Analog Fuel Level Gauge Installation

Important Information

IMPORTANT: This document guides our dealers, boatbuilders, and company service personnel in the proper installation or service of our products. If you have not been trained in the recommended servicing or installation procedures for these or similar Mercury Marine products, have the work performed by an authorized Mercury Marine dealer technician. Improper installation or servicing of the Mercury product could result in damage to the product or personal injury to those installing or operating the product. Always refer to the appropriate Mercury Marine service manual for component removal and installation instructions.

NOTE: After completing installation, place these instructions with the product for the owner's future use.

Parts List and Diagram

The following diagram illustrates the components for installation:

Diagram Description: An exploded view shows the gauge assembly. Component 'a' is a Hex nut, 'b' is a Lockwasher, 'c' is a Retaining bracket, 'd' is the Socket, 'e' is the Bulb, 'f' is the Fuel level gauge, 'g' is the Cable assembly - Black, and 'h' is the Cable assembly - Purple. A female coupler (not shown) is also included.

Preparation for Installation

⚠️ 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.

1. Disconnect battery cables.
2. NOTE: The bezel of this gauge has an outside diameter of 62 mm (2-7/16 in.). Choose a gauge location that will ensure clearance between other gauges and instrumentation.
3. Select a location for the gauge that allows for good visibility and accessibility from behind the dashboard. Ensure that the harness will reach the gauge.

Drilling and Dashboard Preparation

⚠️ CAUTION: Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when looking at the front of the dashboard. Before drilling or cutting any holes in the dashboard, check the area behind the dashboard for obstructions. Do not drill or cut when obstructions are present.

1. Before drilling or cutting, ensure there are no obstructions in the area behind the dashboard.
2. If the dashboard is fiberglass, apply masking tape to the area that is to be drilled or cut to help prevent the dashboard from cracking.
3. If the dashboard is vinyl covered, remove the vinyl with a razor blade from the area to be drilled or cut, to keep the vinyl from tearing.
4. Cut or drill a 54 mm (2-1/8 in.) hole through the dashboard.

Wire Connections

IMPORTANT: An analog fuel level sender with a range of 33 ohms to 240 ohms must be used with this gauge.

IMPORTANT: Position wires on the back of all gauges so they will not rub or contact the retaining (mounting) bracket when it is installed.

1. Before placing gauge in dashboard, connect wires to appropriate terminals using lockwashers and hex nuts. Ensure all connections are secure. Tighten terminal nuts to specified torque. Apply sealant to the terminals.

NOTE: When installing the gauge into the dashboard, if the dashboard is too thin for the retaining bracket to hold the gauge securely, connect the ground wire to the back of the retaining bracket using the ground terminal stud, lockwasher, and hex nut. Tighten the nut securely.

2. If lighting is desired, use lamp terminal wired in one of the two following ways:

• a. If instrument lighting is desired when the key switch is on, connect a jumper wire from the ignition terminal (purple wire) to the lamp terminal.
• b. If using a separate light switch for instrument lighting, connect the lamp terminal to a 12-volt positive (+) switched source.

Wiring Diagram Description: The diagram shows connections for terminals labeled 'a' (Lamp terminal), 'b' (Ground), 'c' (Black Harness from fuel level sender), 'd' (Purple wire to ignition terminal or switched source), and 'e' (Pink Harness from fuel level sender). Wire colors are specified as PNK, BLK, and PUR.

Installing the Gauge

1. Place the gauge into the dashboard.
2. NOTE: On installations where the dashboard is too thick, legs of retaining bracket may have to be shortened to install.
3. Install the retaining bracket.
4. Install the lockwasher and hex nut, and tighten to specified torque.

Assembly Diagram Description: This diagram depicts the gauge installed in the dashboard, showing the relationship between the dashboard, gauge, retaining bracket, lockwasher, and hex nut.

Gauge Maintenance

Maintenance inspection is the owner's responsibility and must be performed at intervals as specified.

• Normal Service: Every 50 hours of operation or 60 days (whichever comes first).
• Severe Service: Every 25 hours of operation or 30 days (whichever comes first).

NOTE: Saltwater area operation is considered severe service.

1. Check the gauge for adequate tightness in the dashboard and retighten the retaining nut if necessary.
2. Check the electrical connections. Tighten and apply sealant to the terminals, if needed.

3. Clean the gauge by washing with fresh water to remove sand and salt deposits. Wipe off with a soft cloth moistened with water. The gauge may be scored or damaged if wiped with abrasive material (sand, saline, or detergent compounds) or washed with solvents such as trichlorethylene, turpentine, or similar solvents.

Company Information

Products of Mercury Marine
W6250 Pioneer Road
Fond du Lac, WI 54936-1939

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