Water Leak - Gen 3 Cool Fuel

[The-Russ]

I noticed a significant water leak at the intake of my Cool Fuel block. I spoke with Mercury and they informed me that they changed the design and I needed to purchase a new Cool Fuel Block and a new hose kit. No other option was available and it is over $500 worth of parts.

After further research on this site, I found a guy that CNC'd a stainless version of the part that he says will fix it forever, Max McAllister max@traxxion.com.

I will post pictures of the part and installation.

 

[rondds]

Just went through this...

You could pull the unit and take it to a machine shop, have the water inlet/output holes drilled and tapped for 3/8" NPT.

http://clubsearay.com/showthread.php/66600-Replacing-Cool-Fuel-III?highlight=

 

[Jeremygavin]

I had the fittings leaking on one of my CF3 units last year, 2005 with only 193hrs on it. I chose to change out both units entirely including the pumps. This was not cheap, cost about $1700 total. I am not sure it was the right answer but with a 2005 boat and all the unknowns ethanol has created, I like the idea of starting over with everything. The CF3 units have 3 problems, the older style non-hose clamp water fittings corrode and leak, the body of the unit itself will corrode internally and you end up with cooling water in your fuel system ( bigger problem in salt water) and the paint peals off from the inside of the unit ( mostly the top cover although I had a little missing from the side wall on one of my units.) and could possible clog the injectors. Drilling the fittings out and threading for barb connectors is the cheapest fix but will only fix the first problem, changing just the CF3 body and not getting the whole new unit including both pumps and their housings will solve problems #1 and #2. Changing the whole thing will solve all three potential issues (at least for the next few years). I am firm believer in preventative maintenance and repairs so if I have a known problem I fix it as best I can before the problem arises. I don't want to have the issue come up on the next nice weekend and strand me at the dock. It really depends on how much you want to spend now to head off future problems now or save some money now and wait and see when they if show up later.