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 0910048, 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.
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.
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.
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.
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.