Replacing A Sea-Doo Fuel Pump: A Step-By-Step Guide

If you're looking to replace the fuel pump on your Sea-Doo, there are a few things you should know. Firstly, Sea-Doos with Direct Injection (DI) are known to have issues with fuel pumps, particularly the Airtex E1067 model, which has a metal roller-vane design that doesn't handle particulates or water in the fuel well, often leading to premature pump failure. To replace the fuel pump, you'll need to remove the storage box, vent tube, glove box, and fuel supply and return lines. You'll also need to disconnect the electrical connector and vent tube from the fuel pump and remove the retaining nuts to lift the fuel pump out of the gas tank. When installing the new fuel pump, ensure you follow the correct torque sequence specified in the Sea-Doo service manual and perform a leak test before closing everything up.

Remove storage box and vent tube

To remove the storage box and vent tube from your Sea-Doo, start by opening the hood. Remove the two nuts from the studs that are holding the vent tube support bracket to the hull/steering assembly. You can tap the studs through. Now, remove the vent tube.

The next step is to remove the glove box. There are two clips holding the glove box to the hull, which can be accessed through the hole left by the removed vent tube. There are also four 1/4" automotive-style plastic push clips that hold the two “wings” of the glove box in place. You can cut these off. You will also need to remove two screws holding the black plastic reverse lever handle so that you can manoeuvre the glove box wing.

Now that the glove box is removed, you can access the fuel supply and return lines. Disconnect them using a 5/16” fuel/AC disconnecting tool. Be prepared for fuel to spill out of the lines. Wrap the area in paper towels to minimise spillage.

Once the fuel lines are disconnected, you can move on to removing the fuel pump assembly. However, this is beyond the scope of your request, which focuses on the removal of the storage box and vent tube.

Disconnect fuel supply and return lines

Disconnecting the fuel supply and return lines is a crucial step in replacing the fuel pump on a Sea-Doo watercraft. Here is a detailed guide on how to perform this task:

To begin, make sure you have the necessary tools and safety equipment. In addition to standard tools like wrenches and screwdrivers, you will need a 5/16” fuel/AC disconnecting tool. It is also important to work in a well-ventilated area and to place absorbent materials, such as paper towels, underneath the work area to catch any spilled fuel.

Now, let's get started:

• Open the hood of your Sea-Doo and remove the storage box and any other necessary components to access the fuel lines. This may include removing the glove box and/or vent tubes, as described in some Sea-Doo models.
• Locate the fuel supply and return lines. These lines are connected to a bracket inside the hull. You will need to disconnect them using the 5/16” fuel/AC disconnecting tool. Insert the tool into the female side of the connection and wiggle it gently to detach the male side. Be prepared for fuel to spill out of the lines, so have your absorbent materials ready to minimise the mess.
• Once the fuel lines are disconnected, you can set them aside and focus on removing the fuel pump assembly. In some Sea-Doo models, there may be additional steps to remove other components before accessing the fuel pump. Refer to your specific Sea-Doo model's service manual for detailed instructions.
• It is important to note that there may be a float arm connected to the fuel pump assembly. Be careful not to bend or damage this float arm during the removal process, as it is crucial for the fuel sensor. You may need to rotate the assembly to get it out in one piece.
• After successfully disconnecting the fuel supply and return lines and removing any obstructions, you should be able to lift out the fuel pump assembly. Again, refer to your specific Sea-Doo model's service manual for additional instructions and torque specifications.

Remember to work carefully and patiently when dealing with fuel lines and the fuel pump. Always refer to your Sea-Doo's service manual for detailed instructions specific to your model. If you are uncomfortable performing this task, it is best to consult a qualified technician or mechanic.

Remove nine nuts holding fuel pump assembly

To remove the nine nuts holding the fuel pump assembly, you will need an 8mm nut driver. Before beginning this step, you should have already disconnected the fuel lines from the starboard hull supports and used a 5/16” QC tool to separate the “Quick-Connects” for both the fuel supply and return lines. You should have also removed the gray vent hose from the top of the module and unclipped the electrical connector.

