AA Ignition Electric Fuel Pump Instruction Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your AA Ignition Electric Fuel Pump. This pump is designed to deliver fuel at a low pressure from the tank to the carburetor system in compatible marine engines, ensuring optimal fuel consumption and power generation.

Figure 1: AA Ignition Electric Fuel Pump

2. Key Features

The AA Ignition Electric Fuel Pump offers several benefits for your marine engine:

• Fixes Common Motor Starting Issues: Ensures consistent fuel delivery for reliable engine starts.
• Exceeds Factory Part Quality & Durability: Constructed with robust materials for long-lasting performance.
• Carefully Assembled & Tested: Each pump undergoes rigorous testing to ensure flawless operation.
• Direct Replacement for Factory Part: Designed for a seamless fit and function.
• Improves Fuel Consumption: Maintains optimal fuel pressure for efficient engine performance.

Figure 2: Overview of Product Features

3. Compatibility

This electric fuel pump is specifically designed for Mercury Boat Engines with low-pressure carburetor-operated systems. It is not compatible with fuel-injected engines.

Compatible models include:

• 1998 Mercury Marine 4.3L 262
• 2000 Mercury Marine 5.0L 305
• 2000 Mercury Marine 5.7L 350
• MCM/MIE 4.3L/V6 and 5.0L/V8 Gen+ engines
• Some 350 ci carburetors

This pump replaces the following part numbers:

• 861155A3
• 861156A1
• 935432 / 935433 / 9-35433
• 18-35433 / 861156-1 / 18-8868
• E11004
• 807949A1
• 861156A03
• 861156A2
• 126511216
• PH500M014

Figure 3: List of Compatible Vehicles

Figure 4: Cross-Reference for Replaced Part Numbers

4. Package Contents

Your AA Ignition Electric Fuel Pump package includes the following components:

• Electric Fuel Pump unit with pre-installed OEM electrical connector plug.
• New wire loom for wire protection.
• Tight seal washers.
• Threaded adapter.

Figure 5: Diagram of Fuel Pump and Included Components

Figure 6: Electric Fuel Pump and Loose Components

Figure 7: Detail of the OEM Electrical Connector

5. Installation Guide

Installation of this electric fuel pump can be performed by individuals comfortable with marine engine work. However, the location of the pump and access to it will vary by application. Always prioritize safety during installation.

Safety Precautions:

• Work in a well-ventilated area to avoid inhaling fuel fumes.
• Disconnect any batteries or shore power before beginning work to prevent electrical hazards.
• Take precautions to limit fuel leakage from the existing fuel pump during removal.
• Ensure all connections are secure and free of leaks after installation.

General Installation Steps:

1. Locate the existing fuel pump on your marine engine.
2. Carefully disconnect the electrical connector and fuel lines from the old pump. Be prepared for minor fuel spills.
3. Remove the old fuel pump.
4. Install the new AA Ignition Electric Fuel Pump, ensuring the new seal washers and threaded adapter are correctly used for a tight seal.
5. Connect the OEM electrical connector and fuel lines to the new pump.
6. Reconnect power, check for leaks, and test the engine's operation.

Figure 8: Professional installation is recommended if unsure.

Figure 9: Example of a marine engine where the pump might be located.

Installation Video:

6. Operation

The electric fuel pump's primary function is to draw fuel from the tank and deliver it at a consistent low pressure (9-10 psi) to the engine's carburetor. This continuous and stable fuel supply is crucial for the engine to generate optimal power and maintain efficient fuel consumption. If the fuel pressure is incorrect (either too high or too low), it can negatively impact engine performance.

7. Maintenance

To ensure the longevity and optimal performance of your electric fuel pump and overall fuel system, consider the following maintenance tips:

• Regular Fuel Filter Checks: Inspect and replace your fuel filter regularly as per your boat's manufacturer recommendations. A clogged fuel filter can strain the fuel pump.
• Fuel Quality: Use clean, high-quality fuel to prevent contaminants from damaging the pump.
• System Inspection: Periodically check fuel lines and connections for any signs of wear, cracks, or leaks.
• Proper Storage: If storing your boat for an extended period, follow proper fuel stabilization procedures to prevent fuel degradation.

8. Troubleshooting

If you experience issues with your fuel system after installing the new pump, consider these common troubleshooting points:

• Engine Not Starting or Rough Idling: This could indicate incorrect fuel pressure. Verify all connections are secure and the pump is receiving adequate power.
• Fuel Leaks: Double-check all threaded connections and ensure the seal washers are properly seated.
• Pump Noise: A new pump might make a slight humming sound, which is normal. Excessive or unusual noise could indicate an issue with installation or a faulty unit.

If problems persist, refer to your boat's service manual or consult a qualified marine mechanic.

9. Specifications

10. Warranty and Support

This AA Ignition Electric Fuel Pump comes with a Lifetime Warranty. If the part ever fails or breaks, simply contact AA Ignition for a replacement. This warranty ensures peace of mind and significant savings compared to dealer prices.

For any questions regarding this product or its application, please reach out to AA Ignition customer support. We are glad to help.