1999 SAN GT-40 EFI Fuel Issue -- Ran Out Of Gas and Engine Won't Run

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  • Jamo
    • May 2019
    • 17

    • Lake Hopatcong, NJ

    • 1999 SAN

    1999 SAN GT-40 EFI Fuel Issue -- Ran Out Of Gas and Engine Won't Run

    Hi all,

    First post here. Thanks for all the material everyone--this site has helped quite a bit over the years.

    I ran out of gas this weekend. Gauge had broken over winter, and I hadn't had the chance to fix it. My guess was that there was probably 6-8 gallons of fuel in the tank over winter. I did pay someone to winterize it, although I can't confirm if they added stabilizer or not (I'll be winterizing on my own henceforth). To be fair, I'm not the most diligent about searching for ethanol free fuel, nor have I been adding fuel stabilizers at all. We've put about 200 hours on the boat since buying it from a brother in law (it currently has 647 hours).

    Anyway... I refilled the fuel tank, boat ran well/normal for 20-25 minutes. Boat sat for a couple hours, I then left the dock and heard a pop/backfire about 5 seconds after hitting the throttle. It sounded more like a backfire than something breaking, but I'm not 100% confident in that. We returned to the dock and opened the hatch. The engine was trying to start (starter working ok), and it would choke out if I gave it too much fuel. To be clear, it wouldn't stay running at all... but I could make it hang on a little longer if I played with the throttle and got it to run poorly for 5-10 seconds, but eventually even that stopped and it didn't want to stay running at all. It definitely sounds like there wasn't enough fuel getting to the engine. We tried pulling the plug on the bottom of the FCC and draining any water, but it seemed to be only fuel that settled in the cup... so water in the fuel didn't seem to be an issue.

    Two days later, I got it back to my dock and on my lift. I removed the Fuel Control Cell and found that the filter was pretty gross and there was plenty of sediment on the bottom of the FCC. The fuel pumped also seemed oxidized, or at least very dirty. I ran out of time before the weekend ended to clean everything... but trying to evaluate all options.

    Other variables: at the end of last year, we noticed that when went to the fuel dock, we could never fill the tank at 100% flow from the pump. We could only pump pretty slowly; otherwise the pressures would not balance out well and fuel would overflow from the tank until pressure could bubble out. Sounds like the tank isn't venting properly.

    I've gone ahead and ordered a new fuel filter and pump for $225, as those need to be done regardless. However, I'm also wondering if it is worth pulling the fuel tank and looking at the fuel pick up line? Is there any chance dirty fuel slipped through to the injectors/fuel rail (my filter was disgusting)? Is the pressure imbalance in the my tank starving the fuel system?

    Wish I would have thought to take some photos this weekend, but alas.

    Thanks for the help all.
  • charlesml3
    1,000 Post Club Member
    • Jan 2008
    • 2453

    • Lake Gaston, NC

    • 2022 G23

    #2
    Sounds like you're on the right track to me. I gather you're replacing the high-pressure pump first. Probably a good place to start. If there was no fuel in the FCC when you took it off I'd suspect the low pressure pump.

    -Charles

    Comment

    • glassywaters
      • Jan 2015
      • 224

      • florida

      • none

      #3
      I would recommend doing some more research. Your fuel system runs in a loop from gas tank (has a anti siphon valve), to low pressure pump, to high pressure pump, and returns to fuel tank. First step is to check for fuel pressure on the rail at priming, cranking, and running. You should see between 35 psi and 40 psi running. Changing the filter and pump isn’t a bad idea, but best to work through a process. The. Lp and H.P. pumps should both prime when turning the key. Good luck.

      Comment

      • Jamo
        • May 2019
        • 17

        • Lake Hopatcong, NJ

        • 1999 SAN

        #4
        Thanks. Is there a guide anywhere on how to check the pressure on the rail? I’d like to avoid buying that pressure gauge if I could (just cus I don’t know how often I’ll actually use it)

        Comment

        • glassywaters
          • Jan 2015
          • 224

          • florida

          • none

          #5
          Honestly, you can grab one from Harbour freight for $20. It’s such a great tool to have. Understanding fuel pressure is vital when diagnosing engine issues. Also, better than just throwing money at parts. You may not need that $200 fuel pump.

          https://m.youtube.com/watch?v=zd13cKndtbo

          Comment

          • Jamo
            • May 2019
            • 17

            • Lake Hopatcong, NJ

            • 1999 SAN

            #6
            Thanks glassy! Will do.

