Replacing The Fuel Pump In A Mercury Bigfoot

If you're looking to replace the fuel pump on your Mercury Bigfoot, it's important to know that there are both low-pressure and high-pressure pumps in the engine. The process of replacement can be complex, and it's recommended that you consult a certified marine technician or a trusted mechanic.

There are several potential issues that could indicate a problem with your fuel pump. These include difficulty starting the engine, the engine running for a short time and then cutting out, or the engine running rough and lacking power.

Before attempting any repairs, it's important to consult the Mercury Bigfoot manual for specific instructions and safety precautions. It's also crucial to have the necessary tools and knowledge to perform the replacement safely and effectively.

If you're experiencing issues with your fuel pump, it's recommended to consult a professional for diagnosis and repair. They will be able to test the fuel pump and, if necessary, replace it with a suitable part.

Some common replacement parts for Mercury Bigfoot fuel pumps include the 883202T02 Fuel Pump, the 892267A51 Fuel Pump Kit, and the 8M0118177 Fuel Pump. These parts are available from Mercury Marine and other authorized dealers.

Mercury 40HP bigfoot fuel pump replacement parts

To replace the fuel pump in a Mercury 40HP Bigfoot, you will need to purchase a replacement fuel pump that fits your specific engine model. You can find Mercury fuel pumps and fuel pump kits online through authorized Mercury Marine retailers or other authorized sellers.

When purchasing a replacement fuel pump, ensure that it is compatible with your Mercury 40HP Bigfoot engine. Look for a fuel pump that specifically mentions compatibility with Mercury 40HP engines, or refer to the part number provided by Mercury for your engine model.

• 8M0118177 892874T01 Fuel Pump Replacement
• 892267A51 898101T67 Fuel Pump Kit
• 857005A1 Fuel Pump Diaphragm Kit
• 14360A78 Fuel Pump
• Upgraded Fuel Pump Z789

Once you have purchased the correct replacement fuel pump or kit, follow these steps to replace the fuel pump in your Mercury 40HP Bigfoot:

• Consult the service manual for your specific Mercury 40HP Bigfoot engine model. This will provide detailed instructions and diagrams to guide you through the fuel pump replacement process.
• Gather the necessary tools and safety equipment, such as gloves and eye protection.
• Locate the fuel pump in your engine. Refer to the service manual for the exact location, as it may vary depending on your engine model.
• Disconnect the fuel lines and electrical connections to the fuel pump.
• Remove the mounting bolts or clamps holding the fuel pump in place.
• Carefully lift out the old fuel pump.
• Clean the area around the fuel pump mounting location, removing any debris or residue.
• Install the new fuel pump, ensuring it is securely mounted and connected to the fuel lines and electrical connectors.
• Prime the fuel lines and check for any leaks before starting the engine.

By following these steps and using the correct replacement parts, you can successfully replace the fuel pump in your Mercury 40HP Bigfoot engine.

Mercury 60HP bigfoot fuel pump replacement parts

To replace the fuel pump in a Mercury 60HP Bigfoot engine, you will need to source the following parts, which are available from Mercury Marine:

• Fuel pump assembly
• Gasket set
• Diaphragm kit
• Gasket
• Plate
• 90-degree connector
• M5 x 40 and M6 x 50 screws
• Base
• Hose
• Fuel filter
• Fuel line
• 8-inch tie strap
• .312 tubing
• Connector
• Check valve
• 15-inch tubing
• Fuel connector assembly
• M6 x 35 screw
• .187 hose
• Clamp
• Enrichner valve solenoid kit
• 36-inch tubing
• 20-foot tubing
• Tee fitting
• M6 x 16 screw

Some of these parts are listed as "unavailable" on the Mercury Marine website, so you may need to contact them directly to source these parts.

The fuel pump assembly is the most expensive part, costing $233.25. The gasket set is also relatively expensive at $23.17. The other parts range in price from $2.42 to $13.29.

It is important to note that this is a general list of parts for the Mercury 60HP Bigfoot fuel pump and that specific models may have different requirements. It is always best to consult a certified marine technician or a Mercury Marine dealer for advice on replacing the fuel pump in your particular engine.

Mercury 50HP bigfoot fuel pump replacement parts

To replace the fuel pump on a Mercury 50HP Bigfoot, you will need to source the correct parts for this specific model. The fuel pump assembly includes several components, and you will need to ensure you have all the necessary parts before starting the replacement process. Here is a list of the parts you will require, as well as some additional information to guide you through the process:

• O-RING, Fuel Connector: This part ensures a tight seal between the fuel connector and the fuel pump. One fuel connector O-ring is required per assembly. The reference number for this part is 25-16524.
• GASKET SET: A gasket set is required to create a seal between the fuel pump and the engine. Only one gasket set is needed per assembly. Unfortunately, the gasket set with reference number 27-832013A96 is currently unavailable.
• FUEL PUMP ASSEMBLY: This is the main component of the fuel pump replacement. The fuel pump assembly includes the fuel pump itself and other necessary parts for installation. The reference number for this assembly is 826398T 3, and it is available for $343.25. It usually ships within 10 days.
• SCREWS: Several different types of screws are required for the fuel pump assembly. These include M5 x 35 screws (reference number 10-809564), M3 x 5 screws (reference number 10-41889M), and M6 x 30 screws (reference number 10-826844 30).
• COVER: The cover is used to protect the fuel pump assembly. The reference number for this part is 809565, and it is available for $7.60. It usually ships within 10 days.
• DIAPHRAGM: The diaphragm is a vital component of the fuel pump, creating a suction effect to draw fuel into the pump. One diaphragm is required per assembly, and the reference number is 809561 2. Unfortunately, this part is currently unavailable.
• NUTS: You will need two types of nuts for the fuel pump assembly. The first type is a standard nut with the reference number 11-82537M. The second type is an M5 nut (reference number 11-82388M), and four of these nuts are required per assembly.
• CHECK VALVE: The check valve ensures that fuel flows in one direction only. Two check valves are required per assembly, and the reference number is 21-41888M.
• PIN: The fuel pump pin is a crucial component for the proper functioning of the fuel pump. The reference number for this part is 17-809566 1, and it is currently unavailable.
• SPRINGS: Two different springs are required for the fuel pump assembly. The first spring, with the reference number 24-809562, is currently unavailable. The second spring does not have a unique reference number but is listed as an M5 spring. Four of these springs are required per assembly, and they are available for $8.50.
• PLUNGER: The plunger is a critical component that helps to draw fuel into the pump. The reference number for this part is 809563 1, and it is currently unavailable.
• O-RING: An additional O-ring is required for the fuel pump assembly, ensuring a tight seal. The reference number for this O-ring is 25-8M0052669, and it is available.
• J CLIP: The J-clip is used to secure the fuel pump assembly in place. The reference number for this part is 54-8M0024808, and it is currently unavailable.
• CONNECTOR ASSEMBLY: The connector assembly connects the fuel pump to the fuel lines. The reference number for this part is 22-816856A 4, and it is currently unavailable.
• HOSE: The hose is used to deliver fuel to the engine. There are several options available for the hose, including different lengths and manufacturers. Ensure that you select a hose that is compatible with ethanol-based fuels to avoid future issues.
• TIE STRAP: The tie strap is used to secure the fuel lines in place. The reference number for this part is 54-816311T, and it is priced individually.
• FILTER, Fuel: The fuel filter ensures that clean fuel is delivered to the engine. There are several options available for the fuel filter, including part numbers 35-816296, 35-816296Q, 35-816296Q03, and 18-7829. The fuel filter is available for $7.69 and usually ships within 10 days.
• DEFLECTOR, Cowl: The cowl deflector helps to direct the flow of air around the fuel pump. The reference number for this part is 8M0007776, and it is available for $15.10. It usually ships within 10 days.

Once you have gathered all the necessary parts, you can proceed with the fuel pump replacement process. Remember to follow a reputable repair guide or seek the assistance of a certified marine technician if you are unsure about any steps.

