Mercruiser 4.3 EFI leaking fuel but can't find leak??

CLi87

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Sep 21, 2018
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I have a Mercruiser 4.3 EFI engine and it appears to be leaking fuel from somewhere but I can't for the life of me figure out where and it's driving me crazy. I've run the engine on the hose for over an hour with no visible fuel leak, I traced the lines from the fuel filter to the fuel pump up to the fuel rail, checked area around all the injectors, and checked the return line, absolutely no visible trace of fuel but once it sits overnight, there's a puddle of fuel in the bilge the next morning, looked all over but don't see any fuel dripping or wet areas anywhere that I can see, anyone have any idea where else to possibly look that I may be missing?
 

Bondo

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but once it sits overnight, there's a puddle of fuel in the bilge the next morning,
Ayuh,.... How about the fuel line to the tank,..??
Or the tank sender,..?? or the tank itself,..??
 

dingbat

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Nov 20, 2001
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line, absolutely no visible trace of fuel but once it sits overnight, there's a puddle of fuel in the bilge the next morning, looked all over but don't see any fuel dripping or wet areas anywhere that I can see, anyone have any idea where else to possibly look that I may be missing?
The last two gas leaks I found where both on the bottom of the fill hose at the bend where it enters the fuel tank.

Only "leaked" after fueling up and or out bouncing around in rough water
 

CLi87

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Sep 21, 2018
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Ayuh,.... How about the fuel line to the tank,..??
Or the tank sender,..?? or the tank itself,..??

Those were the next things I was planning on checking, access is pretty limited on this boat though, it's a 2003 Ebbtide Campione 210, really really dumb designed boat, access is extremely difficult to a lot of things, I guess I'll go unscrew the floor hatch and lift it up to take a look around.
 

CLi87

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The last two gas leaks I found where both on the bottom of the fill hose at the bend where it enters the fuel tank.

Only "leaked" after fueling up and or out bouncing around in rough water

It's not completely full on gas and it's leaking just sitting there not being used (-_-)
 

Jeff J

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Jun 23, 2021
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Could it becoming from the fuel pump? The 4.3 EFI here had the pump conveniently located on the port side behind the motor mount with a plastic cover hiding it. There wasn’t any access to inspect it. Replacing it required the motor to be lifted.
 

cyclops222

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Simple and cheap way to find leaks.
Cut cardboard into smaller pieces and slide them under the complete engine area. Also under fuel line and rubber hose.
 

ESGWheel

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Aug 29, 2015
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You did not say but I assume this is a newly discovered issue. In other words, you have been using the boat all season with no issues and one day went to the boat and strong smell of gas and discovered the puddle in the bilge. Is that correct? Also was any maintenance or other work done recently?

Not sure what year boat but rubber fuel lines do not last forever. When you checked them for dampness, did you notice any hairline cracking of the hoses? If there is sufficient play, try bending any hose with hairline cracks to see if they are really deeper than they appear. Also check the tightness of any / all clamps. Note if they are the perforated worm gear type clamps, the perforation of the clamp can cut into the hose and cause premature hose failure, so look carefully there as well.

The evaporative nature of gas is probably what makes it hard to find wetness when feeling around on the hoses, etc. given it’s a very slow leak. Thus, one way to capture the culprit is to wrap the area with a paper towel and then also put a wrap of cling wrap (fm the kitchen) around it too. With these multiple diapers around the components (including the fuel pump) ‘sealed up’ by the cling wrap, any leaking component should have a wet diaper after some time (overnight).

If all else fails, talk to your local garage that has an emissions tester. These testers can detect unburned hydrocarbons (ie unburned gas). Idea here is with their help they can wave that wand around inside the boat and hopefully get a high reading around the source of the leak.

And to reiterate what Scott said: do not use it, heck I would be even reluctant to start it!

Good luck and please post questions and finding.
 

CLi87

Petty Officer 1st Class
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Sep 21, 2018
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Finally found the leak I believe, I opened the floor hatch and found all the support beams broken and the fuel sender unit had one screw that was not in because someone had stripped out a previous screw so the fuel was coming from the part that wasn't sealed.
 

ESGWheel

Senior Chief Petty Officer
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Aug 29, 2015
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That is great news, but I remain skeptical. The sending unit is typically (always?) at the top of the tank and unless the tank is 'full full' I do not see how it would weep out of that missing screw hole or the cover (due to not being fully clamped onto the tank). Can you take a picture of this area and post it?

Also, of perhaps equal concern, is your comment about support beams being broken…. This sound like the integrity of your hull is in question and thus until proper repairs should not be used. Can you post a picture of those broken beams as well?

Not trying to be a naysayer, my concern is for your safety. Thanks.
 

cyclops222

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I found fuel caps with fuel caps that built up massive tank pressures. They can pressurize the fuel line to the engine during late afternoon to sundown. Causing a fuel loss almost anywhere the fuel line runs.Your missing screw should prevent any pressure build up. But it will force heated and expanding gasoline out that missing screw hole. A carefully wider hole and screw might cure the leak.
 
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