Page 1 of 6 123 ... LastLast
Results 1 to 10 of 60
  1. #1
    Join Date
    Oct 2006
    Location
    None
    Boat
    Of
    Details
    Your
    Engine(s)
    Business
    Posts
    1,239

    *Gen 3 Cool Fuel Module Issue*

    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 service bulletin 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
    Last edited by jg300da; 05-16-2012 at 06:19 AM.

  2. #2
    Join Date
    Jul 2011
    Location
    Orange Beach, AL
    Boat
    Key West
    Details
    2014 219FS Keywest CC
    Engine(s)
    F200 Yamaha Outboard
    Posts
    597

    Re: *Gen 3 Cool Fuel Module Issue*

    Cannot get the link to open?

    2009 260 Sundeck (Sold)

  3. #3
    Join Date
    Dec 2007
    Location
    Newport, RI
    Boat
    Sea Ray
    Details
    300 Sundancer
    Engine(s)
    5.0MPI Bravo III
    Posts
    1,112

    Re: *Gen 3 Cool Fuel Module Issue*

    Recently had an extensive thread on this exact issue

  4. #4
    Join Date
    Dec 2008
    Location
    Sarnia, Ontario, Canada
    Boat
    Sea Ray
    Details
    340 Amberjack
    Engine(s)
    twin 8.1S 370 Hp + 4.5 Westerbeke Genset
    Posts
    1,414

    Re: *Gen 3 Cool Fuel Module Issue*

    Also cannot get the link to open...
    Posted by Jim of "Island Rhythm"
    2001 Sea Ray 340 Amberjack
    LOA 38', approx 18,000 lbs & 13.5' Beam
    Straight Shaft Drives


  5. #5
    Join Date
    Jul 2011
    Location
    Lake Michigan (IL/WI border, Southport Marina E Dock)
    Boat
    Sea Ray
    Details
    '05 Meridian 368 MY, '11 Baltik BA95 Dinghy, '99 GP1200, '03. Still a Sea Ray lover at heart!
    Engine(s)
    8.1L HO Mercruiser (840 horse), 10kw Kohler Genset, Torqueedo 1003 for Dinghy
    Posts
    614

    Re: *Gen 3 Cool Fuel Module Issue*

    How can you determine what gen 'cool fuel' we have...

  6. #6
    Join Date
    Dec 2008
    Location
    South Eastern US
    Boat
    Boatless at the moment
    Details
    Boatless
    Engine(s)
    Boatless
    Posts
    167

    Re: *Gen 3 Cool Fuel Module Issue*

    Is ethanol the culprit here in terms of dissolving the paint?

  7. #7
    Join Date
    Sep 2008
    Location
    Fort Mill, SC / Lake Wylie
    Boat
    Sea Ray
    Details
    2005 280DA, Lowrance HDS7, Windlass
    Engine(s)
    T-5.0 MPI Closed Cooling w/ Bravo Three Drives; Kohler 5E Genny
    Posts
    3,319

    Re: *Gen 3 Cool Fuel Module Issue*

    Quote Originally Posted by psubill78 View Post
    How can you determine what gen 'cool fuel' we have...
    The Cool Fuel Gen 3 System referred to here was introduced by Mercury in 2005. From a Sea Ray standpoint, based on owner reports, many 2005s have it and a few don't. I guess alot depends on back stock of engines at the plant when a given boat was produced. If your engines are original '98 models you do not have Cool Fuel 3 but possibly CF2. I am not as familiar with the lineage of CF2 so can't speak as to when it was introduced. My 2003 had CF2.
    Last edited by jason78; 05-15-2012 at 11:51 PM.

    2005 Sea Ray 280 Sundancer
    Twin-5.0MPI Bravo III, Kohler 5E
    Other: 1997 Boston Whaler 20 Outrage, 200 Merc

    Previous Boat- 2003 Sea Ray 225 Weekender 5.0MPI Bravo III
    Previous Other- 2004 Yahama XLT1200 Waverunner

  8. #8
    Join Date
    Nov 2009
    Location
    Beaufort, SC
    Boat
    Sea Ray
    Details
    2001 400DB / 2009 175 Sport
    Engine(s)
    Cummins 6CTA / 3.0L Merc, Alpha 1
    Posts
    1,755

    Re: *Gen 3 Cool Fuel Module Issue*

    Quote Originally Posted by jason78 View Post
    The Cool Fuel Gen 3 System referred to here was introduced by Mercury in 2005. From a Sea Ray standpoint, based on owner reports, many 2005s have it and a few don't. I guess alot depends on back stock of engines at the plant when a given boat was produced. If your engines are original '98 models you do not have Cool Fuel 3 but possibly CF2. I am not as familiar with the lineage of CF2 so can't speak as to when it was introduced. My 2003 had CF2.
    Three cheers for 2004 models. You get Smartcraft but don't get cool fuel 3. On my 2004 I have external inline fuel filters for each engine (in addition to water separator filters). That may be an indicator you don't have CF3 if you are not sure as I believe the CF3 has the fuel filter inside the module.
    -- Bill

    2009 Sea Ray 175 Sport
    2001 Sea Ray 400DB

  9. #9
    Join Date
    Oct 2006
    Location
    None
    Boat
    Of
    Details
    Your
    Engine(s)
    Business
    Posts
    1,239

    Re: *Gen 3 Cool Fuel Module Issue*

    It looks as though the "Gen 3" module was introduced in 2005 and was installed for at least 3 model years or longer as my boat is a 2007. Pictures of the module can be seen in Dave's thread here...

    http://clubsearay.com/showthread.php...en+fuel+filter

    Daves thread covers in detail the filter changing aspect of the module but doesn't discuss the delamination issue.

    If the service bulletin link doesn't work for you just google Mercruiser service bulletin 2004-06. The engines and serial number affected are listed on page 1.

  10. #10
    Join Date
    Oct 2006
    Location
    None
    Boat
    Of
    Details
    Your
    Engine(s)
    Business
    Posts
    1,239

    Re: *Gen 3 Cool Fuel Module Issue*

    Quote Originally Posted by Ididntdoit View Post
    Recently had an extensive thread on this exact issue
    I was able to find it, thanks. Looks like boats all the way up to 2009 were affected.
    Last edited by jg300da; 05-16-2012 at 06:18 AM.

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •