8M REMOTE WATER-SEPARATING FUEL FILTER KIT 75/80/90/100/115 FOURSTROKE (2.1L) AND 150 FOURSTROKE

Transcription

1 8M REMOTE WATER-SEPARATING FUEL FILTER KIT 75/80/90/100/115 FOURSTROKE (2.1L) AND 150 FOURSTROKE IMPORTANT: This doument is written to id our delers nd ompny servie personnel in the proper instlltion or servie of our produts. Persons who re not fmilir with these or similr produts produed y Merury Mrine, nd who hve not een trined in the reommended serviing or instlltion proedures should hve the work performed y n uthorized Merury Mrine deler. Improper instlltion or serviing of the Merury produt ould result in dmge to the produt or personl injury to the instller or persons operting the produt. Alwys refer to the pproprite Merury Mrine servie mnul for omponent removl nd instlltion instrutions. NOTE: After ompleting instlltion, ple these instrutions with the produt for the owner's future use. Components Contined in Kit d e f Ref. Qty. Desription Prt Numer 1 Wter seprting fuel filter ssemly 8M Hose lmp, 16.2 mm Fitting for 10 mm (3/8 in.) fuel line 8M d 2 Plug, 3/ e 1 6 pin hrness 8M f 1 Adpter hrness 8M Remote Wter Seprting Fuel Filter Instlltion! WARNING Performing servie or mintenne without first disonneting the ttery n use produt dmge, personl injury, or deth due to fire, explosion, eletril shok, or unexpeted engine strting. Alwys disonnet the ttery les from the ttery efore mintining, serviing, instlling, or removing engine or drive omponents. 90-8M JULY Merury Mrine Pge 1 / 12

2 ! WARNING Fuel is flmmle nd explosive. Ensure tht the key swith is off nd the lnyrd is positioned so tht the engine nnot strt. Do not smoke or llow soures of sprk or open flme in the re while serviing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys hek for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. - Fuel filter nd owl ssemly - Filter sel - Seprtor hed d - Bowl O ring e - Wter in fuel sensor (WIF) f - Hrness onnetion g - Drin vlve g d f e Strting with the negtive led, disonnet the ttery les from their terminls. 2. Connet fuel pressure guge to the fuel ril test port nd relese the fuel pressure. Collet ny relesed fuel into n pproprite ontiner. 3. Choose suitle mounting lotion to mount the filter inside the ot. The remote fuel filter is instlled into the fuel line etween the fuel tnk nd the engine. Ensure tht the mounting holes do not penetrte the hull or other finished surfes on the ot. IMPORTANT: When hoosing lotion to mount the filter, ensure tht the lotion provides dequte support for the filter nd provides for esy removl nd instlltion of the filter nister. IMPORTANT: Do not mount the filter in ple where the filter will e in diret sunlight. NOTE: Mount the fuel filter in vertil position long the fuel line t suitle lotion. 4. Drill two holes of the pproprite size 5.1 m (2.0 in.) prt on enter t the hosen mounting lotion. 5.1 m (2.0 in.) - Fuel inlet - Fuel outlet - Drill pttern Pge 2 / M JULY 2015

