Frustrated fuel

[Claytonpa]

Hopefully I can express this in the correct way. I have a 2000 5.7L EFI that had an issue with the starter after this winter. It started up just fine and ran fine after pulling it out of storage. Took it to the lake and the starter must have not been properly tightened down and snapped the back bolt of of the staggered pattern. After trying everything except pulling the motor I decided to try a mini marine starter and it worked perfectly. Only problem was the fuel pump was leaking fuel now. So we pulled what I figured was a cool fuel gen 2. Ordered all new parts regulator and full assembly. My mechanic that is helping reinstalled everything and messaged me that it is still leaking and that he is going tomorrow to look for some new O rings. Really hope this is the issue. Not sure if new assembly came with new o rings or not. Here is a picture of original. Really hope to be on the lake this year it’s been a rough one!

 

[Claytonpa]

O rings just won’t hold! Please help

 

[Claytonpa]

Now I’m not getting spark. I’m so frustrated and lost. Cranked over fine after installing new mini starter but no fire.

 

[Claytonpa]

Here is the serial number I believe. Took it out of storage this winter and fired right up. Now after replacing only the starter and fuel pump. Not getting any fire have checked the coil and seem to be getting correct voltage everywhere.

 

[Claytonpa]

Guess I don’t know how to use this site.

 

[Scott06]

what type of ignition system is on it? Thunderbolt 5 ? If so here is a troubleshooting guide

How Mercruiser Thunderbolt ignition systems work.

Mercruiser Thunderbolt ignition systems. Mercruiser introduced the Thunderbolt IV onto their engines in 1982, alongside the introduction of the 1-R drives. The TB-IV system was used until the introduction of TB-V mid-way through 1996. Thunderbolt V was an improvement on an already exceptionally...

forums.iboats.com

so by voltage evry where with the ignition on you get 12 v to positive side of coil

 

[alldodge]

I'm seeing TB distributor but has MEFI-3 ECM, if correct the TBV troubleshooting guide will not work. Agree check for 12V at the coil

Did you get the fuel leak fixed?

 

[Claytonpa]

I'm seeing TB distributor but has MEFI-3 ECM, if correct the TBV troubleshooting guide will not work. Agree check for 12V at the coil

Did you get the fuel leak fixed?

We were getting 12v at the coil but still no luck. It’s a 21 year old boat so it was suggested by a boat mechanic that he has had issues with distributor caps so may change that next. I’m not sure on what ignition system it has it just says digital. Fuel leak was fixed until after running the pump all afternoon it started to drip again. Not sure what to do there it’s just o rings maybe epoxy? Thanks for the help I’m lost with the spark issue.

 

[alldodge]

Those O rings can get stuck and leave a thin ring behind. The new O ring may not seal because of it. The keeper pin can also be installed before the first O-ring, and if so it will leak. It needs to be installed in the groove of the line between to 2 O-rings.

Your cooler didn't look to good on the outside, and if the inside looked about the same it may need replacing.

When cranking the motor does the Tach show at least 300 RPM?

 

[Claytonpa]

Those O rings can get stuck and leave a thin ring behind. The new O ring may not seal because of it. The keeper pin can also be installed before the first O-ring, and if so it will leak. It needs to be installed in the groove of the line between to 2 O-rings.

Your cooler didn't look to good on the outside, and if the inside looked about the same it may need replacing.

When cranking the motor does the Tach show at least 300 RPM?

I replaced the entire cooler with a new one so all surfaces are clean. There are no keeper pins just push in 2 o rings. I can’t remember I believe so but will have the mechanic that’s helping me check im not around the boat anymore this weekend unfortunately. I would guess that it’s the MEFI ECM-3 would be my guess by the age of the boat. Hope it’s not the issue it’s outrageous to buy a used one!!

 

[alldodge]

There is a keep pin (screw pin) item 9 in link. Can also see it in your first pic above. Its a hex head screw

https://www.mercruiserparts.com/bam/subassembly/31886/4856/90

 

[Claytonpa]

There is a keep pin (screw pin) item 9 in link. Can also see it in your first pic above. Its a hex head screw

https://www.mercruiserparts.com/bam/subassembly/31886/4856/90

Sorry i should have looked up that part diagram. It is actually leaking at part 4

 

[alldodge]

ok, hope the o-rings used are the correct ones as in OEM or at least right size and viton or buna seals and not just ones from a HF kit

 

[Claytonpa]

ok, hope the o-rings used are the correct ones as in OEM or at least right size and viton or buna seals and not just ones from a HF kit

They looks exactly the same as the ones that came out the ones that came in the cooler assembly. I tried new metric and standard nothing fit snug. Hoping the spark has something to do with distributor not the ECM.

 

[alldodge]

If you have Merc kit all Merc and ask them. Been very helpfull

 

[Claytonpa]

If you have Merc kit all Merc and ask them. Been very helpfull

Will do thanks!

 

[Claytonpa]

Trying to find parts but everything says thunderbolt but mine says digital ignition. I think this is the same setup but not sure

Amazon.com: RPS Thunderbolt Distributor Cap and Trigger Wheel Rotor, Coil, Ignition Sensor and Spark Plug Wires for Mercruiser 5.0, 5.7, 7.4, 8.2 V8 Engines : Automotive

Buy RPS Thunderbolt Distributor Cap and Trigger Wheel Rotor, Coil, Ignition Sensor and Spark Plug Wires for Mercruiser 5.0, 5.7, 7.4, 8.2 V8 Engines: Cap & Rotor Kit - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

 

[alldodge]

You have a TB distributor but not the module. The module is part of the MEFI-3 ECM
The kit you have found should work.

 

[Claytonpa]

You have a TB distributor but not the module. The module is part of the MEFI-3 ECM
The kit you have found should work.

Thanks!

 

[Claytonpa]

Ran this diagnostic test and all I got was code 12. Hope that means the ecu is good