2022 G23 - Nautique PCM ZZ8 engine intake air overheat

[brianplatt]

We have a brand new 2022 G23 with the PCM ZZ8 supercharged engine. The boat is about a week old with 15.7 hours. Last night we were surfing and the boat threw two errors at us and essentially shut itself down. I was surfing when it "died" and it wouldn't do anything but idle until the errors were "ignored."

Error 1 of 2. DCT 127: Intake Air Temperature (IAT) higher than expected stage 1
SPN: 105. FMI: 0


Error 2 of 2. DCT 111: Intake Air Temperature (IAT) higher than expected stage 1
SPN: 105. FMI: 15

I've attached both errors from the screen. We reset everything and it threw the same error going back to the dock. Took it to our dealer today, and they could find nothing wrong. Said the logs indicated temps were in-spec and didn't have a good reason for these errors. They though it might be some air in the intercooler?

We are going to lake test tonight but I though I'd ask if anyone had seen a similar issue with a new G23 with the ZZ8.

[RDT-G23]

Intercooler pump leak, I say.

[brianplatt]

Intercooler pump leak, I say.

I think you may be right. The dealer's tech team thought there might have been air in the intercooler that was causing the error and flushed and burped the system.

We went out for a lake test last night. Boat ran perfectly under heavy load (surfing 3650 lbs of ballast) for almost an hour. And then it threw the same errors. Completely went into limp mode and we headed home (at 4mph).

[memerr]

My heart sank when I saw your post. I've seen this message unfortunately.

I've had both codes on two different occasions with my 2020. Both times the SC intercooler pump was toast. For anyone that has this happen, if you cycle power you might be able to get up to 8-8.5 mph with no ballast. A month ago this happened for the second time on a vacation...over 20 miles from our house which resulted in a 3 hr cruise fighting waves and rollers all the way up the lake. My pumps that failed were both the original pump. Newer ZZ8's have a different pump and plumbing. I would highly recommend to anyone with a ZZ8 that has the original style pump setup, pay your dealer to swap to the new one if PCM/Nautique won't replace unless/until it fails. The original setup is a ticking time bomb in my opinion that will only let you down when you need it most.

I'm very interested to hear what resolves your problem because you most definitely have the newer pump setup.

[brianplatt]

I'm very interested to hear what resolves your problem because you most definitely have the newer pump setup.

Thanks for your note -- that is helpful background. Apparently my intercooler pump was an older model (although mounted with the new plumbing). The dealer is planning to replace the pump with the new model under warranty, which hopefully will solve the problem.

[memerr]

If I remember correctly, the old pump cycles on/off. Something like 30 sec on, 30 sec off. The new style pump runs continuous. Fewer duty cycles equals longer motor life in my mind.

[brianplatt]

I wanted to follow-up on the resolution of this issue. As many suspected, this was a malfunctioning intercooler pump (in a boat that was a couple weeks old).

As I've noted before, our dealer is extremely good. They had the boat in for warranty service and replaced the intercooler pump. As it turns out, our original pump was the old style. Nobody knows quite why they put an old-style pump in a new boat (new plumbing, old pump). In any event, they replaced the pump with the new style and it solved with problem. I give them kudos for having it in and out in under 24 hours.

[bhightops]

brianplatt thank you very much for posting this and RDT-G23 for the accurate response. I had the same codes kick up with the fam in the middle of our trip to Lake Powell this week and even though our week is shot for surfing, we have a clean diagnosis of the problem. Marine United in St. George confirmed it. And they were kind enough to point me to the MasterCraft dealer in Page, AZ who could swap the intercooler pump and was authorized to do so under warranty. Unfortunately, we have another issue associated with this where the battery jumps from the norm 12.6/7 volts to 16-17 volts and the check engine light pops on. Given there is a chance I could mess up the battery (or alternator or something else electrical) while driving in limp mode to Antelope Point marina / Page, AZ (4hr trip) with that high of voltage, I have opted to just let our G23 sit in the water the rest of this week and we'll tow it back to the marina behind our houseboat at the end of the week.

[Scooter G]

Looking at a 2022 G with the ZZ8, and homeworking any know problems.
Hey Brian (brianplatt), do you know, or does anyone know if it is possible to ascertain what style of pump you have from a visual, or is it a pull it apart to determine?
bhightops, if you are still around, did you determine what the electrical monkey was?

[brianplatt]

Looking at a 2022 G with the ZZ8, and homeworking any know problems.
Hey Brian (brianplatt), do you know, or does anyone know if it is possible to ascertain what style of pump you have from a visual, or is it a pull it apart to determine?
bhightops, if you are still around, did you determine what the electrical monkey was?

Sorry, I don't know how to tell. If it were me, I would contact your closest service department and see what they know. You could also ping some of the bigger dealers and see if you can find an answer, there. Best of luck. We had a couple big issues and, once resolved, the boat has been great. Make sure your boat has the supplemental ballast.

[Scooter G]

Supp. Ballast, yep that was one of my 1st questions. Dealer boat, so the question will come up on the cooler. Thanks for starting this thread.
Other "big issues"? Do share...

[brianplatt]

We had a couple big issues and a couple small issues.

1. First thing was a "mixture" message about the fuel/air ratio, apparently due to being at 7000+ elevation. Fixed with a computer flash to new software.
2. Intercooler pump (see above)
3. V-drive went out and required a total replacement.
4. We started getting these MCU cylinder "short to ground" messages (you can see my other post about them) but they came at the same time as the V-drive, so fixing them took a very long time to diagnose and resolve. It was the kind of problem that makes you dead in the water but goes away by the time you get to the dealer. Eventually, Nautique stepped up with PCM and they replaced the motor control unit (i.e., a whole new computer) which completely solved the problem.

Knock wood, we've been problem free since the last one. The boat this year has been an absolute pleasure.

[Scooter G]

What the? V-drive went out, now that's a BIG deal.
I love the smooth sailing after you wipe of the bugs, good to hear.

Enjoy the journey, thanks for sharing.

[bhightops]

Scooter G it was an intercooler pump. Crazy story…
changed intercooler pump AND alternator because they weren’t sure if one was causing the other.
took the boat out a few weeks later and the NEW intercooler pump went bad. Same error. Ruined the weekend. Changed the pump again. Now all working. And in the process found out we needed a new transmission and steering column. So I think the only thing left to go out would be the engine, at which point I’d have a new boat — ha! I’m honestly exhausted with this boat right now, but I love it when it’s working.

[Scooter G]

"I’m honestly exhausted with this boat right now, but I love it when it’s working."
Well said bhightops, and I totally understand that statement.
Looked at a '22 yesterday, water testing this afternoon. Dealer said they have replaced all their ZZ8's through '22 with new pumps. They determined that there was also an issue with the way they were mounted. Once they figured that out they haven't had any problems. Looking at an extended warranty into 2027. They are picking up the $2000 transfer bill (in a round a bout way, ying & yang). I will say it is amazing the bells & whistles over our '16. I didn't know all the things we were missing out on, and a much better price tag than the 2025 G25 100th year anniversary model we looked at, $375,000, dang. Beautiful, but I'll say it again, daaang, them babies are getting 'spensive Lucy, and I was told that was a deal, hmm.