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:
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