Gen 3 cool fuel issue
I was reading the issue on the Gen 3 cool fuel issue in the Searay forum, and find funny that nobody in this forum mentioned anything about it, the problem seems to be serious enough. Here is part of discussion going on ............ Well, after chasing a fuel problem around for the better part of two weeks, I finally discovered an issue that Mercruiser has known about since 2004 but is in no hurry to discuss. The early model "Gen 3 Cool Fuel Module" that many of us have on our sterndrive Searays has major design issues, and not just the issue of corrosion at the raw water coolant lines that Frank W posted a while back. A larger issue concerning the fuel itself. It seems that there is a known paint delamination issue with the inside of the module where the paint peels off the casting and clogs the fuel passages, high and low pressure fuel pumps, and fuel regulator. There are also documented cases of big blocks (8.1L) where the paint gets into the fuel rail and clogs the injectors. The service tech instructed me not to run the engine at all until the repair can be made to avoid the possibility of damaging the injectors. This service bulletin covers a large range of sterndive engines including 5.0MPI, 5.7Mag350, 6.2LMPI and 8.1L. I spoke with my local dealer about my engine operating issue and he had the answer to my problem immediately. He didn't even have to test drive it as he has seen so many boats with the same issue in the last several years. It has to be a big problem when he told me that Mercruiser will pay for parts and labor 100%. I am posting a link below to the service bulletin which shows the engines and serial numbers involved (notice the date on the bulletin). The servicebulletin discusses how to check for proper vacuum and fuel pressure but it does NOT explain why you could be experiencing incorrect readings. Your dealer will confirm the why. I know there are some here like CincyAquaholic who have had this exact problem and have already replaced the filters and high pressure fuel pump. That is only a temporary fix as the paint will continue to delaminate and clog the fuel module. The entire module must be replaced to solve the problem. This module retails for close to $1K. Here's the link which covers the corrosion issue but makes no mention of the paint problem: http://www.mercruiserparts.com/bulle...2009/EN_01.PDF And the discussion goes on for many pages........ Since my boat is equipped with the same systems. I was wondering if you guys knew anything about it? I was thinking instead of spending all that money in buying the new system x2 if I could go back to install the older system that used the cartridge for water separator with no cooling system for the fuel that was install on later model to prevent vapor lock, that seems to be not a problem in colder climate like Canada Thanks for any infos L
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New Mercruiser Gen III Cool Fuel Module – Service Bulletin
All MerCruiser sterndrive and inboard engines equipped with Gen III cool fuel systems.
Models Covered Serial Number:
- All sterndrive 5.0, 350, and 377 MPI models equipped with Gen III cool fuel 1A343749 and below
- All sterndrive 496 models equipped with Gen III cool fuel 1A349420 and below
- All inboard 5.7 and 6.2 MPI models equipped with Gen III cool fuel 1A091623 and below
- All inboard 8.1 models equipped with Gen III cool fuel 1A380210 and below
- All Scorpion 350 and 377 models equipped with Gen III cool fuel 1A091623 and below
- All Tow Sports 8.1 MPI models equipped with Gen III cool fuel 1A380210 and below
NOTE: Engines equipped with the Gen II Cool Fuel System are not affected.
Situation: A new Gen III cool fuel module is being introduced to replace the existing Gen III module. Engines with serial numbers above the range listed are equipped with the new module from the factory. The primary difference between the designs is the method of connecting the cooling water hoses to the module. Refer to the Mercury Electronic Parts Catalog (EPC) for replacement modules for engines with serial numbers above the ranges listed. For models in the defined serial number ranges listed see all of the information presented in this service bulletin.
Correction: The new style module will replace any older style module for service needs. In order to use the new module on earlier applications, the cooling water hoses and various fittings must be replaced. Kits are available to accommodate the various possible hose configurations. Order the Gen III Cool Fuel Module with pumps and filter, or a lower module housing only along with the proper hose kit for installation. One module and one kit are required per engine.
Replacement kits Complete Gen III module with pumps and filter 8M0047215 Lower Gen III module housing (no pumps or filter) 8M0047216 Two bib hose kit 865317T02 Three bib hose kit 865208T02
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE. This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or otherwise, without the prior written consent of Mercury Marine. 2009-01 FEBRUARY 2009 © 2009 Mercury Marine Page 1 / 3
New Gen III Cool Fuel Module
New Gen III Cool Fuel Module—General Information Threaded hose barb fittings are supplied with the new Gen III cool fuel module. The threads on the barbed hose fittings and the threaded bore must be coated with Perfect Seal. Any removal of the fitting will require resealing the threads. Refer to the instruction sheet with the module for additional installation information.
a -Gen III cool fuel module b -Barbed hose fitting
The hose connections at the module must be secured with hose clamps. The hose connections at the restrictor are friction fit and are preassembled at the factory.
a -Gen III cool fuel module b -Restrictor c -Hose clamp d -Hose connection at restrictor
Tags: Gen II Cool Fuel, Gen III Cool Fuel, service bulletin
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