Hi Guys

Could use some help. Have a 496 HO. Just had the injectors cleaned and installed a brand new cool fuel system with the help of BUP.

I have developed a leak on the end of the fuel line that plugs into the cool fuel unit. There is a small ORING on the fuel line.

Does the Oring go here. This is where it was when I took the unit apart.





or does it go here?




Next question is I am having a hard time getting the fuel line in either oring configuration shown above seated fully into the cool fuel module.

Picture below shows where the cross pin/screw that holds the line in place should go.




I didn't realize this when I first installed the line but the cross pin went through more in this area.



I been trying to get this connected for a few hours now and cant seem to get the fuel line fully seated that last 1/16 of an inch or so I have also damaged the o ring in the process and have to order another one. I have spent way to much time with this. What is the trick? Do I need a special tool?

Thanks

I feel your pain, got my new motor and after a day with the wife came in and smelled fuel. Looked in the bilge and found fuel, about an inch. Found that the pump pin was not placed in correct position, I fixed and its been good ever since

Mine used 2 O rings back to back in the first slot

Looking a Gen 2 cool fuel I'm seeing in the manual. also 2 O rings, but at BAM I'm seeing part number 25-805063 (quad ring) O ring .301x.070 (item 27)

https://www.mercruiserparts.com/bam/.../31823/6708/50

I use glycerin to insert

He has the GEN 3 cool fuel assembly - it takes a quad ring seal and Merc is the only place to get the correct one. Also I already sold him all that stuff brand new and gave out how to install all correctly. Its his first time ever doing the job so I can see where a mistake can happened.

Been looking at the ring in your pic some more, and the distance in the pic (orange lines) does not look like its .301 width. This distance is a bit less the 5/16 and 5/16 would cover the area (IMO) the bottom opening

Thanks for the feed back. Have some new quad rings on order. We will see how things go when they come in.

Bup gave me some words of wisdom.

Already shipped - Friday delivery at the address you provided and you have spares as well. Also THANKS as well

Thanks for shipping out the orings.... Bup.

Everything went back together as expected with no leaks.

Only explanation I can think of is my oring expanded and I couldn't get it seated properly. Must of been the silicone o ring lubricant I used instead of 2 stroke oil like you recommended.

Thanks again for all the help and phone call.

Take Care

How did you get your fuel line out? Mine seems stuck. It can spin around all day, but want come out. Is there a tool or am I just not pulling on it hard enough?

Check YouTube for how the different tools work. You can buy them at any auto parts store.

At the cool fuel for the fuel line there is a special screw bolt to take out first but it does not require any special tools at the COOL FUEL itself to remover the fuel line with the quad ring

And thats for the GEN 2 cool fuel and the GEN 3 cool fuel - No special tools needed for either at the cool fuel location.