Gen II Cool Fuel box leak

njsr2002

New Member
Jul 3, 2011
30
NorthEast
Boat Info
2002
Engines
4.3 liter MPI Mercruisers. Alpha, Gen II
I have Gen II Cool fuel set up on a 280 Sundancer 2002.


This spring on start up, it starting having a slow fuel leak from the cool fuel box. My mechanic took the whole box out, and tested it in his shop. He pressurized all the lines with air and looked for a leak. Guess what ?? NO LEAK detected. I even sat there and watched him it. Next, he's going to setup a fuel tank and try running the pump with fuel running through and see if it shows up.

Anyone else run into a problem like this ?? Anything we're missing ??

He says he doesn't like to just replace parts without knowing for sure if they are faulty. I'm inclined to replace all seals or O rings. It's costing me about $1000 in labor just to get access to the box. He had to tear down the manifold, P/S unit, and trim pump,to get access What a design nightmare !!!
 

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