Cool Fuel 3

Gen III Cool Fuel System
Fuel System
Section 5C - Gen III Cool Fuel System
Table of Contents
Precautions........................................................................5C-2 Gen III Cool Fuel Module Installation...............................5C-13
Exploded Views and Diagrams..........................................5C-3 Gen III Cool Fuel Module Diagnostics............................. 5C-17
Gen III Cool Fuel Module Exploded View...................5C-3 Electrical................................................................... 5C-17
Gen III Cool Fuel Module Fuel Flow Diagram............ 5C-4 Checking Fuel Pressure and Fuel Supply Vacuum
Changing the Water Separating Fuel Filter Element......... 5C-4 .............................................................................. 5C-17
Gen III Cool Fuel Module Removal....................................5C-6 In the Water Test...................................................... 5C-17
Gen III Cool Fuel Module Disassembly............................. 5C-7 Gen III Cool Fuel Line Replacement................................5C-18
Gen III Cool Fuel Module Assembly................................ 5C-10 Fuel Line Replacement Warnings............................ 5C-18
Fuel Inlet Adapter Fitting.......................................... 5C-10 Removing the Fuel Line............................................5C-18
Top Cover and Fuel Pumps .....................................5C-10
Fuel Pressure Regulator...........................................5C-13
Installing the Fuel Line..............................................5C-19
5
C
90-879288300 AUGUST 2012 Page 5C-1

Precautions
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
! WARNING
Neglect or improper maintenance, repairs, or inspections of the power package can result in product damage or serious injury
or death. Perform all procedures as described in this manual. If you are not familiar with proper maintenance or service
procedures, consign the work to an authorized Mercury Marine dealer.
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before
starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: To avoid damaging the electrical system, follow these precautions:

• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not attempt diagnostics without the proper, approved service tools.
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
Loctite 567 PST Pipe Fuel inlet adapter fitting
9 92-809822
Sealant Fuel line inlet connector to adapter
19 Perfect Seal Cooling hose orifices and mating bore 92-34227Q02
Mercury MerCruiser Full-
Synthetic Engine Oil Fuel outlet line O-ring
154 92-858087K01
20W-40, NMMA FC-W Fuel line O-ring
rated
Page 5C-2 90-879288300 AUGUST 2012

Special Tools
Fuel Pressure Gauge Kit 91‑881833A03
Tests the fuel pump pressure; can be used to relieve fuel pressure.
2807
Fuel Shutoff Tool 91‑805918A1
Tests fuel system pressure/vacuum

7051
Exploded Views and Diagrams

Gen III Cool Fuel Module Exploded View
1- Pressure regulator screws

17 2- Pressure regulator
18
3- Top cover screws
1 4- Top cover
16 5- Top cover seal
2 19
6- Fuel pump outlet seal
7- High‑pressure fuel pump
8- High‑pressure fuel pump isolator
3 20
9- Low‑pressure fuel pump isolator
10 - Low‑pressure fuel pump
21 11 - Low‑pressure fuel pump Inlet seal
4 15 12 - Cool Fuel module housing
14 13 - Stud
14 - Wire harness retainer screw
22 15 - Wire harness retainer
5
16 - Wire harness
6 17 - 2‑pin electrical connector (plug)
9 23 18 - Filter cap screws
7 19 - Filter cap
10 20 - O‑ring
8 21 - Fuel filter
11 24 22 - Filter cup seal
23 - Filter cup
24 - Filter disc
12
13
8810
90-879288300 AUGUST 2012 Page 5C-3

Gen III Cool Fuel Module Fuel Flow Diagram

d e f Fuel flow
a - Fuel inlet adapter fitting
b - Fuel filter element
a b c
c - Low‑pressure fuel pump
d - Fuel pressure regulator
e - High‑pressure fuel pump
f - Fuel outlet
50023
Changing the Water Separating Fuel Filter Element

! WARNING
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
1. Allow the engine to cool down.

