02' 496 Keeps Eating Low Pressure Fuel Pumps
 

Hello All. Looking for feedback on a 2002 496 fuel issue that has been plaguing me. Serial#OM378941, Gen II cool fuel. The last three Augusts in a row, almost to the day, I have lost the low pressure fuel pump, while underway. Prior to this, it runs perfect, no issues, and after it is replaced it runs perfect. Screw on filter has been clear of water/debris at time of failure. Does not give any warning prior to failing, just stops working. The dealer that works on it, cannot figure out what is going on, and told me this last time it failed, to stop running fuel with ethanol. This is fine, but still unsettling as I have several friends running the same set up that have never had a fuel related issue. An email to Mercury a month ago was not replied to, so any feedback/advice is appreciated.

What is the part # of the pump you're installing ? is it a Mercury pump

you joined August of 09 and this is your first post.............you better slow down.....lol

866170A01https://cimg3.ibsrv.net/gimg/www.off...899784a28.jpeg

Haha I try not to ask for help unless I absolutely cannot figure something out. Kelly's Port @Lake of the Ozarks, is who services it, so they use Merc parts. Receipt shows#861155A3

You sure its not a tank pickup issue?

Agree, check that there isn't a restrcion in the tank

Clarify it just stops working?
It stops running or it runs but moves no fuel?
If it stops running then does it loose power, maybe bad connection?

Could remove the boost pump and connect filter direct to HP pump

Thanks for the responses.
They did check the pick-up the last time it failed, and did not think that was the issue.

When the pump fails, it stops all together, will not prime will not pump. As soon as the new one is installed, it works as should until it fails again a year later.

Also, when it does fail, the engine doesn’t die. I can still idle back on the high pressure pump, usually just cannot go over about 1500 rpm.

As far as a restriction in the tank, I am not sure how to check that? If there was a restriction in the tank, wouldn’t it run poorly all the time or die?

Sounds like a bad electrical connection. Might need to get into the harness or the plug

Does it still have the metal automotive style fuel filter between the tank and low pressure pump? If so remove that filter entirely and see if that cures the problem.

By chance, is there a screen on the inlet of this Low psi pump ? If so, are they checking for clogged screen ? Maybe they don’t know about screen if there is one ?

Many people don’t know many things.

Yes.