8.1 Fuel Cool Fuel Pump issues

[Butch5220]

I have a 2009 Sundancer with the 8.1. The paint in the fuel pump has come loose and clogged the injectors. Fuel rail is full of paint too.
Question 1: Pump appears to be in good condition. Can I just remove the paint and run it with no internal paint?
Question 2: Can I replace it with a Volvo pump and bypass the water cooling? Cost is about 1/10th of a Mercruiser pump.
I expect to get beat up about the Volvo question.
Thanks in advance.

 

[scoflaw]

Yes to removing the paint in the fuel cooler that will work. I have no idea about the VP pump

 

[Korkie]

If you take it to a Mercruiser dealer they can contact Mercruiser to get your entire fuel system replaced from the Cool fuel unit to the injectors. Mercruiser has known about this for several years a;though there is really no "service bulletin" published. The dealer will need your engine serial numbers. Will also need to take some pics of the fuel cooler, the fuel regulator and do some fuel pressure testing. If you qualify, and you should, Mercruiser will supply the parts through your authorized Merc dealer / Service center. Only catch is they have ro be installed by the Merc dealer and that cost is on you. I had it done 2 seasons ago. Merc supplied 2 bramd new cool fuel units that included the new style sea water inlet hose fittings to replace the presure fittings along with all new pumps, regulators, etc. It was as simple removal of the old and put the new one on. All the other parts were on back order, so Merc paid to have everything sent out and professionally cleaned. All in all, cost me $750 labor. What a difference in performance and power.
If your regulators look like this you shouldn't have an issue getting it approved.

 

[boatrboy]

View attachment 143685 View attachment 143686 If you take it to a Mercruiser dealer they can contact Mercruiser to get your entire fuel system replaced from the Cool fuel unit to the injectors. Mercruiser has known about this for several years a;though there is really no "service bulletin" published. The dealer will need your engine serial numbers. Will also need to take some pics of the fuel cooler, the fuel regulator and do some fuel pressure testing. If you qualify, and you should, Mercruiser will supply the parts through your authorized Merc dealer / Service center. Only catch is they have ro be installed by the Merc dealer and that cost is on you. I had it done 2 seasons ago. Merc supplied 2 bramd new cool fuel units that included the new style sea water inlet hose fittings to replace the presure fittings along with all new pumps, regulators, etc. It was as simple removal of the old and put the new one on. All the other parts were on back order, so Merc paid to have everything sent out and professionally cleaned. All in all, cost me $750 labor. What a difference in performance and power.
If your regulators look like this you shouldn't have an issue getting it approved.

What Keokie said is true - But Just beware - my boat has been at the dealer since October since they said they would do this service over the winter if I stored the boat there. They replaced all the injectors in December BUT, they are only replacing the cap assemblies and they are Still on back order until the end of May. They can’t start the motors with suspect pumps since they changed the injectors already.
They are not replacing the entire housing assemblies according to merc. I call them every couple of weeks and they apologize and assure me I’m on the priority list, but this is very frustrating.

Good luck - maybe your dealer will have the in stock??

 

[Korkie]

It is all on how it is presented to Merc. wether you get the modules or the just the covers. Washburns in Solomons, MD did mine and 4 others the same year. I know to get the entire module you have to state the raw water pressure fitting is failing as the new ones have the barbed fittings.
The service manager there at the time knew exactly how to present it to get the modules as a unit.

 

[Skyman2112]

View attachment 143685 View attachment 143686 If you take it to a Mercruiser dealer they can contact Mercruiser to get your entire fuel system replaced from the Cool fuel unit to the injectors. Mercruiser has known about this for several years a;though there is really no "service bulletin" published. The dealer will need your engine serial numbers. Will also need to take some pics of the fuel cooler, the fuel regulator and do some fuel pressure testing. If you qualify, and you should, Mercruiser will supply the parts through your authorized Merc dealer / Service center. Only catch is they have ro be installed by the Merc dealer and that cost is on you. I had it done 2 seasons ago. Merc supplied 2 bramd new cool fuel units that included the new style sea water inlet hose fittings to replace the presure fittings along with all new pumps, regulators, etc. It was as simple removal of the old and put the new one on. All the other parts were on back order, so Merc paid to have everything sent out and professionally cleaned. All in all, cost me $750 labor. What a difference in performance and power.
If your regulators look like this you shouldn't have an issue getting it approved.

Wow you can get it replaced on a 2009 boat or does it have to be under warranty still??? I think im having the same problem.

 

[Korkie]

You can get the system replaced/repaired on any boat that has the defective Cool Fuel unit on it. It is not a warranty. It is not a service bulletin. Basically you find out about it and petition SR for the fix. They provide the parts as requested by an Auth Merc Service facility and you pay that facility to do the repair.
Mine cost me $400 total for both motors.

 

[jmauld]

Wow you can get it replaced on a 2009 boat or does it have to be under warranty still??? I think im having the same problem.

Doubtful that you have the defective pumps on that boat. I have a 2010 which already had the cool fuel 3 pumps which aren’t covered

 

[boatrboy]

Mine cost me $400 total for both motors.

Wow - I’m assuming that’s a typo as when we talked about this in another post, you stated $600 per engine and provided me details. Even at that it was a great deal.
I was quoted last year by one dealer $1100 per engine but they would not guarantee Merc would cover it. They said once it’s all apart I would pay for the parts if not covered. I found another dealer who just completed this as I mentioned in another post.
Korkie - I wish I was in MD.

 

[Korkie]

Sorry - Yes it was. Looking at the invoice, the fuel system work directy related to the cool fuel issue was $400 each motor, about 3 hours labor each. The cost for everything we had done was $1200 total. That included the haul out charges and some other minor things we had done as well. It doesn't matter where you are. All Auth. Merc dealers have the ability to make this happen. They just have to want to.