Mercury 40 HP Fuel Filter Replacement

Tools Needed

• Adjustable wrench
• 8mm socket wrench
• 6mm by 1 socket wrench
• Reacher or long needlenose pliers
• Rags
• Glass jar or container

Safety

• Warning: Be cautious when handling fuel as it can be flammable.
• Warning: Do not leave gasoline-soaked rags in the motor to prevent fire hazards.

Steps

1. Remove the cowling by pulling it out and lifting it off.
2. Locate the low-pressure fuel filter on the starboard side.
3. Place rags under the filter to catch any fuel.
4. Use an adjustable wrench to unscrew the low-pressure fuel filter.
5. Remove the old filter and place it in a container to avoid spilling fuel.
6. Install the new low-pressure fuel filter by pressing it into place.
7. Screw the sight glass back in and tighten it down, but not too tightly.
8. Locate the high-pressure fuel filter under the coil pack.
9. Remove the wire from the coil pack and tuck it away.
10. Use an 8mm socket wrench to remove the bolts securing the coil pack.
11. Carefully remove the coil pack and any dropped pieces.
12. Remove the insulative sleeve and place rags to catch any fuel.
13. Disconnect the fuel filter connector by pressing the red button.
14. Remove the old high-pressure fuel filter and clean up any fuel.
15. Insert the new high-pressure fuel filter, ensuring the arrow points in the correct direction.
16. Reassemble the coil pack, using a 6mm by 1 socket wrench to secure the bolts.
17. Reattach the coil wire, ensuring it clips back on properly.
18. Prime the system using a priming ball to ensure fuel flow.

Tips

• Use idiot lines on connections to remember their placement.
• Keep tools like reachers and long needlenose pliers handy for retrieving dropped pieces.
• Be prepared to drop and retrieve small parts during reassembly.
• Tighten bolts enough to hold without stripping the threads.