330 Excalibur fuel pump issues

[freejonesman]

The boat is a 2005 Nautique 216 Sport with the Excalibur 330. We had issues getting it started in the past which was traced to fuel supply to the low pressure pump (LPP). To overcome these issues, the shop installed a hand bulb pump between the tank and the LPP. The boat worked fine for a while, but now the issues are recurring.

Various threads mention that you should hear both pumps prime themselves for a few seconds when the boat starts, I'm not hearing any indication of that on either the LPP or the Fuel Conrol Cell (FCC). Probing across the two pumps' terminals reveals no voltage to either pump. To trouble shoot the issue, the following have been done:

• I confirmed both the LPP and the FCC work independently when fed a straight 12V source from the battery. The pumps themselves seem to be fine.
• I've bypassed the lanyard kill switch.
• I've checked the three 20A fuses in the fuse block on the engine, all are fine.
• The fuel pump relay was located and after pulling it I have confirmed that there is battery voltage on one side of the switch, there's continuity between the other side of the switch and the 12V input to the FCC. I also verified the 12V control signal appears across the coil terminals after the start button is hit a second time (first one turns the panel on, second one turns the engine over).
• I've tested and swapped the three relays (ignition, fuel pumps, something else). All make an audible click when the coil is energized, though my test setup was too rudimentary to check continuity through the switch.

Reading through this, it seems the only thing I've not checked in the pump circuit is continuity to ground from the pumps, and I'll do that in the morning. Am I missing something else? Is there anywhere else that I should be looking?

Thanks in advance.

[shag]

What shop would install a hand bulb pump instead of addressing the real issue? I had a 2005 SAN with a bad low pressure pump... The inside was all corroded secondary to the ethanol fuel attracting moisture and sitting for periods.... (month or two at the most)...

[freejonesman]

The primary problem, 2 yrs ago when the primer bulb was installed, was the fuel pump would lose prime only under heavy ballast conditions with a fat sack. Both pumps tested fine 2 yrs ago but for some reason the shop could not diagnose or duplicate the lack of prime.

[shag]

I'm not sure what to say here, but I never heard of any inboard boat needing a primer bulb. There are thousands of boats with heavy ballast that do not require that.... I'm betting the pump is bad.... Mine tested ok per the PCM dealer, but once pulled apart, the corrosion was found. Replaced the pump - and the intermittent sluggish/starting problem I had went away... Just my .02..... Good luck though! I know how frustrating things can get

[gome123]

My initial thought is Fuel Pump as "Shag" stated. Here is my experience... although this is with and old car of mine. (My 1987 Red IROC-Z baby!!!). Even though you directly add 12v to the pumps and they turn they may be worn and don't have enough juice to do any actual pumping. My car's pump would run when powered, I beat my head for a few days diagnosing the problem. Didn't make sense that the pump would run but still not prime. Finally I broke down and bought a new pump. TA-DA! Problem fixed. I would try to replace the LP fuel pump and hopefully that fixes all your issues.

[Drock]

My LPP pump went roughly 3 years ago(2003SANTE - california boat...probably ethanol/corrosion related). Would test/work fine at the dock/on the trailer but once warm it would not work. They are a common problem on these boats after some research at the time. I would just replace the pump and sleep better knowing you won't be stranded in the future.

D

[freejonesman]

Thanks to Drock, shag & gome123 for the input. We have now replaced the low pressure fuel pump (LPFP) and the pump relay which did not remedy the problem; neither fuel pump would cycle on during start sequence. Bypassed the relay and the both fuel pumps activate but boat doesn't start. Kill switch has been by-passed. The LPFP was an early model that was recalled by PCM -- SUP2006-03owner.pdf--but for some reason the original owner and several dealer visits since have not changed out this LPFP. I've now asked PCM to reimburse me for the cost of this LPFP. I do not have a pressure gauge to test actual pressure output from either fuel pump. The boat is now sitting at a local mechanic's shop for further evaluation & repair. I'll provide further details when available.

[ski4evr]

My 211 is a sport and it has the traditional ignition key switch(which I had to replace) and a cheaper version fuse panel. I have had problems with fuses not making connection while still in the socket. I have also had the ignition fuse fall out while bouncing through rollers in a thunderstorm. Thanks to the good eyes of the little one saying whats that daddy we made it back without getting blasted by the storm. Not sure if it applies, but some ideas.

good luck!

[MAK]

Keep us posted with what you find out... I am having some fuel delivery issues myself