2001 PCM GT-40 Fuel Delivery Issue

[Lidman]

Hoping to find a good boat mechanic around Woodstock GA area. I bought this boat 5 weeks ago and been on the water 4 times. Been towed in 3x. This totally sucks, as I'm a first time boat owner. First couple of issues was the boat would just die, like you pulled the kill switch. I trouble shot that the keypad was bad, replaced it and the problem was solved. (I held in the "Start" button and it ran fine, so no rocket science there).

Next issue: engine coughed and sputtered and died. I drained the FCC in case of water contamination, and it fired up. Decided not to tempt fate and brought it home to change the fuel filter.

After changing the filters, turning on the power, it wouldn't fill the FCC, but you could feel the pump energize. I filled the FCC with gas and it fired up.
Dropped it in the water and she idled fine for about 10 minutes, and as my son and I were leaving the marina, she died again; cough, sputter, dead.

I take it to the Nautique certified mechanic and gave him a brand new high pressure fuel pump and asked him to "fix it, I'm done screwing with it." He replaced the pump and informed me yesterday that did not solve the problem. Next thing they want to try is the low pressure pump.
I hope this fixes it, because I'm running out of patience, money, and warm weather!

Any thoughts?

[Jonny Quest]

Inside the FCC there is a 2-3 inch long hose. If that hose is cracked, you will have problems. That is a very simple fix. Changing out the HP and LP fuel pumps certainly eliminates those variables, so if you change out the small "inside" hose, you will have addressed the most common fuel-related issues. I would also have two (2) fuel pump relays on hand. They are not expensive and they have been known to go out. They are located at the rear of the engine near the remote starter switch/solenoid. At NAPA it would be an Echlin AR 174. Or, Hella brand 007794301. The other thing I would check is the coil. If your coil is failing, it is not unusual to have the coil heat up and then simply stop working. The GT-40 coil part number is R117008.

JQ

[Peter6000]

Hoping to find a good boat mechanic around Woodstock GA area. I bought this boat 5 weeks ago and been on the water 4 times. Been towed in 3x. This totally sucks, as I'm a first time boat owner. First couple of issues was the boat would just die, like you pulled the kill switch. I trouble shot that the keypad was bad, replaced it and the problem was solved. (I held in the "Start" button and it ran fine, so no rocket science there).

Next issue: engine coughed and sputtered and died. I drained the FCC in case of water contamination, and it fired up. Decided not to tempt fate and brought it home to change the fuel filter.

After changing the filters, turning on the power, it wouldn't fill the FCC, but you could feel the pump energize. I filled the FCC with gas and it fired up.
Dropped it in the water and she idled fine for about 10 minutes, and as my son and I were leaving the marina, she died again; cough, sputter, dead.

I take it to the Nautique certified mechanic and gave him a brand new high pressure fuel pump and asked him to "fix it, I'm done screwing with it." He replaced the pump and informed me yesterday that did not solve the problem. Next thing they want to try is the low pressure pump.
I hope this fixes it, because I'm running out of patience, money, and warm weather!

Any thoughts?

Don't give up these are excellent boats and they are quit reliable.
You just have to work.out the kinks.
It is hard to find good technicians to work on these at least in my area.
So I decided a couple of years ago to do it all myself and don't trust anybody.
I'm not a fan of throwing parts on a problem these engines are quite simple and easy to troubleshoot.
Get the pro boss manual from the forum it's under manuals.
Start with testing fuel pressure on the rail if it's ok your pumps are good. Leave the tester on there for a while.
Second is a timing light and spark power tester.
Report results here plenty of people here with a lot of experience.


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[gary s]

First off your boat is 20 years old it's going to require some work,after all BOAT stands for Break Out Another Thousand. Being that it is a late production 40 it most likely not the internal hose- only the earlier ones had the hose trouble,besides if the mechanic is competent I'm sure he would have noticed a hose failing,it is the approx 2 1/2" hose that the HP pump connects to. You brought him a HP pump he did what you asked him to do. Had you come here and asked or took the boat to him to diagnose maybe the LP pump would have been the first thing changed,they are a common failure point. If yours is painted black it's still the original pump. There are alternatives to PCM branded pumps that can save you considerable amount of money but since your not doing the wrenching your mechanic might not want to bother.

[beamons]

There is a lot of experience on these boats as the GT40 was the main power plant for several years. Keep working it and it will be strongs for years. ccfan is also a great resource for the older motors. They even have a GT40 resource thread that is really helpful and full of great insights.

[Lidman]

Excellent, thanks for all the help!

[rbalan]

Hey Lidman, I’m practically next door to you in Canton and just went through this. Feel free to message me if you need any help. I replaced my LP pump and could give you my number how to explain how I went about troubleshooting.

[rbalan]

Just read back through your post. Even though you feel the LP “energize”, it doesn’t mean it’s working and it’s what fills the fcc, so I’m betting a new one will fix your problem.

[Lidman]

That's why I'm fairly optimistic about the LP pump being the problem. I should be able to hear the gas coming through the lines, then change pitch as it fills. I don't hear anything, so hopefully this will take care of it.

[Peter6000]

That's why I'm fairly optimistic about the LP pump being the problem. I should be able to hear the gas coming through the lines, then change pitch as it fills. I don't hear anything, so hopefully this will take care of it.

Fuel pressure tester at harbor freight is $35 and the guessing stops, just saying.

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[Lidman]

True dat. Love me some Harbor Freight. Thanks