Mercury 30-60HP EFI 4-stroke fuel pump replacement parts

To replace the fuel pump on a Mercury Bigfoot motor, you will need to first purchase a replacement fuel pump that is compatible with your specific Mercury model. This may include the following Mercury Marine fuel pump parts:

• Mercury Marine 50 HP Bigfoot (4-Stroke) Fuel Pump: This fuel pump is designed for the 50 HP Bigfoot model and includes various components such as O-rings, gaskets, screws, and hoses.
• Mercury Marine 60 HP EFI (4-Cylinder) (4-Stroke) Fuel Pump: This fuel pump is specific to the 60 HP EFI model and includes items such as tubing, hoses, clamps, and fuel filters.
• FPF Low-Pressure Fuel Pump: This aftermarket fuel pump is compatible with Mercury Outboard 4-Stroke EFI 30HP-60HP models and meets or exceeds OEM performance and durability.
• Fuel Pump 883202T02: This fuel pump is designed for Mercury/Mariner 30-60 HP EFI 4-stroke outboard motors and is a direct replacement for OEM part numbers 883202T02 and 883202A02.

Once you have purchased the appropriate replacement fuel pump for your Mercury Bigfoot motor, you can follow these general steps to replace the fuel pump:

• Prepare the boat by placing it in a well-ventilated area and disconnecting the battery to prevent any accidental startups.
• Locate the fuel pump and identify any components that need to be removed for access, such as the motor cover or any hoses, clamps, or screws securing the fuel pump.
• Carefully remove the old fuel pump, making sure to catch any spilled fuel and dispose of it properly.
• Clean the area around the fuel pump to remove any dirt, debris, or residue.
• Install the new fuel pump, ensuring that all connections are secure and properly routed.
• Reattach any components that were removed for access, such as hoses, clamps, or motor covers.
• Reconnect the battery and start the engine to test the new fuel pump.
• Check for any fuel leaks and ensure that the fuel pump is functioning properly.

Please note that these are general instructions and the specific steps may vary depending on your Mercury Bigfoot model and the fuel pump you are installing. Always refer to the owner's manual or a certified marine mechanic for detailed instructions and safety precautions before attempting any repairs or replacements.

Mercury 4-stroke 30-60HP fuel pump replacement parts

To replace the fuel pump on a Mercury Bigfoot motor, you will first need to purchase a replacement fuel pump that is compatible with your specific Mercury model. You can find Mercury fuel pumps and replacement parts online from authorised retailers or on marine engine and boat repair forums.

For example, for a Mercury 60 HP EFI (4 Cylinder) (4-Stroke) model, you can purchase a fuel pump assembly from marineengine.com, which includes all the necessary parts for a fuel pump replacement. This includes the pump assembly, screws, tubing, hoses, clamps, filters, connector assemblies, bushings, grommets, washers, nuts, and brackets.

For a Mercury 50 HP Bigfoot (4-Stroke) model, you can also find fuel pump parts on marineengine.com. The required parts include an O-ring, gasket set, pump assembly, screws, cover, diaphragm, nuts, check valves, pins, springs, plungers, and J-clips.

Additionally, there are aftermarket options available on Amazon, such as the Pro Marine Fuel Pump Electric Mercury 30-60hp 4 Stroke, the Fundyliue 8M0118177 892874T01 Fuel Pump Replacement, and the RANSOTO 8M0118177 892874T01 Fuel Pump, which are compatible with Mercury 30, 40, 50, and 60 HP 4-stroke outboard engines.

When replacing the fuel pump, you will need to remove the old pump and install the new one, ensuring that all connections are secure and there are no leaks. This may involve disassembling parts of the engine and fuel system, so it is recommended to refer to a repair manual or seek assistance from a certified marine technician if you are unsure about the process.

Additionally, as noted by a user on the Boat Repair Forum, it is important to consider the potential impact of ethanol-containing fuels on your fuel lines, as they can cause deterioration and disintegration over time. It is recommended to use marine-grade fuel lines that are resistant to ethanol fuels and to regularly clean and maintain your fuel system to prevent issues.

Frequently asked questions