2. Close the fuel supply valve, if equipped.
NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal.
3. Disconnect the Cool Fuel module harness from the engine wiring harness.
4. Turn the key switch to the start position and allow the starter to operate for five seconds to relieve fuel system pressure.
5. Turn the key switch to the off position.
6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel module. Do not remove the
filter assembly retaining screws from the filter cap.
NOTE: The filter cap screw holes are not tapped in the housing. If replacing the lower assembly, use the self‑tapping filter
assembly retaining screws.
Page 5C-4 90-879288300 AUGUST 2012

7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not completely remove the filter
assembly from the Cool Fuel module at this time.
a- Cool Fuel module

d b- Cool Fuel module harness
c- Filter cap
c d- Filter assembly retaining screw (self‑tapping)
e- Fuel filter element
f- Filter cup seal
e g- Filter cup
b
h- Cool Fuel module filter reservoir
f
g
49875
8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool
Fuel module filter reservoir.
9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it clockwise while holding the filter cup
stationary.
10. Remove the used water separating fuel filter element from the filter cup, and place it in a clean, approved container.
11. Dispose of any water or debris that may be in the filter cup.
12. Install a new water separating fuel filter element into the filter cup. Push the element into the cup until it is completely
seated.
13. Install a new O‑ring on the filter cup.
14. Attach the filter cap to the filter cup by grasping the filter cap and rotating it counterclockwise while holding the filter cup
stationary. Continue turning until the filter cap locks securely into place.
15. Carefully install the fuel filter assembly into the Cool Fuel module to prevent spilling fuel, and align the screws in the filter
cap with the screw holes in the Cool Fuel module. Tighten the filter assembly retaining screws until they are hand tight.
16. Ensure that the filter cap is firmly seated against the Cool Fuel module and tighten each filter assembly retaining screw to
specification.
Description Nm lb‑in. lb‑ft

Filter assembly retaining screw 6 53
17. Open the fuel supply valve, if equipped.
18. Reconnect the Cool Fuel module harness to the engine wiring harness.
19. Supply cooling water to the engine.
20. Properly ventilate the engine compartment.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
21. Run the engine and check for any leaks. Stop the engine immediately if a leak exists, and correct it before continuing.
90-879288300 AUGUST 2012 Page 5C-5

Gen III Cool Fuel Module Removal

! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
! CAUTION
1. Close the fuel supply valve, if equipped.

2. Close the seacock, if equipped.
3. Disconnect the negative (–) battery cable from the battery.
4. Disconnect the positive (+) battery cable from the battery.
5. Relieve the fuel system pressure as follows:
a. Connect the fuel pressure gauge kit to the Schrader valve on the fuel rail.
a
b Typical MPI fuel rail, excluding Scorpion models
a - Schrader valve
b - Schrader valve cap
c c - Fuel rail block‑off plug
42328

b. Place the end of the fuel pressure gauge relief line into an approved container.
c. Open the fuel pressure gauge relief valve to relieve the pressure.
6. Disconnect the Cool Fuel module 2‑pin harness connector.
7. Disconnect the fuel supply (inlet) hose and plug the hose.
8. Disconnect the fuel pressure regulator vacuum hose from the fuel pressure regulator on the Cool Fuel module.
a
a - Fuel pressure regulator
b b - Fuel pressure regulator hose nipple
c - Fuel pressure regulator vacuum hose
c
8724
Page 5C-6 90-879288300 AUGUST 2012

9. Loosen the nut on the cooling hose bracket and remove the cooling hoses from the Cool Fuel module.
a - Cooling hoses
b - Bracket nut
a 49891
10. Remove the fuel outlet line retainer screw.
a b
50025
24577
Fuel outlet line retainer screw
a - Fuel outlet line
b - Fuel outlet screw
11. Carefully pull the fuel outlet line straight out from the module, and plug the line.
b a - Fuel outlet line

a
b - O‑ring
50038
12. Remove the Cool Fuel module mounting brackets from the engine.
13. Carefully remove the Cool Fuel module from the engine.
Gen III Cool Fuel Module Disassembly

NOTE: Retain all fasteners and hardware unless instructed otherwise.
90-879288300 AUGUST 2012 Page 5C-7

