Electric Fuel Pump Troubleshooting
Contents
1. 10 14H 90 2 psi 24 26 psi 1 2L Warranty Any electric fuel pumps that are returned for warranty and found to function properly No Problem Found may be subject to claim denial and parts returned to dealer THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2003 11R OCTOBER 2003 2003 Mercury Marine Page 3 32. PFERCURY s 2 PERCY Service Bulletin oan e Guin DOOET C Parts Information Circulate to LI Sales Manager LI Accounting IM senice Manager A recien V parts Manager Electric Fuel Pump Troubleshooting Models Affected MERCURY MARINER Four Stroke Two Stroke OptiMax and Jet Drives with Electric Fuel Pumps Mercury receives electric fuel pumps under warranty that when tested have been found to function properly No Problem Found If the electric fuel pump pressure reading is incorrect there are a number of items listed below to consider prior to replacing the pump Items to consider e Is there a good fuel supply to the electric pump e Is the pump receiving the correct battery voltage NOTE Battery voltage too high may cause ECM to turn pump circuit off e Is the fuel pressure regulator operating correctly e Is the air pressure regulator operating correctly OptiMax Product e Is the pressure gauge that is being used to test accurate e Are you using the correct specifications for the engine e Do you have the pressure gauge connected correctly e Is the fuel filter restricting fuel flow to the pump Fuel Pressure Test The location of fuel pumps regulator and hose connections will vary between models but the general process for checking fuel pressure remains the same A test gauge is connected on the output side of the pump and the pump is momentarily run to build pressure In some cases there will be a pressure test port a
3. he original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 2 3 2003 Mercury Marine OCTOBER 2003 2003 11R ELECTRIC FUEL PUMP TROUBLESHOOTING Serial Range High Pressure Low Pressure AMP Draw Boost Pump Electric Pump Electric Pump High Low Jet Drive 22 0T409000 and up 283 310 kPa 3 5 4 5 41 45 psi 250 XB All 234 248 kPa 34 36 psi Op 75 90 115 All 744 6 13 8 kPa 165 5 179 3 kPa 10 14 H 3 Cyl 108 2 psi 24 26 psi 2L 115 175 All 620 5 13 8 kPa 41 4 62 1 kPa 5 9H 90 2 psi 6 9 psi 1 2L i Lo Sp t 4 4 2 0E384500 234 248 kPa 0E406399 34 36 psi 240 M2 0E373933 234 248 kPa 0E406399 34 36 psi 240 M2 0E406400 and up 283 310 kPa 34 5 62 1 kPa 41 45 psi 5 9 psi 200 DFI M2 0E384500 and up 613 6 13 8 kPa 41 4 62 1 kPa 1 10 34 5 62 1 kPa 89 2 psi 6 9 psi 5 9 psi 250 M2 0E407100 and up 620 5 13 8 kPa 41 4 62 1 kPa 1 10 41 4 62 1 kPa 90 2 psi 6 9 psi 6 9 psi H High pressure electric fuel pump L Low pressure electric fuel pump 0E406400 and up 283 310 kPa 27 5 3 4 kPa 41 45 psi 4 0 5 psi 5 250 tiMax 24 i 6 200 225 2002 and prior 620 5 13 8 kPa 41 4 62 1kPa 69H 90 2 psi 6 9 psi 1 2L 200 225 i 24 ort Je 0 0 DFI 7 2003 and later 620 5 13 8 kPa 165 5 179 3 kPa
4. ing Make sure to use a fully charged battery when making this test Amperage reading higher then normal indicates mechanical or electrical problems with the pump Amperage reading lower then normal is an indication that the pump is not under load or pumping fuel There may be no fuel in the VST or there is a blockage preventing the fuel from reaching the pump NOTE An electric pump that has formed fuel gum may have high amperage draw or not operate at all See Outboard Service Bulletin 2002 20 or Jet Drive Bulletin 2002 07 for more information on seized pumps The fuel pump specification chart below is current at the time of the issuance of this bulletin Refer to the proper Service Manual for the latest specifications Serial Range High Pressure Low Pressure AMP Draw Boost Pump Electric Pump Electric Pump High Low Jet Drive Four Stroke 30 40 50 60 0T409000 and up 289 303 4 kPa 42 44 psi 115 01178500 and up 283 303 4 kPa 41 44 psi 225 0T653945 and up 261 303 4 kPa _ 75 8 103 4 kPa 38 44 psi 11 15 psi Two Stroke 150 XRIMAG JAI 248 269 kPa 36 39 psi 175 200 0G303045 and down 248 269 kPa 36 39 psi 175 200 225 250 0G303046 0T408999 234 248 kPa 34 36 psi 175 200 0T409000 and up 283 310 kPa 3 5 4 5 41 45 psi THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of t
5. vailable to connect the gauge to In other cases you may need to temporarily install a TEE fitting to connect the pressure gauge Once the gauge connection is made electrically operate the pump and observe the pressure reading Refer to the correct Service Manual for specifications Situation THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2003 11R OCTOBER 2003 2003 Mercury Marine Page 1 3 ELECTRIC FUEL PUMP TROUBLESHOOTING Fuel Supply to Pump A lack of fuel going to the pump will cause a low no pressure reading Most electric fuel pumps on EFI or OptiMax engines draw their fuel from the Vapor Separating Tank VST Make sure there is a good supply of fuel reaching the VST and pump Refer to the correct Service Manual for test procedure Checking Battery Voltage to Pump If the pump does not run when the ignition key is turned to the ON position or when the engine is cranked over with the starter battery voltage to the pump should be checked Amperage Draw Test An amperage draw test of the electric fuel pump can also be very useful when diagnosing fuel system problems NOTE A properly charged battery is critical to an accurate amp read
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