Thread: Help with fuel issue

If it is no start or starts and runs real rough and no power it sounds like your high pressure fuel pump side. Had to deal with a couple of these last year and read about a couple of more. Going to post a link to a parts diagram on it look at number 12 the float Assy. Seems they have a problem with this float sticking causing your high pressure supply pump to run out of fuel. From what I understand they have a upgrade kit for that if it is your problem. One thing you need to do first is take cowel off find that housing and hold your hand on it while someone turns on the key. You should feel the pump running. If it’s running and not cranking I’m going to guess it’s in that float assy.

Mercury Marine V-200 HP (EFI) Fuel Management System (Vapor Separator) Parts

Thanks for the advice. I’m trying that


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Post your serial number. It will help identify the motor. 1991 would be a 2.4 liter. I agree with Cray on the fuel pressure. Go buy a cheap fuel pressure tester and connect it to the Schrader valve above the vst. The early models had a non integrated vst with the fuel pump on the outside. Prime the primer bulb and turn the key to the run position. It should have between 36-40 psi. The problem you are describing sounds like the fuel pump driver in the ECU. Also, when the problem occurs, take the cowling off and feel the high pressure pump and see if it's running with the key on. Post the results and the serial number and we'll find the problem.

I’ll pick one up and let you know thanks


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Ok I couldn’t find a the Schader valve above the VST. Here’s what I did
With the key on it was 38-40 like you said. It went to 0 immediately after I turned the key off.


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Serial # is 0C110317


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The motor is a 2.4 liter EFI Anniversary Edition. Manufacture date 2-1-1989.It was sold in Eaton Rapids, Michigan. The fuel pressure s good but the quick leak down is not good. Pinch the clear hose, turn the key on and let I build pressure. Pinch off the hose on top of the high pressure pump. If you don't have any visible leaks and it still leaks down, there is something in the fuel rail or a fuel injector causing the problem. If it holds pressure, remove the clamp on the clear hose. If it leaks down then, the fuel pressure regulator is bad. If it's still holding pressure, remove the clamp on top of the pump. If it leaks down then, the pressure is pushing back through the high pressure pump. That is highly unlikely but not unheard of. Post your results and we will find the problem.

Amazing. I did exactly what you said and low and behold I found a leak. It was a 009 o-ring on the bottom schrader valve on the fuel rail. It was dripping where I couldn’t hardly see. Had it replaced in an hour and it holds 38-40 lbs of pressure and bleeds down slowly. I’m guessing that was the problem. I can’t thanks you guys enough.


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