40HP Merc or Not the way I'd do it.

Jim Hawkins

Chief Petty Officer
Joined
Mar 11, 2013
Messages
508
I suppose a 40 Merc 2 stroke is a great motor, almost every 13' whaler has one but I have a fuel issue and am pulling apart the whole system to clean filter, pump ect. and believe this is the most convoluted fuel system I have ever seen. Check valves and more hoses than I can understand. I am going to start drawing out a diagram of everything and where it goes to try to make sense but if anyone knows what all this stuff does and why I would really like to know. I'm going in, wish me luck...
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
28,328
Sounds like you are working on the oil injection system. If they have a remote oil reservoir in the boat, then they have a number of check valves, hoses and other stuff to force oil from the boat reservoir to the engine reservoir.
 

Jim Hawkins

Chief Petty Officer
Joined
Mar 11, 2013
Messages
508
OK well I guess I was just frustrated and it's not so complicated once I drew it out. The problem started with a deteriorated pick up hose in the fuel tank and we all know what that does. So I replaced the hose, flushed all the lines, cleaned all the crap from the fuel filter, replaced the fuel pump because I didn't want to take it apart, unclogged the check valve between fuel filter and oil pump, cleaned the carb and unstuck the float and (fingers crossed) it seeeeeems OK now. Attached find my sophomoric fuel system diagram.
 

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