IMPORTANT: Do not remove the fuel inlet adapter fitting.
31446
1. Remove the Cool Fuel module from the engine. Refer to Gen III Cool Fuel Module Removal.
2. Remove the primary mounting bracket from the Cool Fuel module.
49892
Primary mounting bracket
3. Remove the support bracket from the Cool Fuel module.
8796
Support bracket
4. Remove the filter assembly. Refer to Changing the Water Separating Fuel Filter Element.
5. Remove the six screws holding the top cover.
b a - Top cover screws (not all are shown)

b - Top cover
a 50027
Page 5C-8 90-879288300 AUGUST 2012

6. Pull the top cover straight up.
a- Gen III Cool Fuel module

b- High‑pressure fuel pump
c- Top cover
c
d- Low‑pressure fuel pump
d
a
49989
7. Disconnect the electrical connections from the low‑pressure and high‑pressure pumps and remove the pumps from the top
cover.
a - High‑pressure fuel pump electrical connector

b b - Top cover
c - Low‑pressure fuel pump electrical connectors
a
50028
8. Remove the seals and isolators from the fuel pumps.
d c
c
b
b
a a
50029 50030
Low-pressure fuel pump High-pressure fuel pump

a - Inlet seal a - Isolator
b - Low‑pressure fuel pump b - High‑pressure fuel pump
c - Isolator c - Outlet seal
d - Outlet seal
NOTE: The fuel inlet seal for the low‑pressure pump may not come out with the pump when the pump is removed from the
Cool Fuel module housing. Be sure to remove the seal from the housing before low‑pressure fuel pump installation.
9. Drain the fuel from the Gen III Cool Fuel module into an approved container.
90-879288300 AUGUST 2012 Page 5C-9

Gen III Cool Fuel Module Assembly

Fuel Inlet Adapter Fitting
1. Install the fuel filter assembly. Refer to Changing the Water Separating Fuel Filter Element.
! WARNING
Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting, causing a fuel leak
and possible fire or explosion. Always install fittings and plugs correctly, and do not tighten with power tools.
2. Apply Loctite 567 to the threads of the fuel inlet adapter fitting.

Loctite 567 PST Pipe
9 Fuel inlet adapter fitting 92-809822
Sealant
3. Hand thread the fuel inlet adapter fitting into the Cool Fuel module.
4. Tighten the fuel inlet adapter fitting to the specified torque.
31446

Fuel inlet adapter fitting 22 16
Top Cover and Fuel Pumps

1. Place the fuel pump outlet seals and isolators onto both fuel pumps.
2. Place the inlet seal for the low‑pressure pump into the Cool Fuel module housing.
IMPORTANT: The inlet (bottom) seal on the low‑pressure pump must be placed in the Cool Fuel housing for installation.
Do not place the inlet seal on the pump prior to pump installation. The seal may become dislodged during pump installation
and cause the pump to not seal properly.
d c
c
b
b
a a
50029 50030
Low-pressure fuel pump High-pressure fuel pump

a - Inlet seal a - Isolator
b - Low‑pressure fuel pump b - High‑pressure fuel pump
c - Isolator c - Outlet seal
d - Outlet seal
Page 5C-10 90-879288300 AUGUST 2012

3. Connect the electrical connector to the high‑pressure fuel pump.
a - High‑pressure fuel pump

b - Electrical connector
a
50036
4. Connect the electrical connectors to the low‑pressure fuel pump:

• Red wire to the positive terminal
• Black wire to the negative terminal
The fuel pump is marked positive (+) and negative (–) on the top of the pump. Spade connection sizes are matched to the
appropriate connection.
a - Low‑pressure fuel pump

b - Negative (–) electrical connection
c c - Positive (+) electrical connection
a
49990
5. Route the wires as shown. Ensure that the ground wire terminal at the harness end is positioned against the outer wall of
the casing. The low‑pressure pump wiring must be routed through the slot and above the fuel pump. The high‑pressure
pump wiring must also be routed above the fuel pump. Ensure that the wiring is not bound or pinched.
b Fuel pumps not shown for clarity

a - Ground wire terminal
b - Low‑pressure pump electrical connectors
c - Slot (low‑pressure pump wire routing)
d - High‑pressure pump electrical connector
a
c
d
50031
90-879288300 AUGUST 2012 Page 5C-11