3 5. Use seleted hrdwre (not supplied) to mount the fuel filter. 6. Remove nd disrd the plsti p plugs from the fuel inlet nd outlet holes of the fuel filter seprtor hed. 7. Choose whih fuel inlet nd outlet ports works est for the hosen mounting lotion nd ot onfigurtion.! WARNING Improper instlltion of rss fittings or plugs into the fuel pump or fuel filter se n rk the sting, using fuel lek nd possile fire or explosion. Alwys instll fittings nd plugs orretly, nd do not tighten with power tools. 8. Instll the two fittings into the seprtor hed y hnd until finger tight. 9. Instll the two plugs into the unused fuel inlet nd outlet ports y hnd until finger tight. NOTE: The fittings nd plugs hve prepplied selnt on the threds. Do not use dditionl thred selnt on the threds. 10. Tighten the fittings nd plugs seurely. Do not overtighten, s this my rk the housing nd ould use fuel lek. 11. Ple drin pn under the fuel filter to th ny spilled fuel, then ut the fuel line t point pproximtely entered etween the hose fittings. 12. Ple hose lmp over eh fuel line. 13. Instll the fuel line from the fuel tnk on the inlet hose fitting nd the fuel line to the engine on the outlet hose fitting. Seure the fuel lines to the fittings with the hose lmps. - Fitting (2) - Hose lmp (2) - Inlet fuel line d - Outlet fuel line d Ensure tht the fuel line is instlled free of stress with no shrp ends nd firmly seured to prevent hfing from virtion. 15. Mke the pproprite hrness onnetions. Refer to Hrness Connetions.! WARNING Fuel lekge is fire or explosion hzrd, whih n use serious injury or deth. Periodilly inspet ll fuel system omponents for leks, softening, hrdening, swelling, or orrosion, prtiulrly fter storge. Any sign of lekge or deteriortion requires replement efore further engine opertion. 16. Strting with the positive led, onnet the ttery les to their terminls. 17. Prime the fuel system. Inspet for fuel lekge from the filter while turning the ignition key to the run position, whih will fore fuel into the filter. Refer to Fuel Supply Module Priming Proedure. 90-8M JULY 2015 Pge 3 / 12

4 Hrness Connetions 6 Pin Hrness (Bots Not Equipped with n Add on Bot Sensor Hrness) 75/80/90/100/115 FourStroke (2.1L) 1. Remove the engine 6 pin hrness onnetor from the holder. 75/80/90/100/115 FourStroke (2.1L) - Engine 6 pin hrness onnetor - Holder 2. Route the 6 pin hrness through the rigging grommet. NOTE: The rigging grommet is not shown in this view, it is loted on the strord side of the engine. NOTE: The oil over hs een removed for lrity of the onnetion. 3. Connet the 6 pin hrness etween the engine 6 pin onnetor nd the wter seprting fuel filter sensor /80/90/100/115 FourStroke (2.1L) - 6 pin hrness onnetor - Engine 6 pin onnetor - 6 pin hrness to wter seprting fuel filter sensor Pge 4 / M JULY 2015

5 d Engine 6 pin onnetor - 6 pin hrness onnetor - 6 pin hrness d - 2 pin onnetor 150 FourStroke 1. Remove the engine 6 pin hrness onnetor from the holder. 150 FourStroke - Engine 6 pin hrness onnetor - Holder 2. Route the 6 pin hrness through the rigging grommet. 3. Connet the 6 pin hrness etween the engine 6 pin onnetor nd the wter seprting fuel filter sensor FourStroke - 6 pin hrness onnetor - Engine 6 pin onnetor - 6 pin hrness to wter seprting fuel filter sensor M JULY 2015 Pge 5 / 12

6 d Engine 6 pin onnetor - 6 pin hrness onnetor - 6 pin hrness d - 2 pin onnetor 4. Route the hrness s shown nd seure the hrness to the ttery les with two le ties. - Cle tie - Bttery les Adpter Hrness (Bots Equipped with Bot Sensor Hrness) 1. Connet the dpter hrness 2 pin onnetor to the wter seprting fuel filter sensor. 2. Connet the dpter hrness ring terminl to len engine ground. Pge 6 / M JULY 2015

7 3. Connet the dpter hrness ullet onnetor to the ot sensor hrness "FUEL 2\OTHER" ullet onnetor. PADDLE WHEEL SEA TEMP FUEL 2 \OTHER f e FUEL 1 d pin onnetor to engine - Bot sensor hrness - "FUEL 2\OTHER" ullet onnetor d - To engine ground e - Adpter hrness (provided in kit) f - 2 pin onnetor to the wter seprting fuel filter sensor Finl Cheks 1. Ensure tht the inlet fuel hose is positioned nd seured so it will not mke ontt with the moving shift mehnism. 2. Ensure tht suffiient slk exists in the remote fuel hose to prevent the hose from getting strethed or kinked during full left nd right turns nd full tilt position. 3. After the system is filled with fuel, run the engine nd ensure tht there re no fuel leks from the filter nd hose onnetions. Mintenne! WARNING Fuel lekge is fire or explosion hzrd, whih n use serious injury or deth. Periodilly inspet ll fuel system omponents for leks, softening, hrdening, swelling, or orrosion, prtiulrly fter storge. Any sign of lekge or deteriortion requires replement efore further engine opertion. Alwys hek for fuel lekge fter repling the filter element or drining the olletion owl. Do not remove the olletion owl exept during filter element hnge; otherwise, ontmintion, ingestion, or owl O ring sel swelling my result. Frequeny of wter drining or filter element replement is determined y ontmintion level in the fuel. Inspet or servie the olletion owl for wter dily. Reple the filter element t lest one yer or when loss of power is notied, whihever ours first. To Drin Wter NOTE: Atth drin hose to the fitting on the drin vlve (if pplile). 1. Open the drin vlve to drin the olletion owl of wter. 2. Close the drin vlve. 90-8M JULY 2015 Pge 7 / 12

8 3. Run the engine nd ensure tht there re no fuel leks. - Drin vlve - Open - Close To Reple the Filter Element NOTE: Replement filter element prt numer is IMPORTANT: Removing the filter element my result in some fuel spillge. Use n pproved ontiner to ollet fuel. Wipe up ny fuel spillge immeditely. Mteril used to ontin spillge must e disposed of in n pproved ontiner. 1. Ple drin pn under the fuel filter to th ny spilled fuel. 2. Remove the filter element with the olletion owl tthed. NOTE: The olletion owl is reusle, do not disrd. 3. Remove the olletion owl from the filter element. Clen the owl nd the set for the O ring sel. 4. Instll the new O ring sel supplied with the filter element onto the olletion owl, s shown. 5. Apply film of len motor oil to the O ring sel. Do not use grese. Tue Ref No. Desription Where Used Prt No W-40 Syntheti Blend 4-Stroke Mrine Engine Oil 6. Srew the olletion owl onto the filter element until tight. Do not use tools to tighten. O-ring sel 92-8M O ring sel - Colletion owl Pge 8 / M JULY 2015

9 7. Instll the new sel supplied with the filter element onto the filter element s shown. - Sel - Filter element 8. Apply film of len motor oil onto the filter element sel. Do not use grese. Tue Ref No. Desription Where Used Prt No W-40 Syntheti Blend 4-Stroke Mrine Engine Oil Filter element sel 92-8M Srew the filter element on until the sel mkes full ontt with the se, then hnd tighten n dditionl 1/3 to 1/2 turn. 10. Run the engine nd ensure tht there re no fuel leks. Fuel Supply Module Priming Proedure The fuel supply module (FSM) is not vented to the mient ir. The ir trpped in the FSM, fuel lines, nd fuel ril, will e slightly ompressed during the initil ignition key on with dry or drined fuel system. Additionl key on events under these onditions, will not ompress the ir further to finish the priming of the FSM. Exessive numer of key on events my eventully dmge the fuel pumps. The volume of ir trpped in the FSM must e purged to prime the fuel system. This n e hieved y onneting tool to the fuel ril Shrder vlve fitting to quikly purge the system into n pproved ontiner, or y rnking the engine. Priming the FSM with Fuel Pressure Guge The use of purge tool for priming the FSM is the preferred method, ut is not lwys prtil. The ojetive is to purge the ir entrined in the fuel system through purge tool onneted to the fuel ril Shrder vlve test port. During the key on, opening the Shrder vlve will llow the ir to e purged from the FSM nd fuel ril. This method should e used on vessels where the fuel inlet system to the outord is restritive, hs n nti siphon vlve, or holds reltively lrge volume of fuel euse of long fuel supply line or wter seprting fuel filter. If primer ul is instlled, it n e used during the priming event to shorten the mount of time required to strt the engine. 1. Verify the engine is in level vertil position. 2. Verify the vessel fuel supply line is onneted to the outord fuel system inlet fitting. 3. Connet fuel pressure guge to the fuel ril Shrder vlve. Fuel Pressure Guge Kit A03 Tests the fuel pump pressure; n e used to relieve fuel pressure Seure the fuel pressure guge purge hose into n pproprite fuel ontiner to ollet exess fuel. 90-8M JULY 2015 Pge 9 / 12

