2002 280 Sundancer 4.3 Fuel Pump Assembly Replacement

[rkfrazier]

Good Afternoon all,

We have just purchased a Sander 280 with twin 4.3 MPI and the port engine has a fuel pump that is faulty and needs to be replaced. My question is has anyone replaced one of these units and what all needs to e disassembled the service manual for the 4.3 is useless for this particular boat due to the location in the engine compartment.

I have gotten most of the front mounting plate loose which helps but now it appears the engine mount will need to be removed as it is in the way f the fuel unit mounting bracket. That's my next step tomorrow any suggestions or advice would be greatly appreciated as standing on your head tends to a bit uncomfortable.

Thanks

Keith

 

[rkfrazier]

Ok, it's done in order to access the front of the fuel pump and cooler assembly remove the engine water drain valve and the power steering pump do not disconnect the hoses on the power steering pump it just makes access easier be able to move the hoses out of your way

What I had to do at this point was cut the fuel pump assembly bracket just below the motor mount in order to clear the motor mount, after trying every angle I could move the fuel assembly it simply would not clear the motor mount. A reciprocating saw or cut off wheel work well since the metal mercrusier used is very soft.

Once this is done you will then need to remove the fuel filter housing in order to better get at the fuel lines there will be a little fuel but not too much so be ready for that. At this point the you can pull the fuel pump forward but not too much now reach over the port side of the engine and reach down from the top you are trying to feel for a two wire plug if you give a slight tug you know you have the right one because the fuel pump and cooler will move.

Next disconnect the water hose to the cooler from the back of the engine this will give you a little room to move the pump forward. One last item to disconnect, the fuel line on top of the engine just behind the intake spark arrester. This will require a plastic tool to disconnect the line they come in a pack for about 9 bucks at the parts store.

After all this you can move the fuel pump and cooler far enough forward to remove the plastic cover and the you will see the two nuts on the bracket remove those and your fuel bracket will fall in your hand. I made mine into a two piece bracket that has bolts lower on the bracket that are easier to get to and makes removing the fuel pump and cooler much easier. I hope this helps a little for those of you that have to replace your fuel pump.