350 mag mpi fuel cooler removal help

[nigb]

I need to remove fuel cooler to replace the blue drain plug that has broken off & is filling bilge with water. Common fault I am told. I have removed bracket no 15 in pic but am struggling to remove bracket no 7. I have removed one of the bolts labelled no 8 but can't reach the other one or even see bolt no 9. I have removed alternator for better access. My engine bay is very tight. Appreciate any help.

 

[Fun Times]

The following should be of a few visuals of the bracket and bolts for you that may help some.

Mercury MerCruiser Service Manual (Page 15 of 44) | ManualsLib

www.manualslib.com

Mercury MerCruiser Service Manual (Page 16 of 44) | ManualsLib

www.manualslib.com

Gen Iii Cool Fuel Module Installation - Mercury MerCruiser Service Manual [Page 27]

Mercury MerCruiser Manual Online: Gen Iii Cool Fuel Module Installation. 1. Connect the primary mounting bracket to the Cool Fuel Module. Torque to specification. Description Primary bracket screws (Cool Fuel Module) 2. Connect the support bracket to the Cool Fuel Module. Torque to...

www.manualslib.com

Are you able to reach the blue plug area... Maybe instead of removing the whole unit you could try working first on getting the plug out using something tool wise to unscrew it out as the threaded end shouldn't really be in there that tight/stuck per se.

 

[Scott Danforth]

Drill two small holes next to each other in the plastic plug, drive a screwdriver into it and turn it out

Those plastic plugs need to be replaced every few years

 

[nigb]

Thanks for the replies the pictures are a great help. No room to get a drill in. The screwdriver trick I have used before on motorcycle fittings & it works. I didn't think it would be that tight & used an eziout but that didn't work just chewed the plastic up. I can't believe mercruiser use such a crappy plug - could sink a boat potentially

 

[Scott Danforth]

I can't believe mercruiser use such a crappy plug - could sink a boat potentially

its cheaper than the good stainless versions. its up to the owner to inspect and replace as needed during the annual PMs

 

[alldodge]

Many have had success with a easy out
If you not in salt water I would use a hardin marine stainless steel plug

 

[nigb]

Yep pics were big help. Got it off within 5 minutes. Reassembling was a pia as very little room to move in front of engine bay even a struggle getting serpentine belt on. Thanks guys for the replies & help. Great forum.

 

[Fun Times]

Yep pics were big help. Got it off within 5 minutes. Reassembling was a pia as very little room to move in front of engine bay even a struggle getting serpentine belt on. Thanks guys for the replies & help. Great forum.

Glad it all worked out for you...Sometimes walking away and coming back to it is a big help too.

 

[nigb]

Glad it all worked out for you...Sometimes walking away and coming back to it is a big help too.

Yes last statement definitely worked!

 

[04fxdwgi25]

its cheaper than the good stainless versions. its up to the owner to inspect and replace as needed during the annual PMs

Actually, buying the Hardin S/S plugs is cheaper (when bought in a pack of 5 for $25) than the OEM plastic ones.

Have used the Hardins in my last 3 boats and have never had a problem with them.

Amazon has the blue plastics for $10 for 10 (but bet they are cheapie Chicom knock offs)

Stainless Steel Sea Pump Drain Plugs - Mercruiser 22-806608A02 (5 Pack) - Hardin Marine

Stainless Steel Sea Pump Drain Plugs - Mercruiser 22-806608A02 / 8M2000874 (5 Pack)

www.hardin-marine.com

 

[Scott Danforth]

I was referring to it being cheaper for Merc. the plastic ones are about 7 cents to buy, the stainless ones are about $1. retail is a completely different matter.