1978 Mercury 80 hp leaking fuel at engine inlet screen

[Elkaholic]

When I squeeze the fuel bulb, gas shoots out around the screen cover. This has been happening since I bought the boat 7 years ago, but is worse now. I replaced the o-ring gasket previously and again to no effect. I'm wondering if a regular o-ring is the problem? Does it need a thick o-ring? I tried placing a washer between the cover and bolt to add pressure to the cover before the bolt bottoms out. It seems to me that the o-ring would have a hard time sealing the wire mesh screen area. The plastic cover looks to be okay. Any ideas???

 

[Chris1956]

The proper oring and screen come with a fuel pump kit. The oring goes on top of the screen, so the cover can contact it. There is usually a white plastic washer under the screw head. I would usually install the screw and rotate the plastic cup until it seats on the oring and then tighten the screw. It shouldn't leak.

 

[Elkaholic]

I got a fuel pump kit. The o-ring is slightly larger in diameter and thinner than the one I was trying. Fuel is still leaking profusely when I squeeze the bulb. I don't think there is anything wrong with the housing. My next guess is it must be the plastic cover? It doesn't appear to be damaged. Maybe it warped when I had the extra washer next to the bolt head? Our local shop doesn't have anything that old. Thanks for the advice, Chris.

 

[captain madness]

hello elkaholic
Hoping your still on here cuz I just bought a 78 mercury 800 and I have fuel spraying out around the cover. How did you end up fixing it? please I'd love the help. Frustrated