6. Insert the low‑pressure pump into the top cover.
b Low-pressure fuel pump installation

a - Low‑pressure fuel pump
b - Top cover
c c - Outlet seal
d - Isolator
d e - Inlet seal
a
e
50033
7. Insert the high‑pressure pump into the top cover.
High-pressure fuel pump installation

b a - Isolator
b - Top cover
c - Outlet seal
c d - High‑pressure fuel pump
a
50034
8. Verify that the top cover seal is not damaged. Replace it if necessary.
9. Place the top cover seal into the groove in the top cover.
50035
Fuel pumps not shown for clarity
NOTE: Be sure that mating surfaces are clean and clear of any debris before installing the top cover.
Page 5C-12 90-879288300 AUGUST 2012

10. Carefully lower the top cover with the fuel pumps into the Cool Fuel module housing.
a- Cool Fuel module housing

b- High‑pressure pump
c- Top cover
c
d- Low‑pressure pump
d
a
49989
11. Install the top cover screws and hand‑tighten them.

12. Pull the cover gently into place with the top cover screws.
IMPORTANT: Be sure to tighten the top cover screws evenly when pulling the top cover into place.
13. Tighten the top cover screws to the specified torque.

Top cover screws 14 124
Fuel Pressure Regulator

1. Insert the fuel pressure regulator into the top cover with the hose barb facing the outboard side of the Cool Fuel module.
b a - Fuel pressure regulator

b b - Fuel pressure regulator screws (2)
c - Fuel pressure regulator vacuum hose barb
a
c
50037
2. Install the two fuel pressure regulator screws and tighten them to the specified torque.

Fuel pressure regulator screws 14 124
Gen III Cool Fuel Module Installation

1. Connect the primary mounting bracket to the Cool Fuel module. Tighten to specification.
49892
Primary bracket
90-879288300 AUGUST 2012 Page 5C-13


Primary bracket screws (Cool Fuel module) 23 17
2. Connect the support bracket to the Cool Fuel module. Tighten to specification.
8796
Support bracket

Support bracket screws (Cool Fuel module) 23 17
3. Install the Cool Fuel module onto the engine. Tighten the bracket fasteners to specification.

Primary bracket screw (engine) 31 23
Primary bracket nuts (engine) 47 35
Support bracket nut (engine) 31 23
4. Inspect the fuel outlet line O‑ring. Replace if damaged.
5. Apply a thin coat of oil to the O‑ring.

a
b - O‑ring
50038

Synthetic Engine Oil
154 Fuel outlet line O-ring 92-858087K01
20W-40, NMMA FC-W
rated
6. Carefully insert the fuel outlet line into the Cool Fuel module.
Page 5C-14 90-879288300 AUGUST 2012

7. Install the fuel outlet line retainer screw. Tighten to specification.
50025

Fuel outlet line retainer screw 9 80
8. Install the vacuum hose onto the fuel pressure regulator.
a
a - Fuel pressure regulator
b b - Fuel pressure regulator hose nipple
c - Fuel pressure regulator vacuum hose
c
8724
9. Inspect the quad rings on the cooling hose orifices. Replace if damaged.
10. Coat the cooling hoses orifices and the bore of the fuel cooler assembly with Perfect Seal.
a a - Cooling hose orifices

b - Quad rings
c - Cooling hose bore in the fuel cooler assembly
b c
a 42278

19 Perfect Seal Cooling hose orifices and mating bore 92-34227Q02
90-879288300 AUGUST 2012 Page 5C-15

11. Align the cooling hoses and bracket to the Cool Fuel module and connect the bracket with the attached nut. Push the
cooling hose ends into place on the Cool Fuel module.
a - Cooling hoses and bracket

b - Cooling hose bracket nut
a 49891
12. Tighten the cooling hose bracket nut to specification.

