Mercury Mercruiser Gen III Cool Fuel Service repair manual

Service Manual #40 90-865376 Gen III Cool Fuel Supplement to #30 & 31 Gen III Cool Fuel Supplement to #30 & 31

Page i Notice to Users of This Manual Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures. ! DANGER DANGER - indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. ! WARNING WARNING - indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. ! CAUTION CAUTION - indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification. © 2004, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual.

Page ii Precautions It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. Replacement Parts Use of parts other than the recommended service replacement parts, will void the warranty on those parts that are damaged as a result. ! WARNING Electrical, ignition and fuel system components on Mercury Marine Power Products are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Cleanliness and Care of Product A Mercury Marine Power Product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

Page iii Manual Outline 1 - Important Information A - General Information B - Maintenance 2 - Gen III Cool Fuel Module All Models A - Gen III Cool Fuel Module Removal and Disassembly B - Gen III Cool Fuel Module Assembly and Installation 3 - Fuel System A - Troubleshooting and Repair B - Fuel Flow Diagram 4 - Cooling System A - Coolant and Water Flow Diagrams Important Information 1 Gen III Cool Fuel Module All Models 2 Fuel System 3 Cooling System 4

General Information 90-865376 NOVEMBER 2004 Page 1A-1 1 A Important Information Section 1A - General Information Table of Contents Introduction......................................................1A-2 Gen III Cool Fuel Module Exploded View........1A-3

General Information Page 1A-2 90-865376 NOVEMBER 2004 Introduction This supplement is designed as a service guide for the models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly, and Installation to enable dealers and service mechanics to diagnose and repair the Generation III Cool Fuel Module. Before attempting repairs it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety.

General Information 90-865376 NOVEMBER 2004 Page 1A-3 Gen III Cool Fuel Module Exploded View 2 3 4 5 7 8 13 1 14 15 16 17 18 19 20 21 22 23 24 6 9 11 10 12 8810 1 - Pressure regulator screws 2 - Pressure regulator 3 - Screws, Top cover 4 - Top cover 5 - Seal, Top cover 6 - Fuel pump outlet seal 7 - High-pressure fuel pump 8 - Isolator, High-pressure fuel pump 9 - Isolator, Low-pressure fuel pump 10 - Low-pressure fuel pump 11 - Inlet seal, Low-pressure fuel pump 12 - Cool Fuel Module housing 13 - Stud 14 - Screw, Wire harness retainer 15 - Wire harness retainer 16 - Wire harness 17 - 2-pin electrical connector (plug) 18 - Screws, Filter cap 19 - Filter cap 20 - O-ring 21 - Fuel filter 22 - Seal, Filter cup 23 - Filter cup 24 - Filter disc

Maintenance 90-865376 NOVEMBER 2004 Page 1B-1 1 B Important Information Section 1B - Maintenance Table of Contents Changing Water Separating Fuel Filter Element .........................................................................1B-2

Maintenance Page 1B-2 90-865376 NOVEMBER 2004 Changing Water Separating Fuel Filter Element ! WARNING Avoid Fire or Explosion: The fuel injection system is pressurized during operation. Use care when removing the water separating fuel filter. Allow the engine to cool down before attempting to remove the water separating fuel filter in the following procedure. ! WARNING Be careful when changing the water separating fuel filter. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure the ignition key is "OFF". Do not smoke or allow spark or open flame in the area when changing the fuel filter. Wipe up any spilled fuel immediately. ! WARNING Ensure that no fuel leaks exist before closing the engine hatch. 1. Allow the engine to cool down. 2. Close fuel supply valve, if equipped. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness. 4. Turn the key switch to the start position and allow the starter to operate for 5 seconds to relieve fuel system pressure. 5. Turn key switch to off position. 6. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not completely remove the filter assembly from the Cool Fuel Module at this time.

Maintenance 90-865376 NOVEMBER 2004 Page 1B-3 7. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap. d a b c e f g h 8837 a - Cool Fuel Module b - Cool Fuel Module harness c - Filter cap d - Filter assembly retaining screw e - Fuel filter element f - Filter cup g - Cool Fuel Module filter reservoir h - Seal, Filter cup 8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool Fuel Module filter reservoir. 9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the filter cup stationary. 10. Remove the used water separating fuel filter element from the filter cup, place it in a clean, approved container. 11. Dispose of any water or debris that may be in the filter cup. 12. Install a new water separating fuel filter element into the filter cup. Push the element into the cup until completely seated. 13. Install new O-ring on the filter cup. 14. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary, until the filter cap locks securely into place. 15. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel, and align the screws retained in the filter cap with the screw holes in the Cool Fuel Module. Tighten the filter assembly retaining screws until hand tight. 16. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each filter assembly retaining screw. 17. Open fuel supply valve, if equipped.

Mercury Mercruiser Gen III Cool Fuel Service repair manual

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