Replacing Gen Cool Fuel III units - complete

Katemma Life

Member
Oct 7, 2018
135
cape cod
Boat Info
2007 sea ray 290 SLX
Engines
Twin mercruiser MAG 350 MPI w/ Bravo III
Spent the day upside down (literally) in the engine compartment backing out bolts that were up against engine mounts, impossible to get to and every other thing.
Got the old (leaking) unit free, only to find I can not slide the fuel line out of the fuel pump portal. Its frozen on. I disconnected the fuel line from the fuel rail - moved the entire thing to the work bench and went at it with all my strength and, no budging.
Now need to order new fuel line kits that wont come in until mid next week... what an ordeal! Any one have any ideas on how to get the fuel line out?

cool fuel.jpg
 
I changed both port and starboard modules myself and the most difficult part was pulling out the fuel line. It takes much pulling and wiggling but it will come out.
TIP- use a new o ring when replacing the fuel line.
 
I have to ask.....you took the bolt out, right? Just turn it on end and soak it in penetrating oil - did you get the special o-rings to put it back together?
 
I did remove the screw - should have mentioned that. Also, why the hell doesnt mercury send a new quad ring for replacing the line? do I have to buy those from a mercury rep? would be nice to work on this this weekend.
I will try soaking it in penetrating oil but I have already put ALOT of force on this thing...
 
fred - can I use any o-ring when replacing the line or does it need to be this quad ring from mercury?
 
fred - can I use any o-ring when replacing the line or does it need to be this quad ring from mercury?
It’s a special split o ring. You must use the correct one.

Of course this is a safety issue on the high pressure side of the pump.
 
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allright. ran around and got two of these rings. no clue why they call em quad rings. theyre as round as anything.
got something to do for the weekend now. :)
thanks for the direction fellas.
 
Is the fuel line sacrificial now, meaning that you are going to replace it? If that decisions has been made, a pipe wrench can help you wiggle the line.
 
i ended up getting it out. so I will reuse it. It was hell to get it out of there though
 
Did any of you put hose clamps on the water hoses where they connect over the plastic barbs? The guy at mercury marine didnt even know wether I should or not. Directions call for the perfect fit goop but seems a hose clamp is in order...??
 
I used hose clamps.
 
success. I did have an air lock issue with one of the engines but after I removed the filter cover the fuel flowed and ... success. Thanks so much for your help. This site is wonderful
 

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