10 5. Open the fuel pressure guge purge vlve nd turn the ignition key on. The fuel pumps will run for pproximtely three to five seonds. Priming the FSM with fuel pressure guge - Fuel pressure guge purge vlve - Shrder vlve - Fuel pressure guge purge hose (to pproprite ontiner) 6. Turn the ignition key off nd then on. The fuel pumps will run for pproximtely three to five seonds. Continue this ignition key yle until the purged fuel is reltively ler of ir ules. NOTE: If the outord fuel system does not prime within 15 key on events, hek for leks in the fuel supply line to the outord. Repir s needed. If no lek is found, the fuel supply system to the outord my e too restritive. Corret the ondition nd try gin. 7. Remove the fuel pressure guge. 8. Turn the ignition key on. When the fuel pumps stop running, strt the engine. The engine my not strt on the first ttempt. The engine will run rough t idle for up to two minutes while the residul ir is purged from the fuel system. Priming Proedure Without Purging the FSM The use of purge tool for priming the FSM is the preferred method, ut is not lwys prtil. When the vessel fuel system is void of fuel volume, it n e primed without the use of purge tool. The ojetive is to purge the ir entrined in the fuel system through the fuel injetors during engine rnking to llow fuel to enter the fuel module. This method n e used on vessels where the fuel inlet system to the outord is less restritive nd holds reltively smll volume of fuel; short fuel supply line, no wter seprting fuel filter, or when the wter seprting fuel filter is lredy primed. If primer ul is instlled, it n e used during the priming event to shorten the mount of time required to strt the engine. 1. Verify tht the engine is in level vertil position. 2. Verify tht the vessel fuel supply line is onneted to the outord fuel system inlet fitting. 3. Turn the ignition key on. The fuel pumps will run for pproximtely three to five seonds. 4. Turn the ignition key to the strt position nd relese the key. The ECM ontrols the tivtion of the strter. The strter my ontinue rnking for up to eight seonds. NOTE: When priming drined fuel system, residul fuel my use the engine to flre nd stll whih shortens the engine rnking event Continue with the ignition key on nd strt sequene until the engine ontinues to run. Pge 10 / M JULY 2015

11 IMPORTANT: Prevent strter dmge y llowing the strter motor to ool for 20 to 30 seonds etween full eight seond rnk events. Limit the numer of events to mximum of 10 full eight seond rnking events. 6. One the engine strts, it my run rough t idle for up to two minutes while the residul ir is purged from the fuel system. 7. If the fuel system will not prime within 10 full eight seond rnking events, use the previous proedure Priming the FSM with Fuel Pressure Guge to prime the fuel system. 90-8M JULY 2015 Pge 11 / 12

12 Produts of Merury Mrine W6250 Pioneer Rod Fond du L, WI MERCURY MARINE. All rights reserved. Reprodution in whole or in prt without permission is prohiited. Alph, Axius, Brvo One, Brvo Two, Brvo Three, Cirle M with Wves Logo, K-plnes, Mriner, MerCthode, MerCruiser, Merury, Merury with Wves Logo, Merury Mrine, Merury Preision Prts, Merury Propellers, Merury Ring, MotorGuide, OptiMx, Quiksilver, SeCore, Skyhook, SmrtCrft, Sport-Jet, Verdo, VesselView, Zero Effort, Zeus, #1 On the Wter nd We're Driven to Win re registered trdemrks of Brunswik Corportion. Pro XS is trdemrk of Brunswik Corportion. Merury Produt Protetion is registered servie mrk of Brunswik Corportion. Pge 12 / M JULY 2015