            Comment

            • Jamo
              • May 2019
              • 17

              • Lake Hopatcong, NJ

              • 1999 SAN

              #7
              So i've replaced the fuel pump, it's working but the FCC isn't priming with gas. IT doesn't sound like the low pressure pump is clicking on. I' know I should reset the breakers in back, but I those little red buttons are frozen and can't be pushed. Am I doing something wrong here? Thanks!

              Comment

              • jkallen21
                Senior Member of PLANETNAUTIQUE
                • Jan 2013
                • 399

                • United States

                • 2006 Super Air 220

                #8
                They don’t really move unless they need to be teset

                Comment

                • Jamo
                  • May 2019
                  • 17

                  • Lake Hopatcong, NJ

                  • 1999 SAN

                  #9
                  Ok so..

                  New low pressure fuel pump is on. I tested the old one by going straight to the battery and running 12V. Old one didn't work--new one does! So that's a good sign. I also put a new high pressure fuel pump on. We pulled all the fuel lines from the tank and confirmed fuel is getting through to the engine and returning as well--all looks good.

                  Engine is still not seeming like it's getting fuel, but that could be for a couple reasons. Firstly, I need a fuel pressure gauge, but I'm literally on an island and can't find one to borrow, so that won't happen this weekend.

                  However.... when I replaced the high pressure pump, I also found the attached pieces on the carpet. I didn't realize they came off, and I'm not sure what they fell out of. Can anyone identify the parts and where they should go? I'm suspecting somewhere in the FCC... buuuut I also don't know if maybe the new pump had these in there somewhere and I don't need these old ones at all?


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                  Comment

                  • Jamo
                    • May 2019
                    • 17

                    • Lake Hopatcong, NJ

                    • 1999 SAN

                    #10
                    So it's been suggested that this is a schrader valve. Does anyone know if there is a schrader valve inside of the FCC?

                    Comment

                    • SilentSeven
                      1,000 Post Club Member
                      • Feb 2014
                      • 1843

                      • Bellevue WA

                      • 2004 Nautique 206

                      #11
                      I poked around for a service manual for the FCC with no luck. Closest picture I could find is this - http://www.planetnautique.com/Correc...s%20Manual.pdf

                      See page 36

                      If you don't recognize the parts from the teardown, maybe they were there some prior job? I'd just try to run it and see what happens.
                      2004 206 Air Nautique Limited - Black with Vapor Blue (family style)
                      1997 Masters Edition Nautique - Zephyr Green - gone (amazing ski wake)
                      1982 Mastercraft Powerslot - gone (a primitive but wonderful beast)
                      Bellevue WA

                      Comment

                      • Jamo
                        • May 2019
                        • 17

                        • Lake Hopatcong, NJ

                        • 1999 SAN

                        #12
                        That’s very helpful—thank you! I hadn’t thought to look for a better manual for the engine.

                        I went ahead and and purchased a fuel pressure gauge, so will be going that route this weekend to see what I can find!

                        Comment

                        • Aaren22
                          • Jun 2018
                          • 59

                          • Ohio

                          • 2001 SAN

                          #13
                          What did you figure out?

                          Comment

                          • Jamo
                            • May 2019
                            • 17

                            • Lake Hopatcong, NJ

                            • 1999 SAN

                            #14
                            It was the high pressure pump that I had replaced.

                            When I had replaced it the first time, and replaced the fuel filter inside the FCC—I made the mistake of not spraying into the canister with brake cleaner or adding in some fuel. Ultimately, this meant that the brushing on the bottom of the fuel filter was just dry rubber when I threaded the FCC back on, and that dry rubber had just enough friction to catch the high pressure pump when it was threaded back on. That twisted the high pressure pump JUST ENOUGH (like 90-180 degrees) to disconnect the electrical
                            connections on the high pressure pump. All it took was removing the FCC again, seeing it was disconnected, and replacing the filter again because the rubber seal had torn at the bottom.

                            All in all, it was originally the low pressure pump that went first. Should have had a fuel pressure gauge to check pressures first. And then should have double checked the high pressure pump since that was the only other place I had messed with things! Boat is back to running like a champ.

                            Comment

                            • glassywaters
                              • Jan 2015
                              • 224

                              • florida

                              • none

                              #15
                              Glad you got it sorted.


                              Sent from my iPhone using PLT Nautique

                              Comment

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