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L510032-16
ENGINE MAINTENANCE - 11
WARNING
Extreme caution must be exercised when servicing
the fuel system and/or replacing fuel lter. Gasoline
is extremely ammable and highly explosive under
certain conditions. Be sure the ignition key is o and
do not smoke or allow open ame in the area while
servicing. Wipe up any spilled fuel immediately.
WARNING
Extreme caution must be exercised when servicing
the fuel system. The fuel system operates under
high pressure. Use caution when removing or
replacing components, as residual pressure may be
present.
WARNING
Make sure that there are no fuel leaks before closing
the engine hatch.
FUEL SYSTEM DESCRIPTION
WARNING
Visually inspect unit for fuel leaks before operating
the engine. If fuel leaks are present, DO NOT
operate the engine, contact your service center
immediately.
Fuel Control Cell (FCC) Fuel System
Some Challenger engine applications contain a Fuel
Control Cell (FCC) System.
The Fuel Control Cell (FCC) eliminates vapor lock and
air ingestion caused by fuel tank slosh, and provides the
necessary ltration and water separation required by
today’s fuel’s.
The FCC system incorporates two (2) fuel pumps to
provide an uninterrupted ow of fuel to your Crusader
Challenger marine engine. Fuel is fed into the FCC bowl
by a low-pressure, high-volume electric fuel pump. This
pump ows fuel at a volume much greater than the fuel
ow rate required of the high-pressure pump and engine
demands. The high-pressure pump, mounted inside the
FCC bowl, provides the necessary fuel pressure and
volume to maintain proper engine performance. The
FCC constantly has an ample supply of fuel to meet the
idle, cruise and acceleration fuel requirements of the
engine.
The fuel pressure regulator may be located on the fuel
rail or inside the FCC bowl, controls the fuel pressure
and maintains a constant pressure across the fuel
delivery system. Excess fuel, not used by the engine,
returns to the FCC bowl.
The fuel delivered to the engine by the FCC is ltered
by a lter and water separator element, which surrounds
the high pressure pump inside the FCC bowl.
As indicated above, fuel enters the FCC bowl from
two (2) locations, the low-pressure pump (initial input)
and the fuel pressure regulator (unused, recirculating
fuel). Fuel exits the FCC bowl at two (2) locations, the
high-pressure output to the fuel injection system and all
excess fuel in the FCC bowl is routed back to the tank
via the return line.
In-Tank High Pressure Fuel Pump System
Some Challenger engine applications contain an In-Tank
High Pressure Fuel Pump System.
The In-Tank fuel system incorporates two (2) high
pressure fuel pumps, fuel lter and fuel pressure
regulator. The In-Tank fuel system provides the
necessary fuel pressure and volume to maintain proper
engine performance. The In-Tank fuel system constantly
has an ample supply of fuel to meet the idle, cruise and
acceleration fuel requirements of the engine.
The fuel pressure regulator is located on the In-Tank
Assembly, controls the fuel pressure and maintains
a constant pressure across the fuel delivery system.
Excess fuel, not used by the engine, returns directly
inside the fuel tank.
The fuel delivered to the engine by this system is ltered
by an In-Tank lter. Consult your boat manufacturer for
proper service on this lter.
WARNING
Accumulation of water and other fuel contaminants
may form corrosive compounds that can damage
the fuel lter, and result in fuel leakage. Ethanol
blended fuel may increase this risk. For this reason,
annual replacement of the fuel lter, at a minimum, is
required to avoid risk of explosion or re.
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