outlet water hoses |
| Step 2 | Disconnect the fuel line inlet to the fuel/water separator and plug with a 3/8" bolt, tying the hose as high in the bilge as possible to keep fuel from siphoning |
| Step 3 | Plug or cap (whatever is required) the fuel inlet to the filter |
| Step 4 | Disconnect its corresponding fuel hose and then disconnect the fitting, keeping the copper crush washer with it to reuse too |
| Step 5 | After determining your fuel pressure is not or cannot hold the required 32psi +- 2psi, locate your cool fuel module on the engine forward motor mount, engine port side |
| Step 6 | Disconnect the electrical connection at the fuel pump |
| Step 7 | Unbolt the pump from the motor mount |
| Step 8 | Drag the whole apparatus, fuel lines and fuel filter out of the boat |
| Step 9 | Remove the pump and cooler assembly from the housing making sure to not get any white heat-dissipating grease on your skin |
| Step 10 | If you did not buy a new brass fitting that goes into the fuel pressure regulator you will have to remove the existing unit and hope it does not break |
| Step 11 | Assemble the new pump using o-rings and grease supplied in the cooler kit |
| Step 12 | Install the new fuel pressure regulator making sure the tiny screen is installed in the copper tube prior to bolting down the regulator |
| Step 13 | Install the brass fitting in the pressure regulator |
| Step 14 | Install the pump and fuel cooler making sure to use grease on the water drain plastic plug and o-ring |
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What You'll Learn
Disconnect water inlet and outlet water hoses
To disconnect the water inlet and outlet water hoses, you will most likely need a hose removal tool. The hoses are welded in place, so you will need to use the tool to disconnect them. Once they are disconnected, you can move on to the next step, which is to disconnect the fuel line inlet to the fuel/water separator. It is important to note that gasoline spraying from this area is dangerous, so have multiple rags ready to catch the fuel draining from the fuel rail when the nut is loosened.
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Disconnect the fuel line inlet to the fuel/water separator
To disconnect the fuel line inlet to the fuel/water separator, you will need to have multiple rags ready to catch the fuel draining from the fuel rail when the nut is loosened. Disconnect the electrical connection at the fuel pump. Unbolt the pump from the motor mount. It is held in place with 2 nuts, 9/16" hex heads. Drag the whole apparatus, fuel lines and fuel filter out of the boat. Remove the pump and cooler assembly from the housing, making sure to not get any white heat-dissipating grease on your skin, as it burns.
If you did not buy a new brass fitting that goes into the fuel pressure regulator, you will have to remove the existing unit and hope it does not break. Install the new fuel pressure regulator, making sure the tiny screen is installed in the copper tube prior to bolting down the regulator. If you have questions on orientation, look at the old one because you'll need the screws from the old pressure regulator. Install the brass fitting in the pressure regulator.
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Plug or cap the fuel inlet to the filter
To plug or cap the fuel inlet to the filter, you will need to disconnect the fuel line inlet to the fuel/water separator. You can then plug or cap the fuel inlet to the filter. It is important to tie the hose as high in the bilge as possible to keep fuel from siphoning.
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Disconnect the electrical connection at the fuel pump
Disconnecting the electrical connection at the fuel pump is a crucial step in replacing the fuel pump on a Mercruiser. Here's a detailed guide on how to do it:
Firstly, make sure you have multiple rags ready to catch any fuel that may drain from the fuel rail when the nut is loosened. This is an important safety precaution to avoid any potential hazards. Next, locate the electrical connection at the fuel pump. It is usually held in place with two 9/16" hex head nuts. Using the appropriate tools, carefully loosen and remove these nuts. Once the nuts are removed, you can gently pull and disconnect the electrical connection from the fuel pump. Ensure that you do this slowly and carefully to avoid any damage to the surrounding components.
After disconnecting the electrical connection, you will need to unbolt the pump from the motor mount and carefully remove the entire apparatus, including the fuel lines and fuel filter. It is important to be cautious during this process to avoid any spills or damage to other parts. Additionally, make sure to wear gloves and avoid direct skin contact with any substances, especially the white heat-dissipating grease, as it can cause burns.
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Unbolt the pump from the motor mount
To unbolt the pump from the motor mount, you will need to disconnect the electrical connection at the fuel pump. The pump is held in place with two 9/16" hex head nuts. Once these are loosened, gasoline will spray from the area, so have multiple rags ready to catch the fuel draining from the fuel rail. Drag the whole apparatus, fuel lines and fuel filter out of the boat.
Next, remove the pump and cooler assembly from the housing, being careful not to get any white heat-dissipating grease on your skin as it burns. You will also need to remove the existing brass fitting that goes into the fuel pressure regulator. If you did not buy a new one, you will have to remove the existing unit and hope it does not break.
Now, disconnect the water inlet and outlet water hoses. You will most likely need a hose removal tool as these are welded in place. Disconnect the fuel line inlet to the fuel/water separator and plug with a 3/8" bolt, tying the hose as high in the bilge as possible to keep fuel from siphoning. Plug or cap the fuel inlet to the filter.
Finally, assemble the new pump using o-rings and grease supplied in the cooler kit.
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Frequently asked questions
First, disconnect the water inlet and outlet water hoses. Then, disconnect the fuel line inlet to the fuel/water separator and plug with a 3/8" bolt, tying the hose as high in the bilge as possible to keep fuel from siphoning. Next, plug or cap the fuel inlet to the filter. Then, disconnect the electrical connection at the fuel pump. After that, unbolt the pump from the motor mount. Drag the whole apparatus, fuel lines and fuel filter out of the boat. Remove the pump and cooler assembly from the housing, making sure to not get any white heat-dissipating grease on your skin. Assemble the new pump using o-rings and grease supplied in the cooler kit. Install the new fuel pressure regulator, making sure the tiny screen is installed in the copper tube prior to bolting down the regulator. Install the brass fitting in the pressure regulator. Finally, install the pump and fuel cooler, making sure to use grease on the water drain plastic plug and o-ring.
You will need to buy the brass fuel fitting connection at the fuel pressure regulator, Mercruiser P/N (#22-808002A1), for an additional $30. It will be a lifesaver if the old one breaks during removal, which they usually do. You will also need a hose removal tool to disconnect the water inlet and outlet water hoses.
If you are experiencing low fuel pressure woes, you may need to replace your fuel pump. After determining your fuel pressure is not or cannot hold the required 32psi +- 2psi, locate your cool fuel module on the engine forward motor mount, engine port side. It's a neat black box, rectangular in shape.
