FCC help needed

[skiview]

We were skiing the course on Monday and the boat just died and won't restart.

After some help from the dealer diagnosing the problem, I replaced the relay, no change. Next I replaced the filter and high pressure fuel pump and it still won't start.

I have fuel at the return line, but no pressure at the Schrader valve.

When I unplug the 2-wire connector going into the FCC, I get voltage between the wires, initially, then it goes to zero and comes back while cranking.

Any other ideas?

2001 Ski Nautique c/b with keyless ignition, GT 40 Pro Boss

[gride300]

RE: FCC help needed

did you make sure the kill switch is connected?

[skiview]

One of first places I looked. If I remove the lanyard and then reattach it while in the on position, I can hear the volume pump spin up

[AirTool]

If these things are like the autos...Upon initial ignition on, the pump runs for only two seconds. Also runs while cranking, anytime reference pulses are received, and when the oil pressure is above "x" psi. (I don't know if the boats have this oil pressure feature.)

So you will only see power at the pump for two seconds or while cranking/running.

How much fuel pressure do you have at the rail when cranking?

Are your gauges and engine light coming on after putting in the code and pressing start?

You need to get a spark checker or a timing light and check for spark. Don't do the old pull the wire off trick.

If you don't have spark, you might need a new ignition module. You can have yours tested at an auto store. Be sure to put the white heat sink paste on when re-installing. The computer chip stuff works great....better than the silicon.

Please check the pump again and for spark. Your spark should be perfect...no skipped beats. Your pump pressure should be 50 to 60 psig IIRC.

AirTool

[skiview]

Thanks for the suggestions. Everything electrical seems to be working. Haven't checked for spark yet, will try the timing light first thing Thursday.

I don't think it's getting fuel because I can squirt some into the throttle body and it tries to fire.

[gride300]

you might check the recall notice on here. probly not on there but you might find your solution. bryan at south east correct craft is a good/knowledgeable guy. since you know what you're talking about and have done alot of trouble shooting he might be able to help by phone. good luck

[AirTool]

Thanks for the suggestions. Everything electrical seems to be working. Haven't checked for spark yet, will try the timing light first thing Thursday.

I don't think it's getting fuel because I can squirt some into the throttle body and it tries to fire.

BE CAREFUL with the fuel tricks !!!

If you do the timing light and fuel trick with a friend or two....your timing light flash should be perfect. You can also hook it to the coil wire which will give 8 times the flashes. Again, that thing should flash like a metronome or your module is bad. One missed beat out of a hundred and no good...IMO.

Also, if like the autos...and probably so, there is a low speed and high speed component of the module. Its characteristics change at 400 rpm. Try to get it going past 400 rpm and it may run....and start pulsing fuel on its own. If it does, probably your module again.

I still want the fuel pressure while cranking. Also, if you have high pressure on the rail and no fuel, you may need to make a NOID light and check to see if the injectors are pulsing. If the injectors don't pulse, likely no reference pulses are being received or your ECM is bad.

Finally, as already mentioned, there was a recall on the low pressure pump. There is a write-up on the PCS site.

http://www.pcmengines.com/pdfs/enhan...06-03owner.pdf

AirTool

[AirTool]

Re: FCC help needed

2001 Ski Nautique c/b with keyless ignition, GT 40 Pro Boss

Oops. I just read this.

All the tech details on ignition I gave you are for GM engines.

The general stuff is still good though.

Sorry.

AirTool

[DanielC]

Go to the downloads section of this site, down load the GT-40 service manual.
Page 6-8 has the electrical circuit for the fuel pumps.
Find the fuel pump relay, it is one of the two Bosch type relays on the back of the engine. You can unplug the relay, and use a wire with two male 1/4 spade terminals to jump across where terminal 30 and 87 on the relay are. The fuel pumps should both run, and fuel pressure should be 39 + or - 3 psi. The key will need to be on, do not start the engine.
You can also get access to the test port on the engine. if you ground the Blue/orange wire, that will command the engines ECU to turn the fuel pumps on. See the GT-40 service manual. I know it is a hassle to down load the large document, but it is worth it.

[jos]

Check the hose in the FCC.
Take of the bowl.
See the pump hanging on the wire and the hose
The hose becomes harder over time and can rupture, not oftten but it happens.

[skiview]

OK, so I have no timing light flash on the coil wire, while cranking. However, I do get one brief flash when I stop cranking.

Now where do I start looking?

[AirTool]

Is the FORD ignition module the same as automotive? ...you could take it to a parts house and get it checked. I still think the module is your problem.

You should also test the coil. Parts house may be able to test...else you can with a multi-meter. Google testing an ignition coil.

AirTool

[skiview]

Ign. module and coil tested OK at Auto Zone, so I reinstalled them. Now I'm getting spark wit the timing light, but not as constant as I think it should be.

[skiview]

SUCCESS!!!

Turned out to be a corrodded connector on the wires inside the FCC leading to the high pressure pump. Only found it because one of them fell off while checking the connections. Replaced both butt connectors and we're back on the water.

Thanks again for all the help

[AirTool]

That is wierd stuff about your timing light flash.

Another way to test the pump is the jump that relay (like the previous post indicated) with an amp meter also in the line. Include a fuse if your meter is not fused. You can then check the amp draw. You might have picked out the bad connections using this method.

I'm glad it's all fixed.

AirTool