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Author Topic:   Changing fuel pump on 90 Mercury

jtms posted 01-20-2010 07:43 PM ET (US)
Engine is a 2001 90 Merucry Saltwater (2 stroke). I will spare everyone the details, but I had a fuel problem and it appears that the only thing left to replace is the fuel pump. I am thinking that the fuel pump is full of junk and it isn't pulling the fuel through the lines. Boat runs fine until gas runs out of the engine. Once I manually pump gas with the bulb, she will fire back up and run fine.
How difficult is it to change a fuel pump? I am not the most handy person, but I am trying to learn and get better. There doesn't seem to be a whole lot to it. Is this something that I can do myself or should I pay someone? I just paid a mechanic to fix my engine and he ended up ripping me off.
Does anyone know where I can order a rebuilt fuel pump? I hear you can get one of these for $75 for my engine.
Thanks for the tips as always-
an86carrera posted 01-21-2010 12:19 AM ET (US)
Get a rebuild kit. They are about $20 and come with instructions.
Len
jtms posted 01-21-2010 09:25 AM ET (US)
Where do I get a rebuild kit? Can I get one from a local Mercury dealer?
sosmerc posted 01-23-2010 12:56 AM ET (US)
It's a very good idea to service the fuel pump as part of annual service.
HOWEVER, you may also want to check the condition of the fuel line from the boat to the engine. I have seen a few cases now where the inside of the fuel line is coming apart and this debris then clogs the check valves in the primer bulb and/or clogs the quick connect fittings. The high alcohol content of today's fuels is very hard on all rubber parts. The marine industry is being challenged to come up with better materials to deal with the problem.
Also, the fuel pickup tubes in some of the portable tanks are not holding up well to the alcohol.
You may want to test your engine on a known good seperate fuel tank and line assembly just to isolate the problem to the boat or the engine.
whalercop posted 01-27-2010 09:16 PM ET (US)
I had the same problem with one of my twin 90's. It was not too hard to trouble shoot, because they both run off the same tank. After replacing the fuel line from the filter to the motor, I was convinced it was the fuel pump. 86Carrera is right, buy the rebuild kit, it is available from the mercury website, and is fairly cheap, you just need your motor id number. It turned out that one of the diaphragms in the pump was torn, that is why it would only run when you pumped the priming bulb. I have a question for you, do you have problems with the cap on your oil reservoir leaking? I have had to replace one of them and then the new one started leaking, so I just doubled the o-rings on the caps and that seems to have fixed the problem.
jtms posted 01-28-2010 07:47 PM ET (US)
Yes, I have the same problem with my oil tank leaking. I just don't fill it all the way up any longer and that seems to be working. If not, I will add a new O ring. That seems to be the easiest fix.

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Author	Topic: Changing fuel pump on 90 Mercury
jtms	posted 01-20-2010 07:43 PM ET (US) Engine is a 2001 90 Merucry Saltwater (2 stroke). I will spare everyone the details, but I had a fuel problem and it appears that the only thing left to replace is the fuel pump. I am thinking that the fuel pump is full of junk and it isn't pulling the fuel through the lines. Boat runs fine until gas runs out of the engine. Once I manually pump gas with the bulb, she will fire back up and run fine. How difficult is it to change a fuel pump? I am not the most handy person, but I am trying to learn and get better. There doesn't seem to be a whole lot to it. Is this something that I can do myself or should I pay someone? I just paid a mechanic to fix my engine and he ended up ripping me off. Does anyone know where I can order a rebuilt fuel pump? I hear you can get one of these for $75 for my engine. Thanks for the tips as always-
an86carrera	posted 01-21-2010 12:19 AM ET (US) Get a rebuild kit. They are about $20 and come with instructions. Len
jtms	posted 01-21-2010 09:25 AM ET (US) Where do I get a rebuild kit? Can I get one from a local Mercury dealer?
sosmerc	posted 01-23-2010 12:56 AM ET (US) It's a very good idea to service the fuel pump as part of annual service. HOWEVER, you may also want to check the condition of the fuel line from the boat to the engine. I have seen a few cases now where the inside of the fuel line is coming apart and this debris then clogs the check valves in the primer bulb and/or clogs the quick connect fittings. The high alcohol content of today's fuels is very hard on all rubber parts. The marine industry is being challenged to come up with better materials to deal with the problem. Also, the fuel pickup tubes in some of the portable tanks are not holding up well to the alcohol. You may want to test your engine on a known good seperate fuel tank and line assembly just to isolate the problem to the boat or the engine.
whalercop	posted 01-27-2010 09:16 PM ET (US) I had the same problem with one of my twin 90's. It was not too hard to trouble shoot, because they both run off the same tank. After replacing the fuel line from the filter to the motor, I was convinced it was the fuel pump. 86Carrera is right, buy the rebuild kit, it is available from the mercury website, and is fairly cheap, you just need your motor id number. It turned out that one of the diaphragms in the pump was torn, that is why it would only run when you pumped the priming bulb. I have a question for you, do you have problems with the cap on your oil reservoir leaking? I have had to replace one of them and then the new one started leaking, so I just doubled the o-rings on the caps and that seems to have fixed the problem.
jtms	posted 01-28-2010 07:47 PM ET (US) Yes, I have the same problem with my oil tank leaking. I just don't fill it all the way up any longer and that seems to be working. If not, I will add a new O ring. That seems to be the easiest fix.