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Mercury MerCruiser Service Manual
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Mercury MerCruiser Service Manual

Gen iii cool fuel supplement to #30 & 31
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Service Manual #40
Gen III Cool Fuel Supplement to #30 & 31

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Summary of Contents for Mercury MerCruiser

  • Page 1 Service Manual #40 Gen III Cool Fuel Supplement to #30 & 31...
  • Page 2 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.
  • Page 3 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.
  • Page 4 Manual Outline Important Information 1 - Important Information A - General Information Gen III Cool Fuel Module All Models B - Maintenance 2 - Gen III Cool Fuel Module All Models A - Gen III Cool Fuel Module Removal and Fuel System Disassembly B - Gen III Cool Fuel Module Assembly and...
  • Page 5 General Information Important Information Section 1A - General Information Table of Contents Introduction............1A-2 Gen III Cool Fuel Module Exploded View..1A-3 90-865376 NOVEMBER 2004 Page 1A-1...
  • Page 6 General Information 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.
  • Page 7 General Information Gen III Cool Fuel Module Exploded View 8810 Pressure regulator screws 13 - Stud Pressure regulator 14 - Screw, Wire harness retainer Screws, Top cover 15 - Wire harness retainer Top cover 16 - Wire harness Seal, Top cover 17 - 2-pin electrical connector (plug) Fuel pump outlet seal...
  • Page 8 Maintenance Important Information Section 1B - Maintenance Table of Contents Changing Water Separating Fuel Filter Element .................1B-2 90-865376 NOVEMBER 2004 Page 1B-1...
  • Page 9 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.
  • Page 10 Maintenance 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. 8837 Cool Fuel Module Fuel filter element Cool Fuel Module harness Filter cup Filter cap Cool Fuel Module filter reservoir...
  • Page 11 Maintenance Description lb. in. lb. ft. Filter assembly retaining screw 18. Reconnect the Cool Fuel Module harness to the engine wiring harness. 19. Supply cooling water to the engine. 20. Properly ventilate the engine compartment. WARNING Avoid serious injury or death due to FIRE or EXPLOSION. Ensure that the engine compartment is well ventilated and that no gasoline vapors are present to prevent the possibility of a FIRE or EXPLOSION.
  • Page 12 Gen III Cool Fuel Module Removal and Disassembly Gen III Cool Fuel Module All Models Section 2A - Gen III Cool Fuel Module Removal and Disassembly Table of Contents Gen III Cool Fuel Module Removal....2A-2 Gen III Cool Fuel Module Disassembly....2A-5 90-865376 NOVEMBER 2004 Page 2A-1...
  • Page 13 Gen III Cool Fuel Module Removal and Disassembly Gen III Cool Fuel Module Removal WARNING Always disconnect battery cables from battery before working on fuel system to prevent fire or explosion. WARNING Fuel vapors can be present in the engine compartment. Avoid injury or power package damage caused by fuel vapors or explosion.
  • Page 14 Gen III Cool Fuel Module Removal and Disassembly 8. Disconnect fuel pressure regulator vacuum hose from fuel pressure regulator on Cool Fuel Module. 8724 Fuel pressure regulator Fuel pressure regulator vacuum hose Fuel pressure regulator hose nipple 9. Loosen nut on cooling hose bracket and remove cooling hoses from Cool Fuel Module. 8783 Cooling hoses Bracket nut...
  • Page 15 Gen III Cool Fuel Module Removal and Disassembly 10. Remove the fuel outlet line retainer screw. 8784 Fuel outlet line Fuel outlet screw 8785 Fuel outlet line retainer screw 11. Carefully pull the fuel outlet line straight out from the module and plug the line. 8755 Fuel outlet line O-ring...
  • Page 16 Gen III Cool Fuel Module Removal and Disassembly 13. Carefully remove the Cool Fuel Module from the engine. Gen III Cool Fuel Module Disassembly NOTE: Retain all fasteners and hardware unless instructed otherwise. IMPORTANT: Do not remove the fuel inlet adapter fitting. 8269 Fuel inlet adapter fitting.
  • Page 17 Gen III Cool Fuel Module Removal and Disassembly 3. Remove support bracket from Cool Fuel Module. 8796 Support Bracket 4. Remove filter assembly. Refer to Section 1B of this manual for filter removal procedure. 5. Remove 6 screws holding top cover. 8706 Gen III Cool Fuel Module Top cover screws (not all shown)
  • Page 18 Gen III Cool Fuel Module Removal and Disassembly 6. Pull top cover straight up. Gen III Cool Fuel Module Low-pressure fuel pump Top cover High-pressure fuel pump 7. Disconnect electrical connections from the low-pressure and high-pressure pumps and remove the pumps from the top cover. 8711 Top cover High-pressure fuel pump electrical...
  • Page 19 Gen III Cool Fuel Module Removal and Disassembly 8. Remove seals and isolators from fuel pumps. 8739 Low-pressure Fuel Pump Low-pressure fuel pump Inlet seal Outlet seal Isolator 8740 High-pressure Fuel Pump High-pressure fuel pump Outlet seal Isolator NOTE: Fuel inlet seal for low-pressure pump may not come out with the pump when pump is removed from the Cool Fuel Module housing.

  • Page 20: Table Of Contents

    Gen III Cool Fuel Module Assembly and Installation Gen III Cool Fuel Module All Models Section 2B - Gen III Cool Fuel Module Assembly and Installation Table of Contents Gen III Cool Fuel Module Assembly....2B-2 Top Cover and Fuel Pumps .....2B-2 Fuel Inlet Adapter Fitting......2B-2 Fuel Pressure Regulator......2B-7 Gen III Cool Fuel Module Installation....2B-8...

  • Page 21: Gen Iii Cool Fuel Module Assembly

    Gen III Cool Fuel Module Assembly and Installation Lubricant, Sealant, Adhesives Tube Ref No. Description Where Used Part No. Loctite 567 PST Pipe Sealant Fuel line inlet connector to adapter. 92-809822 Gen III Cool Fuel Module Assembly Fuel Inlet Adapter Fitting 1.
  • Page 22 Gen III Cool Fuel Module Assembly and Installation IMPORTANT: The inlet (bottom) seal on the low-pressure pump must be placed in the Cool Fuel housing for installation. Do NOT place the inlet seal on the pump prior to pump installation. The seal may become dislodged during pump installation and cause the pump not to seal properly.
  • Page 23 Gen III Cool Fuel Module Assembly and Installation 3. Connect the electrical connectors to the low-pressure pump. Red wire to positive terminal. Black wire to negative terminal. The fuel pump is marked (+) positive and (-) negative on the top of the pump. Spade connection sizes are matched to the appropriate connection as well.
  • Page 24 Gen III Cool Fuel Module Assembly and Installation 5. Route the wires as shown. Ensure that the ground wire terminal at the harness end is positioned against the outer wall of the casing. Low-pressure pump wiring must be routed through the slot and above the fuel pump. High-pressure pump wiring must also be routed above the fuel pump.
  • Page 25 Gen III Cool Fuel Module Assembly and Installation 7. Insert the high-pressure pump into the top cover. 8751 High-pressure Fuel Pump Installation High-pressure fuel pump Top cover Outlet seal Isolator 8. Verify that the top cover seal is not damaged. Replace if necessary. 9.

  • Page 26: Fuel Pressure Regulator

    Gen III Cool Fuel Module Assembly and Installation Carefully lower the top cover with fuel pumps into the Cool Fuel Module housing. Cool Fuel Module housing low-pressure pump Top cover High-pressure pump 11. Install the top cover screws and hand-tighten. 12.

  • Page 27: Gen Iii Cool Fuel Module Installation

    Gen III Cool Fuel Module Assembly and Installation Description lb. in. lb. ft. Pressure regulator screws Gen III Cool Fuel Module Installation 1. Connect the primary mounting bracket to the Cool Fuel Module. Torque to specification. Description lb. in. lb. ft. Primary bracket screws (Cool Fuel Module) 21.7-25.1 16-18.5...
  • Page 28 Gen III Cool Fuel Module Assembly and Installation Description Where used Part No. Mercury/Quicksilver Synthetic Blend, NMMA FC-W rated, 4-cycle oil Fuel outlet line O-ring 92-883724K01 8755 Fuel outlet line O-ring 6. Carefully insert the fuel outlet line into the Cool Fuel Module.
  • Page 29 Gen III Cool Fuel Module Assembly and Installation 8. Install the vacuum hose onto the fuel pressure regulator. 8724 Fuel pressure regulator Fuel pressure regulator vacuum hose Fuel pressure regulator hose nipple 9. Inspect quad rings on cooling hose orifices. Replace if damaged. 10.
  • Page 30 Gen III Cool Fuel Module Assembly and Installation 11. Align the cooling hoses and bracket to the Cool fuel Module and connect the bracket with the attached nut. Push the cooling hose ends into place on the Cool Fuel Module. 8783 Cooling hoses and bracket Cooling hose bracket nut...
  • Page 31 Gen III Cool Fuel Module Assembly and Installation 15. Install the fuel line inlet connector by hand, finger-tight. 16. While holding the fuel inlet adapter fitting securely, tighten the fuel line inlet connector an additional 1-3/4 to 2-1/2 turns with a wrench. Do not overtighten. IMPORTANT: Hold fuel inlet adapter fitting securely when installing fuel line inlet connector.
  • Page 32 Troubleshooting and Repair Fuel System Section 3A - Troubleshooting and Repair Table of Contents Gen III Cool Fuel Module Diagnostics.....3A-2 Checking Fuel Pressure and Fuel Supply Electrical...........3A-2 Vacuum.............3A-2 In-Water Test..........3A-2 90-865376 NOVEMBER 2004 Page 3A-1...
  • Page 33 Troubleshooting and Repair Special Tools Fuel Shut Off Tool 91-805918A1 Tests fuel system pressure / vacuum 7051 Gen III Cool Fuel Module Diagnostics Electrical 1. Disconnect the electrical connector at the Cool Fuel Module. 2. Connect a Digital Volt / Ohm Meter (DVOM) to the engine side of the electrical connector.
  • Page 34 Troubleshooting and Repair 3. If fuel pressure is less than 40 psi (276 kPa), but greater than 13 psi (90 kPa): Verify that the vacuum from the fuel source is within specification. If the vacuum exceeds 2 in. Hg (7 kPa) , excessive fuel restriction exists. Correct the fuel restriction before proceeding.
  • Page 35 Fuel Flow Diagram Fuel System Section 3B - Fuel Flow Diagram Table of Contents Gen III Cool Fuel Module Fuel Flow Diagram..3B-2 90-865376 NOVEMBER 2004 Page 3B-1...
  • Page 36 Fuel Flow Diagram Gen III Cool Fuel Module Fuel Flow Diagram 8963 Fuel inlet adapter fitting Fuel pressure regulator Fuel filter element High-pressure fuel pump Low-pressure fuel pump Fuel outlet fitting Page 3B-2 90-865376 NOVEMBER 2004...
  • Page 37 Coolant and Water Flow Diagrams Cooling System Section 4A - Coolant and Water Flow Diagrams Table of Contents Water Flow Diagrams........4A-2 Sterndrive Water Flow Diagrams....4A-2 Inboard Water Flow Diagrams....4A-6 90-865376 NOVEMBER 2004 Page 4A-1...
  • Page 38 Coolant and Water Flow Diagrams Water Flow Diagrams Sterndrive Water Flow Diagrams V-8 CLOSED COOLED BRAVO MODELS WITH RISERS 8182 Seawater inlet Exhaust elbow Power steering cooler Seawater pump Gen III cool fuel module Heat exchanger Exhaust and seawater outlet To power steering pump Exhaust manifold -From seawater pump...
  • Page 39 Coolant and Water Flow Diagrams V8 CLOSED COOLED BRAVO MODELS 9385 Y-fitting Exhaust elbow Power steering cooler Seawater pump Gen III cool fuel module Heat exchanger Exhaust and seawater outlet To power steering cooler Exhaust manifold -From seawater pump Distribution housing Seawater Water circulating pump Ethylene glycol mix...
  • Page 40 Coolant and Water Flow Diagrams V8 SEAWATER COOLED BRAVO MPD MODELS 9387 Seawater inlet Water circulating pump Power steering cooler Thermostat housing Gen III Cool Fuel Module Exhaust elbow Exhaust and seawater outlet Seawater pump Exhaust manifold To power steering cooler Check valve From seawater pump Page 4A-4...
  • Page 41 Coolant and Water Flow Diagrams V8 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS 9389 Seawater inlet Thermostat housing Power steering cooler Exhaust elbow Gen III cool fuel module Seawater pump Exhaust and seawater outlet To starboard exhaust manifold. (Drain from starboard exhaust Exhaust manifold manifold when activated).
  • Page 42 Coolant and Water Flow Diagrams Inboard Water Flow Diagrams CLOSED COOLED INLINE EXHAUST MODELS NOTE: Certain components in the following diagram may look different than on your particular power package, but the water flow paths remain similar on all engines. 8182 Seawater inlet 14 degree exhaust elbow...
  • Page 43 Coolant and Water Flow Diagrams CLOSED COOLED V-DRIVE EXHAUST MODELS 8183 Seawater inlet Exhaust elbow Transmission cooler Seawater pump Gen III Cool Fuel module Heat exchanger Exhaust and seawater outlet To transmission cooler Exhaust manifold -From seawater pump Distribution housing Seawater Water circulating pump Ethylene glycol mix...
  • Page 44 Coolant and Water Flow Diagrams SEAWATER COOLED MODELS 8184 Seawater inlet Thermostat housing Transmission cooler Exhaust elbow Gen III Cool Fuel module Seawater pump Exhaust and seawater outlet To starboard exhaust manifold. (Drain from starboard exhaust Exhaust manifold manifold when activated). Distribution housing To power steering cooler Water circulating pump...