Cooling hose bracket nut 20 15
13. Pull the heat‑resistant sleeve until the vacuum hose and the fuel outlet line are completely covered at the module.
c a - Heat‑resistant sleeve
b - Fuel pressure regulator vacuum hose
c - Fuel outlet line
a
b 8809
14. Apply Loctite 567 to the fuel supply line inlet connector.

Loctite 567 PST Pipe
9 Fuel line inlet connector to adapter 92-809822
Sealant
15. Install the fuel line inlet connector by hand, finger‑tight.
16. While holding the fuel inlet adapter fitting securely, tighten the fuel line inlet connector an additional 1‑3/4 to 2‑1/2 turns
with a wrench. Do not overtighten.
IMPORTANT: Hold the fuel inlet adapter fitting securely when installing the fuel line inlet connector.
Typical
a - Fuel inlet adapter fitting
b - Fuel line connector (typical 90° hose barb)
b
a
50039
17. Connect the Cool Fuel module 2‑pin harness connector.

18. Connect the positive (+) battery cable to the battery.
Page 5C-16 90-879288300 AUGUST 2012

19. Connect the negative (–) battery cable to the battery.
20. Open the seacock, if equipped.
21. Open the fuel supply valve, if equipped.
22. Run the engine and check for any leaks. Stop the engine immediately if a leak exists, and correct it before continuing.
Gen III Cool Fuel Module Diagnostics

Electrical
1. Disconnect the electrical connector at the Cool Fuel module.
2. Connect a digital volt/ohmmeter (DVOM) to the engine side of the electrical connector.
3. Turn the ignition switch to the run position.
4. Verify that there is 12 volt battery (+) power going to the Cool Fuel module. If voltage is less than 11.5 vdc, find and correct
the cause of the voltage drop.
NOTE: The fuel pump relay will only remain active for 2–3 seconds while the key is in the run position.
Checking Fuel Pressure and Fuel Supply Vacuum

1. Connect a fuel pressure gauge to the Schrader valve on the fuel rail.
2. Cycle the key switch 2–3 times ("OFF" to "RUN" position) at three‑second intervals to reach maximum fuel pressure.
3. Verify that the pressure is within specification.
4. If the fuel pressure exceeds 303 kPa (44 psi), replace the fuel pressure regulator.
5. If the fuel pressure is less than 276 kPa (40 psi), but greater than 90 kPa (13 psi):
a. Relieve the fuel pressure in the fuel rail. Refer to the Fuel Pressure Relief procedure in Section 5A (non‑Scorpion
models) or Section 5B (Scorpion models).
b. Use a T‑fitting and connect a vacuum gauge to the fuel inlet side of the Cool Fuel module. Do not remove the fuel
inlet fitting adapter.
c. Cycle the key switch 2–3 times ("OFF" to "RUN" position) at three‑second intervals to reach maximum pressure.
d. Verify that the vacuum from the fuel source is within specification. If the vacuum exceeds 7 kPa (2 in. Hg), excessive
fuel restriction exists. Correct the fuel restriction before proceeding.
e. With the vessel secured to the dock and the engine running in neutral, restrict the fuel supply with a fuel shutoff tool,
and verify that the Cool Fuel module has the ability to cause an inlet vacuum reading of 37 kPa (11 in. Hg) or greater.
If the vacuum reading is less than 37 kPa (11 in. Hg) with the fuel supply restricted, but fuel pressure is within
specification, replace the low‑pressure pump.
Fuel Shutoff Tool 91‑805918A1

6. If the fuel pressure is 90 kPa (13 psi) or less and the inlet vacuum is less than 51 kPa (15 in. Hg), replace the
high‑pressure pump and the fuel pressure regulator.
In the Water Test

