2002 200 hp Mercury EFI starting problems

[okstatefan]

After sitting for over 14 months, we finally had the time to prep the boat for summer. Sta-bil had been added to the fuel tank prior to hibernation, but no other fuel degrading precautions were taken. Today I replaced the fuel hose and primer bulb and the Raycor water separator (outside the motor). She started just fine and ran for a few minutes as I expected. However, she started to slow down and eventually stopped altogether. it sounded just like someone turned the fuel supply off. I disconnected the "out" hose on the fuel pump, squeezed the primer bulb and could not get fuel to pass through the pump. Is this normal? Or does the fuel pump only work when the motor is running? Am I headed in the right direction? Any help would be greatly appreciated as my family simply wants just to go for a boat ride. Thanks for your help.

 

[jeffersondodson561]

Re: 2002 200 hp Mercury EFI starting problems

No, fuel should flow thru the fuel pump, do you have a fuel filter inline that may be plugged?

 

[okstatefan]

Re: 2002 200 hp Mercury EFI starting problems

I disassembled the fuel pump and cleaned out the pieces of what appeared to be the internal lining of the primer bulb/fuel line. I now have fuel leaving the fuel pump when I squeeze the primer bulb. I removed the spin-on internal filter on the engine and poured the fuel into a mason jar to determine if water was present. After sitting for over an hour, I didn't see any stratification. There was what appeared to be tiny bits of rust-colored crap in the bottom of the jar. I poured fresh gas into the old filter, shook it and poured out the contents until no more bits of garbage came out. I re-installed the filter, primed the bulb and still cannot light up the motor. Could there be a vapor lock somewhere? Thanks for your replies.

 

[okstatefan]

Re: 2002 200 hp Mercury EFI starting problems

Is there a fine fuel screen on the throttle body inside the aluminum housing? If so, how difficult is it to access.

 

[Faztbullet]

Re: 2002 200 hp Mercury EFI starting problems

If you turn the key on and hear the fuel pump "run" it is likely the fuel line debris is blocking the VST inlet for the float.If you do not hear pump run its locked up or stuck.

 

[okstatefan]

Re: 2002 200 hp Mercury EFI starting problems

I fixed it. Turns out, the needle valve inside the aluminum housing was stuck closed, preventing the float from dropping and allowing fuel to fill the reservoir. I sprayed the fine screen inside the fuel pump for good measure with carb cleaner. Thanks for all your help.