High-performance mechanics and tuners often like to remove the Oil Injection System from their Mercury 2-Stroke V6 Outboard due to its known tendency to fail and its unreliability above 6400 rpm.
To install our Oil Injection Block-Off Kit on the Mercury 2.0, 2.4, 2.5 Liter outboards (compatible with part numbers 818304-A1, 8M0095447, 43453, 43453T, and 32509) on your outboard engine, follow these detailed steps:
Tools and Materials Needed:
Oil Injection Block-Off Kit (includes block-off plug, O-ring, and mounting screws)
Screwdrivers (Phillips and flathead)
Socket set with ratchet
Clean rags
Marine-grade sealant
Procedure:
Safety Precautions:
Disconnect the battery to prevent accidental engine starts.
Shut off any fuel lines disconnects
Ensure the engine is cool and in a well-ventilated area.
Drain Oil:
Remove oil from the oil lines and the oil tank to prevent spills during the installation process.
Access the Oil Pump:
Remove any covers or obstacles obstructing access to the oil pump.
Refer to your engine's service manual for specific disassembly instructions.
Disconnect Oil Lines:
Carefully disconnect all oil lines from the pump.
Plug or cap the lines to prevent oil leaks or contamination.
Remove the Oil Pump:
Unbolt the oil pump from the engine block using the appropriate socket or wrench.
Remove bolts, pump, or-ring, long gear drive, and sleeve.
Install the Block-Off Plate:
Clean the mounting surface to remove old gasket material and debris.
Align the block-off plate from the kit over the oil pump mounting area.
Apply a light bead of marine-grade sealant around the O-ring area.
Secure the block-off plate with the bolts provided in the kit.
Be careful; over-tightening the bolts could crack the cap.
Reassemble and Final Steps:
Inspect all connections and ensure everything is properly secured.
Reinstall any covers or components removed during disassembly.
Drain and Refill your fuel tank with the appropriate type and amount of pre-mixed fuel (24:1 to 50:1 fuel-to-oil ratio).
Reconnect the battery cables and ensure a secure connection.
Start the engine and let it run briefly to ensure there are no leaks around the block-off plate.
Additional Considerations:
Over-Temperature Alarm: After removing the oil injection system, it's crucial to ensure that the over-temperature alarm remains functional. The warning alarm system typically has two modes: a constant alarm indicating an over-temperature problem and a pulsing alarm indicating an oil injection problem.
When you disable the oil injection system, the pulsing alarm will no longer function, but the over-temperature alarm should still work. To test this, locate the Tan/Blue wire that was connected to the warning module. Grounding this wire with the ignition on should trigger the over-temperature alarm, confirming its functionality.
Oil Injection Warning Module: You can choose to remove the oil injection warning module entirely or leave it in place. If you decide to remove it, disconnect all associated wiring and cap the wires to prevent short circuits.
Crankshaft Gear: It's advisable to keep the old oil pump gear on the crankshaft, as it provides crankcase volume. Removing it may cause that cylinder to run lean.
Labeling: After converting to pre-mixed fuel, place clear labels near the fuel fitting on the motor, the dashboard, and the fuel fill fitting on the boat to alert operators that the gas requires oil to be added.
By following these steps and considerations, you can successfully install the Mercury Oil Injection Block-Off Kit and transition to a pre-mixed fuel system, ensuring the continued reliable operation of your outboard engine.
The complete kit is available here at Buckshot Racing 77 on the link below:
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