2009 ZR409 cutting out around 3200 RPM

[ericchile]

So in the past 3 weeks my SANTE 230 with the ZR409 CES engine has developed a problem where it cuts out while throttling up at around 3200 RPM. If I throttle back immediate the engine will pick up again. Other wise it just idles, but does not die.

The curious thing is that it happens for about 10 minutes after starting the engine, but if left running long enough the issue seems to go away. (which leads me to leaving it on when I really shouldn't).

Hours : 160

I have changed the FCC filter (which was pretty dirty) and the inline fuel filter. Not certain, but seems like a fuel delivery issue? Anyone have ideas on how to diagnose the issue? When the transmission is disengaged the issue does not occur.

Thanks for any help

[ericchile]

Also it doesn't happen if the V-Drive is disengaged...

Does this suggest a low or high fuel pump issue?

[ericchile]

Anyone know how to test the PSI to the fuel system and what it should be at? I would really like to diagnose the issue rather than just buying low and high pressure fuel pumps and guessing that is the issue.

[KTM525]

Is there no PCM Dealer near you with a diagnosis Device (Diacom?)

[jhersey29]

57 to 62 psi under load. Low pressure pump 7 to 9 psi. There are.good videos on YouTube on how to check fuel.pressure.
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[ericchile]

Replaced the High Pressure fuel pump inside the FCC and that didn't solve the problem.... On to the low pressure.

[2009216v]

I would highly suggest replacing the spark plugs. I have the same motor and I had a huge loss of power(felt like it had 200hp, not 409) and I couldn't figure out what the problem was. I didn't think it was the plugs since the boat still ran really smooth. Ultimately it was the plugs and the boat runs great now. The ZR409 motors are supposedly known to foul out plugs (per Orlando Nautiques). From now on, I will replacing my plugs every year. Let me know if you need the part # for the AC Delhi plugs. You can buy them on eBay for half of the price vs nautiqueparts.com. Same exact platinum Delco plug.


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[ericchile]

I would highly suggest replacing the spark plugs. I have the same motor and I had a huge loss of power(felt like it had 200hp, not 409) and I couldn't figure out what the problem was. I didn't think it was the plugs since the boat still ran really smooth. Ultimately it was the plugs and the boat runs great now. The ZR409 motors are supposedly known to foul out plugs (per Orlando Nautiques). From now on, I will replacing my plugs every year. Let me know if you need the part # for the AC Delhi plugs. You can buy them on eBay for half of the price vs nautiqueparts.com. Same exact platinum Delco plug.


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Thank you very very much for responding. Maybe I should try the plugs before spending another $140 on the low pressure pump. Do you have the part number the generic ones? Here are the ones from nautique parts.
http://www.nautiqueparts.com/sparkpl...-platinum.aspx

Also do I need to change the gap at all?

[ericchile]

I believe these are the right plugs for ZR6 409. Tell me if I am wrong.

ac delco 41-110
NGK Iridium Spark Plug IZTR5B11

[ericchile]

Thank you very very much for responding. Maybe I should try the plugs before spending another $140 on the low pressure pump. Do you have the part number the generic ones? Here are the ones from nautique parts.
http://www.nautiqueparts.com/sparkpl...-platinum.aspx

Also do I need to change the gap at all?

Took the old plugs out. They looked used, but really not that bad. Put brand new ones in. Tested it on the lake this morning and although the engine ran well the first 3 minutes it didn't have the same issue of cutting out.

Started going down the lake. Turned it off, and back on, bingo the issue is still there. Cuts out at any aggressive throttle amount.

[2009216v]

AC Delco 41-110 is correct but they should be platinum, NOT iridium. I am not 100% on the pros and cons of going with iridium but I am certain that PCM recommends the platinum version of the plug.
You will get different results when searching the correct gap. My PCM manual states one thing, supposedly PCM has since revised the gap since my 2009 manual, then the head Nautique tech suggested something different altogether. Ultimately the tech gapped mine at .045. If I remember correctly, the PCM manual states .060.


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[ericchile]

AC Delco 41-110 is correct but they should be platinum, NOT iridium. I am not 100% on the pros and cons of going with iridium but I am certain that PCM recommends the platinum version of the plug.
You will get different results when searching the correct gap. My PCM manual states one thing, supposedly PCM has since revised the gap since my 2009 manual, then the head Nautique tech suggested something different altogether. Ultimately the tech gapped mine at .045. If I remember correctly, the PCM manual states .060.


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At this point I am guessing that it is not the plugs.. but I guess I could be wrong.
Maybe it is best to drop $200 at the dealer to tell me what to fix. Or not to fix.

If the check engine light is not on will there still be some kind of code they can read?

[H2O]

Did you put the inline fuel filter in the correct orientation? It has an arrow (very tiny) showing flow direction. Another possibility is a deteriorating fuel hose. Mine acted the same due to breakdown of the inner lining of the fuel hose causing an obstruction to fuel flow at higher RPM only. Also, check the anti=siphon valve inside fuel tank for debris.

[2009216v]

If you service engine light isn't on, it is very unlikely that the dealer would be able to pull any codes.


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[ericchile]

Did you put the inline fuel filter in the correct orientation?

Yup, 99% sure I did.

Also, check the anti=siphon valve inside fuel tank for debris.

How do I get to it?