Collapsed Fuel Filter

[hoowahfun]

1987 Mercruiser 3.0, S/N B515218.

Has anyone ever seen this happen? Fuel filter crushed and starting to separate. Came in a fuel pump I bought on Amazon less than a year ago. Any thoughts on what could cause this? Cheap junky parts maybe?

I've only had this boat out two times since I bought it and made some repairs. I noticed the 2nd time out that once I got to 3000 rpm, it didn't get higher. No bogging just low WOT rpm. Verified the throttle opened up all the way. Went to start it today to make sure everything was good since I planned to take the family out tomorrow and it wouldn't start, but could *kind of* keep it going if I continued to pump the throttle, but that wouldn't last long.

The carb is recently rebuilt, but I took it apart and checked/cleaned it again anyways but didn't see anything that would make me think the carb was clogged. Tank inlet screen was clear. Then checked the fuel filter and found this. There was some sediment in the filter bowl, but didn't see enough of anything in there to make me think it clogged enough to collapse it like that.

Could all my symptoms be related to this? I tried throwing in the old stone filter that came out of the previous pump that was failed, but still had a no-start condition. Who knows how old that thing is so it could be clogged as well. My next step is to remove the fuel pump and make sure all the fuel lines are clear. I have a feeling something from this filter coming apart and collapsing clogged the fuel pump or line, or something got past it and clogged it.

Any recommendations on a quality fuel filter other than OEM?

Sorry for all the questions, kind of venting my frustration while trying to troubleshoot lol. Thanks!

 

[GA_Boater]

Your problem between the tank and filter, not after the filter.

Something is blocking the fuel and the filter is crushing. Or a junk filter that collapsed. Try a new filter before getting carried away. Was any crud in the filter pleats?

 

[hoowahfun]

Filter didn't look all that dirty which was surprising. However, before my first time out I had some trouble starting and ended up having the inlet screen on top of the tank clogged by a bug, restricting fuel flow. Cleared it out and it started right up. Maybe that incident killed the filter?

 

[GA_Boater]

Filter didn't look all that dirty which was surprising. However, before my first time out I had some trouble starting and ended up having the inlet screen on top of the tank clogged by a bug, restricting fuel flow. Cleared it out and it started right up. Maybe that incident killed the filter?

That bug could do it. The pump would have tried to suck the bug up to the filter, causing the filter to pucker.

 

[hoowahfun]

Man what a bummer on something so simple. Guess that kills boating plans tomorrow. Might end up being a good thing since I've been a little nervous taking it out on a busy holiday without much boating experience.

Will follow up once the new filter is in place. Thanks!

 

[hoowahfun]

Okay so here's an update: bought a genuine mercruiser fuel filter to put in and this time I was able to get it started by pumping the throttle a bit and could get it to hold about 1000 rpm. It struggled at first, but then something changed and it started to hold at 1000 rpm. There was a noticeable difference in sound, but can't really describe it. I also noticed the carb was making some kind of a weird suction noise that changed when I placed my hand over the side of the flame arrestor. I also heard a strange squeaking sound, but went away before I thought it might be good to source where it was coming from. I don't recall hearing any of that before all this started.

Before I put the filter in I took off the pump and took it apart to make sure nothing was stuck, didn't find anything but blew it out anyways. Also blew out the metal fuel line between the pump and carb. Diaphragm looked good and was still soft and flexible.

After my test, I took out the sending unit on the fuel tank so I could get a good peak inside. Looked pretty clean, just a small amount of sediment in the bottom. Inlet screen and check valve are clear and is moving freely as far as I can tell. I used my boroscope and a flashlight to make sure nothing was stuck between the tank and the bottom of the pickup tube, it was clear as well.

After this I noticed a small melted spot on the flexible fuel hose between the tank and pump so I took it off and cut it in half to see if it was maybe damaged. Didn't noticed anything out of the ordinary but decided to replace it anyways since it looked pretty old, have a section on order.

Only thing I can think of next is to go back to the carb and double check all my work and re-clean everything. Thoughts anyone?

 

[hoowahfun]

So I went though the carb again for the 3rd time and ran wire through every hole and passage, cleaned with brake cleaner, and blew it out. Verified all measurements and adjustments to spec. Reinstalled and still has the same problem. I think at this point it's safe to say it's not the fuel system. I've been through everything and the fuel pump is brand new.

While I had it "pumped up" and running around 1000 rpm, I decided to pull the plug wires off the distributor cap one by one while it was running to see what would happen. The first two, made absolutely no difference in the way it was running which I thought was odd. Not even a spark when I pulled the wire off. The third one immediately caused the engine to stumble, sparked, and I quickly tried to put it back in to keep it going, but it died on me. I tried to restart it briefly after that, but no luck and had to clean up for dinner.

Now I'm thinking I have a spark issue and this thing is trying to run on maybe 2 cylinders?! Could be why I couldn't get over 3000 rpm last couple times out, maybe I had cylinders dropping out for some reason. Would also explain the fuel smell while running at low speed or on the hose....not all my fuel is being combusted.

My system has the Pertronix Ignitor module in it with new plugs and plug wires and what looks like the original coil. I'm thinking it's probably the ignition module or the cap.

Any thoughts?

Edi: the rotor is also new.

 

[Scott Danforth]

check the cap or wires

 

[hoowahfun]

Ordered a new cap since I'm unsure on the age of the old one. The contacts under the cap didn't look that bad, but you never know.