2002 SAN GT40 Starting Prob

[h20thief]

Dewinterized the boat a few days ago and got everything put together right except the water pump. I noticed it within a few seconds of the start up, shut it down and installed the pump correctly. During this I noticed someone helped themselves to a full tank of my gas over the winter months.

I refilled the boat and tried to start it with no luck. It turns over great but wont fire. I tried a little starting fluid in the flame arrestor (oxymoron?) and it'll fire. As soon as the starting fluid is burned away, the boat dies. Anyone have an issue like this? I think it's a fuel delivery problem, maybe sucked in some junk on the empty tank?

Could it possibly be the starter relay? Another suggestion was to change the fuel filter but I dont know. Any way to narrow it down before I sign the check to the local CC dealer?

Thanks

[richard]

2002 SAN GT40 Starting Prob

I suspect the kill switch than the starter relay, use a jumper bypass the kill sw, my though.

[h20thief]

My wife has been more than happy to ask if the kill switch was the prob. I jumped around it with no success. Could voltage cause an issue like this? I bought the boat last year (used) so I dont know the history of the batteries. I know they tested at or above 12 V.

[slob02]

Are the fuel pumps making noise when you hit the key?

[h20thief]

I can hear what sounds like a prime each time I hit the start button. It only lasts for a few seconds so I assumed it was the injectors priming.

[Laptom]

No, that is the first fuel pump turning. That is good news.

Here is the case; Fuel tank -> first fuel (low presure) pump -> to the (FCC) fuel bowl (where a filter is in), in this bowl there also is a second fuel (high presure) pump. If there is to much fuel in the bowl it will returned by a normal fuel hose to the fuel tank -> on top of the fuel bowl (FCC) there are 2 high presure fuel lines coming out, one to each injector rail on each cilinder row. Also on top of the FCC fuel bowl there is a nipple to vent air out of the bowl.
Check this nipple if it spills some fuel and air. If not the bowl doesn't get enough fuel, the first pump needs to be primed then (if it runs). If it bleeds fuel and air, find the second nipple on one of the injector rails. Check if this will bleed some fuel. If not, the second pump (in the fuel bowl) doesn't run (check voltage, if good; check pump). If it bleeds, the injectors (all eight) won't work. It's almost unreal that all eight stopped working, so it must be in the controls then.
But I think it's something easy, like the first fuel pump needs some priming. Just unscrew the fuel hose between the first pump and FCC, disconnect the connector for the first fuel pump, check with a voltage meter if there is any voltage for 2-3 seconds when turning the ignition on (2 pushes on the start button). If that is the case, check which is the positive and the negative terminal on the connector. Apply a +12V on the fuel pump connector and check if the pump is running and sucks some fuel. If not you'll have to fill the fuel line (between the tank and pump) with petrol.

Good luck.

[h20thief]

Wow, thanks for the info. I'm headed to Florida for 10 days but I'll be under the cover as soon as I get back. I've downloaded the schematic for the fuel delivery system so I dont goof that up. Thanks again, I'll let you know if it works.

[lukeduke95]

Hey Laptom,

Would the line between the tank and the first pump ever go dry if there was fuel in the tank?

Ours wouldn't start for a bit on Sunday after 2 weeks and that line was bone dry. Quick shot of gas to the back of the throat(sucking) and it was ready to run. The tank had plenty of gas, so its not like it was empty.

[Laptom]

Yep, the line can go dry if there is still fuel in the tank. Expecially if there is a small leak in the line or the hose clamps are not tight enough. But it's very uncommon, we only had a problem once after de-winterize to get the fuel pump working. I would renew the fuel line, just to be save.
Also, when the line is dry I've seen the first pump cannot get it primed. Our 2000SAN had this problem, when running out of fuel we had to fill the pump and line also. It's first class sh#t work. Our 97SSN or 02Air with GT40 didn't had that problem.

[lukeduke95]

Muchos Gracias Senor! Figure our original line from the tank is about 20 years old. Eveything else is new.

[h20thief]

Update on the starting issues:

I replaced the batteries hoping for a simple fix but not so. I drained the FCC and found lots o' water. After it was put back together is started in the driveway. I killed it and let it cool down for another cold crank and success.

Trailered the boat to the local lake and it would not start on the ramp! I tried the flooded procedure and all with no success as well. Just for grins I thought I would go to battery 1 and try but after letting the fuel pump prime, when I hit the start button, I lost power to everything. Tried several more times on battery 2 then all with the same results. Now it looks electrical in nature. I give up, it's at the dealer for a more qualified mechanic. Thanks for the info, I sure understand the fuel system a little better.

[aaron]

dude. my boat is normally well maintained and even i had a problem( starts and dies on acceleration)
Checked all the relays...but nothing.then i decided to dismantle my FCC and discovered that the water filter was just plain dirty, and there was dirt at the bottom of the filter once i removed it( the water filter).
If u want to do it right with peace of mind, do it all the way..just removing the bottom drain plug of the FCC isnt enough to get dirt and other crap out.
Last time i did a full removal was only 30 hrs prior, but i remember running til empty once, and with the "not so clean" fuel or jerry cans , we never know what the intake has sucked into the fuel system.
So you shd;
dismantle fuel pump and FCC
open FCC and replace filter AND high pressure fuel pump( if u want)
assemble FCC carefully with o-ring seated properly, and pit alittle grease when screwing cover back on( important for removal next time)
put everything back together with Laptom's very clear instructions and you'll be fine

Looking at this thread, isnt it amazing that someone from texas gets info from the netherlands (laptom) and all the way to the other side of the world to me in malaysia!

[h20thief]

Thanks for the assistance. I just talked to the dealer and he said there was so much water in the injectors and FCC they were afraid to even start it. They are draining the fuel tank and starting over. I hate to think it was picked up at a gas station but even worse, I may have a neighbor who doesnt like me having a boat. It ran like a champ last summer so I cant imagine there is an internal problem where it might be picking up water.

Malaysia? Where the **** is that? :mrgreen: