Same problem on my 2008 600 sci, it happens with all mercs, I drilled a hole in my and tapped it. Now every 10 hours pull out the tap and drain it and put fresh oil in, every time i drain it has gas in there . This saves having to by the cheap a$$ pumps that are made in india for 2 bucks and marked up .

I thought they already had plugs in them?

he,s talking about another plug to drain the oil,,that one you have to do yourself

So it has a fill plug and no drain? great design.

Correct. So you have to remove it and turn it on the side to drain, or if you leave it in place you need to use a little siphon pump to try to suck it out.

I keep meaning to drill and tap a drain plug on mine, but always in such a hurry to get it removed and re-installed I never do.

I saw this pump in another post. Can someone confirm this will work on the 525efi?

http://http://www.autozone.com/autozone/catalog/parts/partsProduct.jsp?itemIdentifier=77698_0_0_&skuDesc ription=Airtex+Master+/+Fuel+Pump&brandName=Airtex+Master&displayName=Fue l+Pump&categoryNValue=14999999&sortType=&store=243 9&isSearchByPartNumber=true&fromWhere=&fromString= search&counter=0&itemId=78-0&navValue=14900078&filterByKeyWord=60932&productI d=77698&searchText=60932&categoryDisplayName=Fuel+ Delivery&parentId=49-0

I dont think it will. If you run the part number for the fuel pump used on the 525efi... you will see that it is used on only a handful of engines... mostly EFI and SC based systems. Not sure if its the GPM or PSI but...

If you desire to replace the mech pump simply use a Holley 12-454-11 (or more if you need) by re-using the main body of the existing pump (with armature), remove the 6-8 screws and mount the new diaphram assembly and outer housing with the Holley unit.
Works pefect...
Dave

I am pretty sure the airtex is the oem, but once you add shipping, costs pretty close to the same and you need to epoxy paint it so I just bought Merc ones to replace both my pumps this spring. One was a mess, the other not bad. Definitely a 100 hour max replacement cycle on these.

We got the 502 Mag Mpi year 1998-2000 without this stupid water/gass pump combo,
is this only electric presure pump enough for this motor?I`m afraid not, why cant Merc put a proper el pump on the blue motors and eliminate this old mechanical car gas pump in a bad combination with sea water pump?What happens if I skip the me:party-smiley-004:ch pump on my 525 and 500 EFI motors?Are they starving and burning up?Thanks
Bjorn.

Ok, so I have a question. I have a 96 502, that was a MPI, but I have convereted it to a carb motor. I have used the factory sea pump/fuel pump feed gas to the carb. Cause on these motors, they used the sea/fuel pump to feed the vst pumps. I have has this set up for 3 seasons now with no real issues. What should I do to check for fuel in the oil, or is this fuel/sea pump not the ones you are talking about..

2 bolts on top takes off the fuel pump part then make sure it's full of oil

What fair priced electric pumps do you recommend? That
Pull and push fuel?? Bc holly red didn't prime or stay primed..

Manley marine makes a 140GPH pump that can lift up to 16", model #4142 and its USCG certified.

Heres a question maybe some one can answer for me.....I have one each of the sea-water pumps i'm rebuilding. One of the old style (less fuel pump) and one of the newer style (with fuel pump). The old style had greese packed bearings...the new ones i'm guessing are an oil bath. (I assume this as i have yet to take it apart)
question i have is would it be worth while to convert the old style to an oil bath type setup instead?? Easy enoguh to drill and tap a set of screw holes with some small allen head set screws to fill/drain it.

That's a mega-understatement. Having to service your $$ engines every month is stupid beyond belief. Why didn't they just throw a small electric lift pump inline???

Sounds like a great application for an aftermarket manufacturer...

