See the parts, including a Mercury 40 HP fuel pump kit and more here: https://bit.ly/Mercury-40-HP-Fuel-System-Rebuild
See how to rebuild the fuel system on your Mercury 40 HP EFI outboard in this video from Boats.net. This motor hasn’t run in a while, so we knew going in that there were going to be issues. What we didn’t was that the motor would be missing a fuel pump! We’ll get that first fuel pump replaced, and then we’ll dig deeper into the fuel system.
John will show you how to remove the VST and open it to inspect the components. We’ll replace the VST pump and the float needle, and then get the tank closed back up and reinstalled.
See a Mercury 40 HP EFI fuel pump diagram here: https://www.boats.net/catalog/mercury/outboard-by-year/mercury-outboard/2003/40HP/1a40412ad/fuel-pump?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN
See the lower cowling diagram here: https://www.boats.net/catalog/mercury/outboard-by-year/mercury-outboard/2003/40HP/1a40412ad/bottom-cowl?utm_source=youtube&utm_medium=video&utm_campaign=card_BDN
See the VST tank diagram here: https://www.boats.net/catalog/mercury/outboard-by-year/mercury-outboard/2003/40HP/1a40412ad/vapor-separator-usa-1b036613-bel-0p340241-and-below?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN
See the Mercury 40 HP fuel line diagram along with the Mercury 40 HP fuel filter here: https://www.boats.net/catalog/mercury/outboard-by-year/mercury-outboard/2003/40HP/1a40412ad/fuel-lines?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN
Read how to do this job step by step: https://www.boats.net/blog/mercury/40hp/fuel/system/rebuild?utm_source=youtube&utm_medium=video&utm_campaign=description-blog-link
Installing new fuel pump – 1:50
Removing VST tank – 3:50
Disassembling VST tank – 6:50
Removing VST fuel pump – 9:25
Replacing VST pump – 10:20
Installing VST tank – 12:17
Find Mercury 40 HP outboard parts here:
Talk to us:
In the video we’re working with a 2003 Mercury 40HP 4-stroke outboard motor, but you may have similar steps for your Mercury outboard. If you’re not sure whether these steps apply to your motor, leave a comment and we’ll get back to you.
Mercury 40 HP output seal replacement:
Mercury 40 HP water pump repair: