804844002 Mercruiser CARBURETOR REPAIR KIT

Illustration 1 g02212173
Typical exampleTooling (A)
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Note: Ensure that the tools are stored with the caps in place. Store the tools in a clean plastic bag.
Ensure that the fuel level in the fuel tank is above the level of the suction pipe in the fuel tank.
Inspect the fuel system thoroughly for leaks. If necessary, repair the fuel system.
Check all low-pressure fuel lines from the fuel tank for restrictions. Replace any damaged components.
Install new fuel filters. Refer to Operation and Maintenance Manual for the correct procedures.
Run the engine. Check if the problem has been resolved. Stop the engine. Refer to Operation and Maintenance Manual for the correct procedure.
Illustration 2 g02210878
(1) Bolt (2) Block
Install Tooling (A) into block (2) . When possible, install the sight gauge in a straight section of the fuel line that is at least 304.8 mm (12 inch) long. Do not install the sight gauge near the following devices that create turbulence:
Elbows
Relief valves
Check valvesObserve the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel in the sight gauge, prime the fuel system
Illustration 3 g01096678
2P-8278 Tube As (SIGHT GAUGE) (1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable amount of air in the fuel. (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there is 2 second to 3 second intervals between bubbles. (3) Excessive air bubbles in the fuel are not acceptable.
Install a second sight gauge at the inlet to the fuel transfer pump if excessive air is seen in the sight gauge in the fuel return line. Move the sight gauge from the fuel return line and install the sight gauge at the inlet to the fuel transfer pump if a second sight gauge is not available. Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If the engine starts, check for air in the fuel at varying engine speeds.If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump. Proceed to Step 11.If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of the fuel system.
Remove Tooling (A) and (B) . Reconnect the low-pressure lines.
To avoid personal injury, always wear eye and face protection when using pressurized air.
To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the fuel tank.
Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel transfer pump. Repair any leaks that are found.
If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair the fuel tank or the stand pipe in the fuel tank.
If the injector sleeve is worn or damaged, combustion gases may be leaking into the fuel system. Also, if the O-rings on the injector sleeves are worn, missing, or damaged, combustion gases may leak into the fuel system.
Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. Check that fuel is flowing from the secondary fuel filter base. If there is no flow of fuel, check the operation of the fuel priming pump. If there is still no flow of fuel, replace the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install - Secondary Fuel Filter" for the correct procedure.