Engine cutting out with accessory activation 2001 SAN

[Ox269]

I have been having some issues this summer with my 2001 SAN, the engine began cutting out with application of throttle after about two weeks of us. No warning signs or lights, not overheating and no other indications. Was able to restart, as the keypad and electric systems did stay on. But any application of throttle more than idle speed would immediately cut the engine.
Took to shop and found clogged fuel filter and internal filter in fuel pump. Replaced and cleaned fuel pump screen without issue and got the boat back.
Dropped it in the water and was able to make it to our lake after testing for a short time around dock with no issues. After running for about 10-15mins at idle speed with the radio running, I turned the bilge pump on and the engine immediately cutout again. Restarted engine and was able to run again, but any press of a accessory button(bilge, Nav lights, blower, ballast pumps) kills the engine. Can run any accessory without boat running with no issues
Pulled both batteries and tested, the secondary was not holding a charge so I replaced and tried again, same symptoms. Checked ground from engine to mounts at back of boat and was intact and tight. Recently had depth sounder installed and rewired tower light. No alternator upgrade. Keypads have been replaced several years ago and gauges are all new in last two years. As far as I know, ground wires are original ,which I have read here, thanks to those who have come before, can cause issues with the gauge clusters and keypads. I do get some gauge issues with nav light button and oil pressure gauge. Volt meter reads no more than 13 when engine running, drops to 12 with accessory activation.
Any advice on where to start/go next would be appreciated.

[ag4ever]

Sounds like there is a problem in the control box. The box with the circuit breakers. The keypads talk to this box and it is the brains of your boat, not the engine though. The engine is a stand-alone system. It can be safely run totally without the boat wiring working.

if you have the EX330 there will be 3 relays on top of the engine. One is for fuel, one is for engine ecm, and the 3rd is for the starter. Pull the relay to either the fuel pump or the ecm and use a volt meter to measure voltage on the circuit from the control box. Turn the keypad on to engine run, but don’t start the engine. Then have one person look at the voltmeter while a second presses a button on the keypad like bilge or ballast, etc... if your voltage stays steady and does not blip or drop out go to the other circuit and do the same. If you have steady voltage without a blip or loosing voltage it will be on the engine side, not the control box or keypad side. My bet is that you will see a drop on voltage and that is causing the engine to die from the ecm or fuel pump loosing power. If you are loosing continuous power, it will be the control box. Don’t have a solution to that other than to replace as I have never looked inside the box on my boat.

[Lakejackson]

Had similar problems with my 2004 216. Turned out to be the accessory ground wire connection at the battery. Not the large gauge wire for the battery. The smaller gauge wire had a bad connection that was difficult to assess until I took the connections apart. The ground wire was mostly broken in the crimp connect. Replaced and no further issues.


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[dkimball]

Had a similar issue with a 2003 216. It was a bad fuse holder on the positive wire running to dash. Turn the boat on and wiggle the wires connected to the battery see if it cuts out.

[Ox269]

Thanks for all the advice, haven’t had a chance to actually get in the boat the last week, hoping this weekend.

The engine is the PCM Gt-40 ford, not sure if the relays are in the same spot, but if I remember correctly there are some relays next to the ECM.
Hope to test the ground and battery cables as well.
Will update when I get a chance.