How do you get the upper diaphragm off the pump arm? i bought 12-454-11 and replacing the bottom half is not a problem. The upper diaphragm is what leaks. thanks

Look like you. Have to remove that pin from side somehow,,iam trying to rebuild mine too,and an asking the same question

only way to get it out is to drill a hole the size of the pin .but you better be right on the money .1 hole on each side knock the pin thru with a small punch . if you bought a new diaphram kit witch they sell it will come with new plugs you tap in .i took mine completly apart and had them coated to reasemble i tapped the holes and installed stainless set screws now they are completely rebuildable

Did a lot of research and found a few interesting things. Holley does make replacement diaphragms that will work with our type of fuel pump. The problem is getting to arm out to replace it. I have attached a picture of one of mine that I drilled to get the pin out, smoking gun is right you have to be perfect..I missed by a 1/16 as you can see in the photo. I do have 2 other bodies to use after I make a template. The other interesting part is there is a seal on top of the shaft that should seal any gas from getting in the fresh water pump housing. Mine was torn so when the diaphragm leaked there we no seal. Holley also make a pump that is rebuildable but it’s more than the merc. If we could just buy the upper housing we could change the merc arm and be good to go.

Couldnt I just convert it to a older style sea water pump that doesnt have a fuel pump on it, and then put a mechanical pump like the automotive big blocks?

ttt

stlliberator, on the gen 5 -6 motors there is no place to mount a mechanical fuel pump directly on the motor to run it, that is why Merc is using the sea/water pump to drive the fuel pump. I just helped my brother eliminate his and put on an electric fuel pump for his carbed 454.
troper - smokin' gun, if you drill the hole bigger than the pin, can you then tap and plug the holes or use set screws like smokin'gun? I'm sure it will make cense once I look at one of them. I have about 4 of these laying around that could be rebuit if I had the parts.

http://www.cvproducts.com/ProdDet.aspx?PN=SPIN-MP-2630

Just another option. I'm a CV dealer if anyone wants real world pricing let me know.

What electric pump did you use? i put a holly red in mine but wouldnt suck fuel..

My brother picked it up at a local parts store. I don't remember the name, and it wasn't one of the big performance name brands, but it looks just like this Mr. Gasket fuel pump. http://compare.ebay.com/like/3307450...Types&var=sbar

OK,
So I'm trying to change my seawater pump impellers, and notice that there is gas in my Fuel pump oil resevroir..... I go to BAM marine website and even called Mercruy Racing and I/they can't find a Fuel Pump rebuild kit for Fuel Pump Part # 889275T. This is for a 2006 600 SCi engine. Where did everyone get their rebuild kits for their blue motors?
Thanks,
Dean

I'm glad this is posted, I was thinking of putting one on my small block. I actually started a thread on it. Thanks.

My local Merc shop says that Merc DOES'NT even sell rebuild kits, (liability?!) for the fuel pump... Who makes the fuel pump for Merc? This really sucks!

rebuild kits
 

i found them a wile back. they are for carter X pumps, DSC motorsport.com had them they were 48.00$ plus shipping. hope this helps:thankyouthankyou:

Brian,
Thanks for the info, and the link. What engines did you do your rebuilds on?
Thanks,
Dean

does it have to be drilled on the side of the pump to get the pin out first,,,not sure if a rebuilt kit is worth it or not

Yes, it does, and on the Merc pump I can't see where you can drill to remove the pin. In fact the pin on the Merc pump is swedged from the inside, I don't even see how you can get the pin out without screwing up the pump..... What a sh!tty design.:angry-smiley-038:

Dean, here is a photo on the one I did that I got from Holley. Look at my post #60 to get the part #'s

The pin slid out from the swege thru the hole I drilled. I then tap it and put in a set screw and JB weld on the outdide hole.

its not a bad job guys, if i recall i used a screwdriver a drumell and small punch,

Brian,
Is this where you ground out the stacking for the pin, (End of the screwdriver) BTW, sorry about the crappy pics, I will try to take some more later, Thx.

Dean after I drilled the hole, I pushed the pin out with a thin nettle nose pliers.

NO. go to www.428cobrajet.org/how-to-fuel-pump.html gives instructions and alot of pics, the kit i showed you comes with all the parts listed.

dean ,the pin looks like it has to come out from the side of the housing,,,to me it looks like you woulds have to grind some of the housing out of the way ,in order to get a straight shot at the pin,,is this what you see also???

Just another incredible Mercury PITA! I have not had a problem yet, but figure I better do something now rather than have it go bad in the middle of boating season.

Has anyone found a electric pump that will work to replace the crappy mechanical pump? Then run the old style raw water pump?