How to Install an Outboard Motor Gasoline & Water Separator
An outboard motor gasoline and water separator can be a great investment for your boat. Boats are subject to copious amount of water and mist over the bow while cruising or moving on plane, and marine gas tanks routinely gather condensation inside and send water through the fuel system. Water corrodes metal parts, destroys lubrication and in some cases, if allowed to enter the cylinders, will stop the motor. Gas and water separators trap unwanted water in the fuel system, allowing it to be disposed of during routine maintenance.
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Things You'll Need
- Fuel/water separator kit
- Marine plywood (1-inch thick or larger)
- Jigsaw
- Epoxy adhesive
- Pencil
- Drill motor
- Drill bits
- Silicone seal
- End wrenches
- 4 fuel hose clamps
- Screwdrivers
- Gasoline
- Cup
Instructions
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1
Trailer your boat and take it to a convenient location for the installation of the fuel water separator. Activate the cutoff switch for the ignition and turn off the fuel supply valve to the engine. Place a good amount of rags underneath the gas tank line that leads to the outboard engine compartment. Open the deck hatch if your fuel line runs underneath. Look for a mounting location close to the bilge area, where you can screw a bracket to the hull, like a runner or chine.
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2
Use a jigsaw to cut a square piece of 1-inch marine plywood, if you do not have a suitable mounting place on hard wood. Glue the plywood square to the hull with marine epoxy adhesive, halfway between the gas tank and the engine fuel inlet. Let it dry. Position the kit bracket onto the wood surface and use a pencil to mark two drill holes on the wood mount. Use a drill and small bit to drill the holes 1/2 inch into the wood.
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3
Screw the bracket in place, using the kit screws provided. Dab some silicone sealant on the two kit nozzle fittings and screw them into the fuel-water separator flange, by hand. Tighten the fittings with an end wrench. Hold your tank fuel line up and cut it in half with wire cutters. Let any gas drip on the rags. Place two hose clamps onto each fuel line end, for a total of four clamps.
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4
Push the fuel lines firmly onto the nozzle fittings. Loosen the hose clamps enough to push them over the nozzle fittings. Tighten all four hose clamps with a slot screwdriver. Unscrew the bottom separator bowl and fill it with gasoline from a cup, for priming purposes. Screw the bowl back onto the separator, hand-tight only. Wipe up any spilled gas. Remove the rags.
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5
Transport the boat to water, or immerse the lower unit in a barrel of water. If you have a muff flush device, hook it up to a garden hose and install it over the water intake ports on the lower unit. Turn your electrical cutoff switch to the on position. Turn on the engine fuel valve. Depending on your starter type, pull the recoil starter rope or turn the ignition key to start the engine.
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6
Run the starter several times in short spurts, allowing the fuel to build up in the lines. Look for leaks in the fuel line connections when the engine starts. Remove your tools and clean up.
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Tips & Warnings
Do not smoke anywhere near this installation procedure. To be safe, remove the battery from the boat if you have one on board.