1. With a vacuum gauge and a fuel pressure gauge in place, operate the boat throughout the RPM range and record the
pressure and vacuum readings.
2. If the fuel supply vacuum reading is greater than 7 kPa (2 in. Hg), find and correct the fuel supply restriction.
3. If fuel pressure is less than 276 kPa (40 psi), but greater than 90 kPa (13 psi):
a. Verify that the vacuum from the fuel source is within specification. If the vacuum exceeds 7 kPa (2 in. Hg), excessive
fuel restriction exists. Correct the fuel restriction before proceeding.
b. If no excessive fuel supply restriction exists, replace low‑pressure fuel pump.
4. If fuel pressure is 90 kPa (13 psi) or less and no excessive fuel supply restriction exists, replace high‑pressure pump and
fuel pressure regulator.
IMPORTANT: It will be necessary to conduct a sea‑trial of the boat following repairs to ensure that the pressure and the fuel
system vacuum remain within specification throughout the RPM range.
90-879288300 AUGUST 2012 Page 5C-17

Gen III Cool Fuel Line Replacement

Fuel Line Replacement Warnings
! WARNING
Improper fuel line installation can cause fuel leaks, causing serious injury or death from fire or explosion. Install the fuel line
so it is not restricted, pinched, or in contact with any sharp or rough surfaces. Ensure that the fuel line and required clips are
installed according to the installation instructions.
! WARNING
Removing the Fuel Line

! CAUTION
1. Remove and retain the engine cover.

1. Disconnect the negative (–) battery cable from the battery.
2. Disconnect the positive (+) battery cable from the battery.
NOTE: Place a rag or other suitable material under the fuel line fittings and connections to catch any fuel.
3. Relieve fuel system pressure as follows:
a. Connect a fuel pressure gauge kit to the Schrader valve.
IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe
manner in accordance with all local, federal, and international regulations.
b. Place the end of the fuel pressure gauge relief line into a suitable container.
c. Open the fuel pressure gauge relief valve to relieve pressure.
4. Disconnect the fuel line from the fuel rail fitting:
a. Using a 3/8‑inch fuel line disconnect tool, disconnect the fuel line from the fuel rail.
a - Fuel line disconnect tool

b - Fuel line
c - Fuel rail
25370
Description SPX Part Number

3/8‑inch fuel line disconnect tool J‑41769‑1
b. Drain any fuel remaining in the fuel line into a suitable container.
5. Disconnect the fuel line from the Gen III Cool Fuel module:
Page 5C-18 90-879288300 AUGUST 2012

a. Remove the fuel line retainer screw. The fuel line retainer screw may differ from the screw pictured.
a b
51271
a - Fuel line (heat‑resistant sleeve pulled back for clarity)

b - Typical fuel line retainer screw
b. Carefully pull the fuel line straight out from the module and plug the line.
6. Discard the fuel line and the heat‑resistant sleeve.
Installing the Fuel Line

Connecting the Fuel Line to the Gen III Cool Fuel Module
1. Install the O‑ring onto the fuel line connector as shown.

b - O‑ring
a
24580
2. Apply a thin layer of oil onto the O‑ring.

Synthetic Engine Oil
154 Fuel line O-ring 92-858087K01
20W-40, NMMA FC-W
rated
3. Carefully insert the fuel line into the Gen III Cool Fuel module.
90-879288300 AUGUST 2012 Page 5C-19

4. Rotate the fuel line toward the engine block as shown in the following photograph.
a Heat-resistant sleeve removed for visual clarity

a - Fuel line
b - Bracket
b
24390
5. Install the fuel line retainer screw. Tighten it to specification. The fuel line retainer screw may differ from the screw pictured.
a - Fuel line
b - Typical fuel line retainer screw
24692

Fuel line retainer screw 9 80
IMPORTANT: The replacement fuel line has a heat‑resistant sleeve pre‑installed. Do not remove the sleeve from the fuel
line; ensure that the sleeve covers the fuel line to within 6 mm (1/4 in.) of the connection.
6. Pull the heat‑resistant sleeve over the fuel line to within 6 mm (1/4 in.) of the Gen III Cool Fuel module.
Installing the Fuel Line J-Clip

