Cool Fuel System Repair; Removal - Mercury MerCruiser MCM 454 Mag MPI Service Manual

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

Cool Fuel System Repair

Removal

1. Disconnect battery cables from battery.
IMPORTANT: Suitably plug open ends of fuel line connections to prevent fuel leaks
and entry of water or contaminates into lines while working.
2. Close fuel shutoff valve, if equipped, and remove the fuel tank inlet line from the water
separating fuel filter. If boat is not equipped with a fuel tank shut off valve, remove the
fuel tank inlet line at the water separating fuel filter and plug the line.
If boat is to remain in the water, the seacock, if equipped, must remain closed until
engine is to be restarted to prevent water from flowing back into seawater cooling
system. If boat is not fitted with a seacock, water inlet hose must be disconnected
and plugged to prevent water from flowing into cooling system and/or boat. As a
precautionary measure, attach a tag to the ignition switch or steering wheel with the
warning that the seacock must be opened or the water inlet hose reconnected prior
to starting the engine.
3. Close seacock, if so equipped. If boat is not equipped with a seacock, remove and plug
the seawater inlet hose.
4. Drain seawater system. Refer to SECTION 1B.
5. Disconnect seawater hoses from fuel cooler.
6. Disconnect fuel lines from water separating fuel filter adapter.
7. Remove flame arrestor, throttle body and plenum.
8. Remove distributor cap to gain access to fuel rail.
9. Remove the screw and retainer plate holding the cooler-to-fuel rail fuel line. Disconnect
the fuel line from the rail.
10. Remove the cover from the cool fuel system.
11. Disconnect electrical connector at each fuel injector.
12. Disconnect the fuel pump electrical connector.
13. Disconnect the vacuum hose connected to the pressure regulator.
14. Remove the two upper engine mount bracket nuts retaining fuel cooler bracket to the
engine.
Index
Page 5A-12
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b
a - Filter Adapter
b - Fuel Lines
CAUTION
a
SERVICE MANUAL NUMBER 23
75533
90-861326--1 MARCH 1999