Now, use the 8mm nut driver to remove all nine nuts holding the module to the top of the tank. Remember to save the nuts and washers aside in a container so they don’t get lost in the bilge, as the nuts are brass and the washers are stainless steel, so a retractor magnet won’t help to retrieve them.

When viewing the fuel pump from the top, you will notice an alignment arrow on the fuel module top, pointing at both the PWC port side and the rubber gasket protruding tab. Due to the uneven spacing of the mounting studs, the gasket and module can only be replaced properly when these are aligned.

Carefully lift out the fuel pump module, noting that there is a float for the fuel sensor on the end of a pivoting metal rod. It may help to rotate the module 180 degrees when halfway out so the bent float rod has a better exit angle. If it helps, remove the rod from the gauge now instead of later, with careful prying at the attachment point to pop it out of the plastic retainer clip on the gauge.

Remove fuel pump assembly

To remove the fuel pump assembly, you will need to first open the hood and remove the storage box. Remove the two nuts from the studs holding the vent tube support bracket to the hull/steering assembly and tap the studs through. Remove the vent tube.

Next, remove the glove box. There are two clips holding the glove box itself to the hull, accessible through the hole for the vent tube you just removed. There are also four 1/4" automotive-style plastic push clips that hold the two “wings” of the glove box to the hull. You will also need to remove two screws holding the black plastic reverse lever handle to manoeuvre the glove box wing over it.

Now, remove the fuel supply and return lines from the bracket holding them to the inside of the hull. You will need a 5/16” fuel/AC disconnecting tool to do this. Push the tool all the way into the female side of the connection and the male side will disconnect with a little wiggling. Be prepared for all the fuel in the lines to come out.

Remove the nine 8 mm nuts holding the fuel pump assembly to the fuel tank. Take the whole assembly out, remembering there is a float arm connected to the assembly so you will have to rotate it to get it out in one piece. The manual says to pull it out of the front, but you may find it easier to pull it partially out towards the rear (via the glove box) and then back out towards the front.

Replace filters

To replace the filters of your Sea-Doo fuel pump, follow these steps:

Step 1: Remove the storage box and vent tube support bracket

Open the hood and remove the storage box. Remove the two nuts from the studs holding the vent tube support bracket to the hull/steering assembly. Tap the studs through and remove the vent tube.

Step 2: Disconnect the fuel supply and return lines

Remove the glove box. Disconnect the fuel supply and return lines from the bracket holding them to the inside of the hull. You will need a 5/16” fuel/AC disconnecting tool. Push the tool all the way into the female side of the connection, and the male side will disconnect. Be prepared for fuel to come out of the lines.

Step 3: Remove the fuel pump assembly

Remove the nine 8 mm nuts holding the fuel pump assembly to the fuel tank. Take out the whole assembly, being careful not to damage the float arm connected to it. You may need to rotate the assembly to get it out in one piece.

Step 4: Replace the filters

There are two filters in the fuel pump assembly: an external strainer and an internal strainer. Drill out and replace the two 1/8” rivets holding the end cap on the internal strainer. Make sure to keep the steel and rubber washers underneath intact. Install the new internal filter and replace the rivets. Then, install the bottom external filter.

You can purchase replacement filters online or at a local store. The part numbers for the filters are Airtex FS220 for the internal strainer and Airtex FS242 for the external strainer.

Additionally, the inline fuel filter on the line to the fuel rail may also need replacement. This filter is not designed to be replaced, and the SeaDoo part may be difficult to find or expensive. One option is to cut the fuel line close to the filter fittings and replace it with a standard metal canister fuel filter, such as the Wix 33095.

By following these steps, you can effectively replace the filters of your Sea-Doo fuel pump, ensuring the continued smooth operation of your watercraft.

Frequently asked questions