1. Install the fuel line J‑clip onto the Cool Fuel module mounting bracket stud.
a. Remove and retain the nut (item a) as shown in the following photograph.
b. Slide the curved end of the J‑clip over the top of fuel line and heat‑resistant sleeve as shown.
• For models that are not equipped with closed cooling, the open end of the clip faces away from the engine block.
• For models equipped with closed cooling, the open end of the clip faces the engine block.
c. Install the J‑clip over the stud.
Page 5C-20 90-879288300 AUGUST 2012

d. Reinstall the J‑clip nut. Tighten to specification.
c
a b
a b
25373 25372
Model without closed cooling Model with closed cooling

a - Nut
b - J‑clip
c - Fuel line

J‑clip nut 48 36
2. Ensure that the fuel line is routed in a manner such that it is not restricted, pinched, or in contact with any sharp or rough
surfaces.
• On models without closed cooling, the fuel line should be routed behind the drain valve assembly and drain hoses.
• On models with closed cooling, the fuel line should be routed behind the cooling hose.
Connecting the Fuel Line to the Fuel Rail

1. Install the fuel line onto the fuel rail fitting. Listen for a snap.
2. Test that the fuel line is properly seated by tugging firmly on the line.
3. Position the heat resistant sleeve to within 6 mm (1/4 in.) of the fuel rail fitting.
4. Install the engine cover.
5. Connect the positive (+) battery cable to the battery.
6. Connect the negative (–) battery cable to the battery.
7. Ventilate the engine compartment.
8. Start the engine and test for fuel leaks. If leaks exist, stop the engine immediately. Wipe up any leaked fuel. Find and repair
any fuel leaks before restarting the engine.
90-879288300 AUGUST 2012 Page 5C-21

Notes:
Page 5C-22 90-879288300 AUGUST 2012

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90-879288300 AUGUST 2012 Page 5C-1

IMPORTANT: To avoid damaging the electrical system, follow these precautions:

Lubricants, Sealants, Adhesives

Page 5C-2 90-879288300 AUGUST 2012

Fuel Shutoff Tool 91‑805918A1

Tests fuel system pressure/vacuum

Exploded Views and Diagrams

1- Pressure regulator screws

90-879288300 AUGUST 2012 Page 5C-3

Gen III Cool Fuel Module Fuel Flow Diagram

Changing the Water Separating Fuel Filter Element

1. Allow the engine to cool down.

Page 5C-4 90-879288300 AUGUST 2012

a- Cool Fuel module

Description Nm lb‑in. lb‑ft

90-879288300 AUGUST 2012 Page 5C-5

Gen III Cool Fuel Module Removal

1. Close the fuel supply valve, if equipped.

Fuel Pressure Gauge Kit 91‑881833A03

Page 5C-6 90-879288300 AUGUST 2012

b a - Fuel outlet line

Gen III Cool Fuel Module Disassembly

90-879288300 AUGUST 2012 Page 5C-7

Primary mounting bracket

3. Remove the support bracket from the Cool Fuel module.

b a - Top cover screws (not all are shown)

Page 5C-8 90-879288300 AUGUST 2012

a- Gen III Cool Fuel module

a - High‑pressure fuel pump electrical connector

Low-pressure fuel pump High-pressure fuel pump

90-879288300 AUGUST 2012 Page 5C-9

Gen III Cool Fuel Module Assembly

Tube Ref No. Description Where Used Part No.

Description Nm lb‑in. lb‑ft

Top Cover and Fuel Pumps

Low-pressure fuel pump High-pressure fuel pump

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3. Connect the electrical connector to the high‑pressure fuel pump.

a - High‑pressure fuel pump

4. Connect the electrical connectors to the low‑pressure fuel pump:

a - Low‑pressure fuel pump

b Fuel pumps not shown for clarity

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6. Insert the low‑pressure pump into the top cover.

b Low-pressure fuel pump installation

7. Insert the high‑pressure pump into the top cover.

High-pressure fuel pump installation

Fuel pumps not shown for clarity

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a- Cool Fuel module housing

11. Install the top cover screws and hand‑tighten them.

Description Nm lb‑in. lb‑ft

Fuel Pressure Regulator

b a - Fuel pressure regulator

Description Nm lb‑in. lb‑ft

Gen III Cool Fuel Module Installation

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Description Nm lb‑in. lb‑ft

Description Nm lb‑in. lb‑ft