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VRO2® Pump Kit

Crowley Marine

SAFETY

These installation instructions contain information that can help prevent personal injury and damage to equipment. Understand the following symbols before proceeding:

(Safety Warning):  Alerts you to the possibility of danger and identifies information that will help prevent injuries.

NOTE:  Identifies information that will help prevent damage to machinery.

IMPORTANT:  Appears next to information that controls correct assembly and operation of the product.
 

TO THE OWNER

The assembly procedures outlined in this sheet should be performed by a skilled technician. If you have questions, see your DEALER. Save these instructions in your owner's kit. This sheet contains information important to the future use and maintenance of your engine.
 

TO THE INSTALLER

Give this sheet to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.
 

PREFACE

This kit services a VRO2® pump that has the 4-wire warning system, or services a "VRO® style" fuel-only pump.

[1] Contents of Kits

Fuel-Only Pump Kit
Ref. P/N Name of Part Qty.
1 435009 Pulse Limiter - Threaded 1
2 335230 Thick O-ring 3
3 345237 Fuel Outlet Fitting - Hose 1
4 345238 Fuel Outlet Fitting - 60° V6 1
5 345239 NOT USED  
6   NOT USED  
7   Fuel-Only Pump 1
8 343172 Large Retainer 1
9 124549 Retainer Screw 2
10 125203 Thin O-ring 1
11 340186 Pulse Fitting - Straight 1
12 340200 NOT USED  
13 340201 Small Retainer 1
14 125212 Retainer Screw 2

  

Fuel/Oil Pump Kit
Ref. P/N Name of Part Qty.
1 435009 Pulse Limiter - Threaded 1
2 335230 Thick O-ring 3
3 345237 Fuel Outlet Fitting - Hose 1
4 345238 Fuel Outlet Fitting - 60° V6 1
5 345239 Fuel Outlet Fitting - 60° V4 1
6   Fuel/Oil Pump 1
7   NOT USED 1
8 343172 Large Retainer 1
9 124549 Retainer Screw 2
10 125203 Thin O-ring 1
11 340186 Pulse Fitting - Straight 1
12 340200 Pulse Fitting - 90° 1
13 340201 Small Retainer 1
14 125212 Retainer Screw 2

Installation of this kit involves procedures described in detail in the Service Manual.

To avoid accidental cranking or starting of outboard while servicing, disconnect battery cables at battery, and twist and remove all spark plug leads.

Relieve fuel tank pressure by momentarily loosening the cap is a portable tank is being used. Disconnect fuel line from outboard. Fuel spills can contribute to fire or explosion.

[2]
Remove wire retainer, disconnect 4-wire connector (A), and remove original pump.

Remove and discard original pulse limiter.

[3]
Apply Pipe Sealant, P/N 910048, to threads of new pulse limiter (1). Install and torque to 60-84 in. lbs. (7-9 Nm). Reconnect pulse hose.

[4]
Select the correct fuel outlet fitting and install one thick O-ring (2) on hose fitting (3), or install three thick O-rings (2) on longer 60° V6 fitting (4) or on shorter 60° V4 fitting (5).

[5]
Position fuel outlet fitting in new pump pointing fitting toward the fuel outlet hose or fuel components bracket inlet. Secure with the larger retainer (8) and screws (9). Tighten screws carefully.

NOTE: If a fitting must be positioned directly over one of the retainer screws, tighten that screw first, carefully rotate the fitting over the tightened screw, and then tighten the other screw. Do not use pliers to turn fuel fitting.

[6]
Check to see if the pulse fitting in the old pump is a straight or a 90° fitting. Place thin O-ring (10) in pulse fitting hole first, then insert pulse fitting (11) or (12) in pump. Point 90° fitting toward pulse hose.

[7]
Secure with a smaller retainer (13) and screws (14). Tighten screws carefully.

[8]
Install new pump. Reinstall all hoses reusing ratchet clamps where removed, and install new tie straps on other pump fittings. See Service Manual Section 2, for details.

[9]
Tighten pump mounting screws to a torque of 18-24 in. lbs. (2,0-2,7 Nm). Reconnect 4-wire connector, if on your pump, and reinstall wire retainer.

NOTE: Whenever a thread forming screw is reinstalled in a plastic part; always remove all oil from hole and screw, and turn screw backwards until it drops into original threads - before turning screw forward. If screw is allowed to form new threads with each use, or if there is any oil in hole or on screw, it will deform material until the screw pulls out.

NOTE: The pump oil inlet hose connection (where used) must be absolutely air tight and air-leak free under suction, or oil delivery will be reduced and engine damage could occur. If hose does not seem tight, shorten the oil hose slightly to position a different part of hose on the barb of oil inlet fitting.

Connect fuel tank hose to outboard and squeeze primer bulb until definite pressure is felt in the bulb. Check for leaks at fuel pump inlet and outlet. Operate outboard and check for leaks at fuel outlet connection. Repair any leaks before returning outboard to owner.

NOTE: Any time the VRO oil supply line has been disconnected, you must run a 50:1 fuel/oil mixture in the fuel tank until oil pump delivery is verified. Once oil delivery has been confirmed, use clear fuel in the fuel tank.

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