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02' 496 Keeps Eating Low Pressure Fuel Pumps

Old 11-02-2020, 04:20 PM
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Default 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.

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Old 11-02-2020, 04:41 PM
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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

866170A01


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Old 11-02-2020, 04:49 PM
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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
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Old 11-02-2020, 05:06 PM
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You sure its not a tank pickup issue?
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Old 11-02-2020, 05:27 PM
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Originally Posted by Keith Atlanta View Post
You sure its not a tank pickup issue?
Agree, check that there isn't a restrcion in the tank

just stops working.
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
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Old 11-02-2020, 06:05 PM
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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 doesnít 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, wouldnít it run poorly all the time or die?

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Old 11-02-2020, 06:12 PM
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Sounds like a bad electrical connection. Might need to get into the harness or the plug
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Old 11-02-2020, 09:26 PM
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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.
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Old 11-02-2020, 09:49 PM
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By chance, is there a screen on the inlet of this Low psi pump ? If so, are they checking for clogged screen ? Maybe they donít know about screen if there is one ?

Many people donít know many things.
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Old 11-03-2020, 08:16 AM
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Originally Posted by SB View Post
By chance, is there a screen on the inlet of this Low psi pump ? If so, are they checking for clogged screen ? Maybe they donít know about screen if there is one ?

Many people donít know many things.
Yes.
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