8.1 Fuel Leak, Sourcing a Replacement Fuel Rail

[Scotty370]

Ahoy,

New to forum, seeking help with an 8.1 in a SeaRay 370.

In the process of diagnosing suspected faulty injector number one on port engine (physically swapping injector one with neighboring injector three, to see if fault follows), I encountered a fuel leak at the fuel rail/supply quick connect. Confirmed the leak when cycling high pressure pump with injectors installed on rail, but with injectors resting on shop towels before re-installation into intake/plenum (checking for closed injector pintle leak). Hoping for just an o-ring to be re-seated, I removed surface rust and proceeded to disconnect fitting. The fuel rail end was rusted through and fatigued. It didn't take much force to break by hand while trying to separate from fitting. The fitting's plastic spacer between the o-ring and retainer was seized on the rusted fuel rail end. I replaced spacer, washers, o-rings, and retainer on female fuel supply line. Now I'm left with a rusted broken off end on the fuel rail. Attached pictures below for reference.

I've spent quite some time trying to locate a replacement fuel rail, and at least the starboard side segment of the "H" assembly that houses the fuel dampener and has fuel supply quick connect end. The engine is a 2004 Mercruiser 8.1S Horizon Inboard, serial 0M319125 thru 0W089999. Discontinued Mercruiser OEM part number for fuel rail is 881691 or 881691001. This is a single line fuel system with a two line fuel rail (the return line is capped off). I see these 8.1 fuel rail/line woes have come up in previous posts here. I considered the Volvo Penta (PN: 3817696) or GM truck (PN: 12575055), but these are either ridiculously overpriced or not available anywhere, respectively.

Has anyone recently sourced one of these fuel rails successfully?

Does anyone know if the Crusader 8.1L fuel rail (PN: RA086001A) from 2007, is compatible? I tried reaching out to Crusader directly to confirm compatibility. They said they have no way of knowing if it's compatible. I found Crusader to be available and less than half the cost of the Volvo Penta (PN: 3817696).

I was also hoping to provide a sort of a public service announcement about the fuel line to fuel rail fitting. It seems the fuel line is left unsecured with no strain relief running from fuel cooler to fuel rail, with weight of line resting on the quick connect fitting.

I'm not expecting anyone to provide me with a direct amazon link. Any help would be greatly appreciated, to get me pointed in the right direction.


Thanks in advance!

 

[Ididntdoit]

Try an 8.1 chevy truck application

 

[Bill Curtis]

Wonder if that is the same as a std GM 8.1 fuel rail? Mercuiser sites show NLA, but places have them available for the 8.1 GM. I did the crusader at substantially less than the Mercruiser had but NLA.

Did you look at ebay?

 

[Scotty370]

Thanks for the quick response!

Try an 8.1 chevy truck application

You're right. I was leaning towards the Chevy truck application at first, thinking it would be cheaper and more readily available. Then simply prep the exterior surface for a marine application. However, searching through all of the suppliers, currently they all appear to be out of stock.

Wonder if that is the same as a std GM 8.1 fuel rail? Mercuiser sites show NLA, but places have them available for the 8.1 GM. I did the crusader at substantially less than the Mercruiser had but NLA.

Did you look at ebay?

It appears to me to be the same as the GM 8.1 fuel rail. Where have you seen the 8.1 GM fuel rail available? It's been out of stock everywhere I look. Of course, I'm still keeping tabs on ebay.


In reference to the GM truck application, can anyone confirm if the fuel pressure regulator housing on the rail is the same tolerance/dimensions as marine? I assume all of these fuel rails are manufactured to same spec.

 

[JHornsby3]

8.1L Fuel Rail without Fuel Return | Crusader RA086001A (marinepartssource.com)

Product Details | SimplePart (wholesalegmpartsonline.com)

Here is two of many that I found. Another great source for GM engine parts is gmparts.com. This is where I got my injectors for my diesel pick up when the dealer couldn't get them. And I paid over $300 less per injector.

 

[Bill Curtis]

Here is one for a crusader 8.1. Is it different, have no idea.They have 4 in FL warehouse right now.
One of 1st to pop up on Google
https://marinepartssource.com/catal...MIjcT-3aaQgAMVA4rICh2p7g3MEAQYASABEgIX_fD_BwE

 

[Raul]

Ahoy,

New to forum, seeking help with an 8.1 in a SeaRay 370.

In the process of diagnosing suspected faulty injector number one on port engine (physically swapping injector one with neighboring injector three, to see if fault follows), I encountered a fuel leak at the fuel rail/supply quick connect. Confirmed the leak when cycling high pressure pump with injectors installed on rail, but with injectors resting on shop towels before re-installation into intake/plenum (checking for closed injector pintle leak). Hoping for just an o-ring to be re-seated, I removed surface rust and proceeded to disconnect fitting. The fuel rail end was rusted through and fatigued. It didn't take much force to break by hand while trying to separate from fitting. The fitting's plastic spacer between the o-ring and retainer was seized on the rusted fuel rail end. I replaced spacer, washers, o-rings, and retainer on female fuel supply line. Now I'm left with a rusted broken off end on the fuel rail. Attached pictures below for reference.

View attachment 147584 View attachment 147585 View attachment 147586 View attachment 147587

I've spent quite some time trying to locate a replacement fuel rail, and at least the starboard side segment of the "H" assembly that houses the fuel dampener and has fuel supply quick connect end. The engine is a 2004 Mercruiser 8.1S Horizon Inboard, serial 0M319125 thru 0W089999. Discontinued Mercruiser OEM part number for fuel rail is 881691 or 881691001. This is a single line fuel system with a two line fuel rail (the return line is capped off). I see these 8.1 fuel rail/line woes have come up in previous posts here. I considered the Volvo Penta (PN: 3817696) or GM truck (PN: 12575055), but these are either ridiculously overpriced or not available anywhere, respectively.

Has anyone recently sourced one of these fuel rails successfully?

Does anyone know if the Crusader 8.1L fuel rail (PN: RA086001A) from 2007, is compatible? I tried reaching out to Crusader directly to confirm compatibility. They said they have no way of knowing if it's compatible. I found Crusader to be available and less than half the cost of the Volvo Penta (PN: 3817696).

I was also hoping to provide a sort of a public service announcement about the fuel line to fuel rail fitting. It seems the fuel line is left unsecured with no strain relief running from fuel cooler to fuel rail, with weight of line resting on the quick connect fitting.

I'm not expecting anyone to provide me with a direct amazon link. Any help would be greatly appreciated, to get me pointed in the right direction.


Thanks in advance!

Good morning Scotty370 , I own a Monterey 268SS with a 496 Volvo Penta . I have a leaking fuel rail. No luck finding a part. GM does not make part anymore. Wondering if you were able to solve or locate a replacement?

 

[Jesse Wichelhaus]

Good morning Scotty370 , I own a Monterey 268SS with a 496 Volvo Penta . I have a leaking fuel rail. No luck finding a part. GM does not make part anymore. Wondering if you were able to solve or locate a replacement?

Raul....do you still need a fuel rail? I have one if needed.