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Thanks for helping me learn! A question for IG30- seems a smaller amount of water goes out your exhaust mixer and more out the side? Why would a boat manufacturer not want all the water going out and cooling the exhaust? Easier path is water out the side instead of overcoming exhaust pressure so...

From Valvoline: Coolant 101 What Does Coolant Do for My Engine? The primary purpose of coolant is transferring heat and preventing engine damage caused by freezing or boiling. From Caterpillar: Coolants Cat Coolants provide excellent protection against boiling and freezing to prevent component...

The pressure also raises the boiling point as does the coolant. Just look it up. Race cars also dump the mixture after every race....something none of us will do.

What!? The main benefit in our cooling systems is "anti-boil" and at 50/50 it raises the boiling point to 265 degrees (I just read that). A lower solution as you suggest lowers the boiling point and gets one closer to spontaneous boiling of the solution in contact with the very hot combustion...

You said specifically it is pushing "coolant out around the header tank cap" meaning "the cap" as opposed to out the overflow hose- correct? Is there an overflow hose, is there a recover tank? What is the exact engine?

I wonder if hardened stainless has to have a higher iron content than others that are less susceptible to corrosion. The more corrosion proof the softer the metal and it could twist easier? Maybe that's why they use it as those tabs are pretty thin on my pump. Next question for corrosion...

Pumps do wear out....

Do you see the crack at the base of the other tab and the slight counterclockwise twist to the remaining tab? Had similar issue with sailboat friend- impeller fused to housing as it sat a very long time. When he cranked it over impeller blew up. We didn't discover the twist to the tabs until...

I don't agree yet as it looks to me that the remaining tab is bent and there is a decent crack at it's base. It looks a little twisted to my eye as well....I don't see how that can be caused by any sort of corrosion. I'd go looking for the broken off tab. Too new to the forum to figure out how...

Part # for that relay is 119773-91850...looks like any other cube relay but I can't find the location.

Are you saying that the Gen alt charges the house battery but uses the port battery to start?

LongJohn- this is a 6LP. DiverRob- wiring diagram attached for a "C" type panel

How about this- The 6LP stop solenoid is open (energized) to run. As you say- you shut off the power it kills the engine. How about pulling off the connector at your 3 way switch and see if it stops the engine? If it does the problem is that 3 way switch?

I'm in late and trying to understand- how is it you have 2 separate 12v connections on the genny? One 12v is house and the other is the port battery? You indicate them as separate circuits?

Is the coolant getting lighter and lighter in color as if being diluted by seawater? The heat exchange has 2 rubber "boots" one on each end- tighten up the clamps and see if the flow stops or becomes less. The boots separate the coolant from the seawater and if they are loose your WP pressure...

Do you hear the stop solenoid click open when you hit the preheat button? That solenoid pushes a plunger or something in the fuel rack so fuel can flow to injectors. Mine stuck closed after a long winter and I was able to loosen it up with a finger.