2005 Crownline Fuel System Charge/Prime on key turn

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BombKnox

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I have been fighting with this issue for a couple years now. It is inconsistent, so that makes it really fun! I have a 2005 Crownline 250CR with a 5.7OSXi-D Volvo Penta. When the key does the first half turn it should charge/prime the fuel system. My issue is it does sometimes. It will work fine for a day/week/month then stop for a day/week. What I know:
1. Fuel Pump has been replaced
2. MEFI has been checked and cleared
3. Relay has been replaced.
4. I just determined when the issue happens the relay is not switching
So, now I am guessing it is the wiring between the relay and the key? Where to go from here? Is there a way to test? Everything else turns on with the key turn.

Any assistance would be appreciated.
 
alldodge

alldodge

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Fuel pump relay turns ON by the ECM applying a ground to the negative side of the relay. Check the contacts and wire between relay and ECM
 
Fun Times

Fun Times

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BombKnox

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Fun Times said:
You may have a failing fuse box from back in that era... Follow
Marine Mechanic advice for testing starting about a 1/4 way down the page, https://www.justanswer.com/boat/295yk-04-volvo-8-1-stern-drive-will-not-start-new.html

Click to expand...
Thanks. I am heading to the boat today. I am going to check the ground and test the fusebox.
 
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BombKnox

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I think I am getting closer, maybe. First I wiggled/jiggled the fuse box and connectors. It seemed to make no difference. It is, 3863460, which is one of the boxes identified in the parts bulletin. After playing around a bit I tested the relay pins with the multimeter. I am getting good power to 30 and and 86. It is my understanding is 87 runs to the fuel pump and 85 is where the ECM should provide the ground? If I have 85 and 30 meetered I should get 12+ volts on the turn of the key? I got nothing, which I assume means I am not getting a ground from the ECM. This is where I got a little confused if I tested if wire J1-6 caused a multimeter sound with 85, it did not. However, It did with 30 and 86 - positive? I feel I am missing something, I assumed j1-6 would run to pin 85 and it would be causing the ground to flip the relay to make 87 a circuit? Any ideas what I missing?
 
alldodge

alldodge

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Should have power to 30 and 86, and and 87 will go to the fuel pump.

When ground is applied to 85 the relay energizes

I don't know which pin on your OSX because I don't have a wiring diagram. Look at the color of the wire on pin 85 and try to find it on the ECM

relay contacts.jpg
 
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BombKnox

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alldodge said:
Should have power to 30 and 86, and and 87 will go to the fuel pump.

When ground is applied to 85 the relay energizes

I don't know which pin on your OSX because I don't have a wiring diagram. Look at the color of the wire on pin 85 and try to find it on the ECM

View attachment 359014
Click to expand...
Thanks. The simplicity of wiring color, which I didn't even think about while at the boat. I will get there this week. I have not found much specific to the OSX, everything is GX. It seems the main difference is the composite sterndrive. OS is for their Ocean Series.
 
alldodge

alldodge

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Have 2 GXI diagrams and one shows a Black/Yellow wire going to J1-6 or J1-25
 
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BombKnox

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I got out to the boat again this morning. It is j1-6 and the wire tested good through. Today I tested:
  1. The fuel pump relay has 12V power to pins 86 and 30 (multimeter test).
  2. When the key is turned no ground is received on pin 85 (multimeter test)
  3. Wires connection test good (audible sound multimeter) for 85 to J1-6 and 87 to fuel pump.
  4. ECM Wiring harness connectors J1-13, 28, 29 all test good ground.
  5. ECM Wiring harness connectors J2-1 has good power.
This winter I did send the ECM (MEFI 4) to be tested. It can back as testing good. They reported one error code stored, but is was not related. I am thinking maybe the ECM is temperamental? I don't know I am really stuck. I think I may have to have someone with a scan tool come out when the issue is present to see what ECM reads and if the scan tool can send the fuel pump the on command. Any other good ideas or test?
 
alldodge

alldodge

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Did you send the ECM to OBDiagnostics or another?
When it was sent in, was this fault mentioned?

I'm thinking the ECM
 
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BombKnox

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alldodge said:
Did you send the ECM to OBDiagnostics or another?
When it was sent in, was this fault mentioned?

I'm thinking the ECM
Click to expand...
OBD Diagnostics, Inc http://mefiburn.com/ecmrepair.asp. This fault was not mentioned. Everything tested good. He said it had one item logged - M14 Coolant High. His note read - 442 hours - 971 starts, M14 Coolant High Logged, 18/255 Good on harness wiring, all sensors & relays good. IC2Bypass good. That is why I am thinking the ECM it is temperamental.
 
alldodge

alldodge

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Suggest give Bob a call of what you've found and test done, he might be willing to look again for discount or other. Its worth a call
 
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QBhoy

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Hi. My suggestion isn’t nearly as clever as the guys above…but having a similar engine myself…I can tell you that a dodgy kill switch lanyard system can do this exact thing. With that failing or loose, you won’t get the pump priming or ignition…but it will turn over the engine. I use this very thing to prime the engine with oil (without it starting) each time before I let her fire up…just because I only use her a couple of times a year.
 
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BombKnox

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QBhoy said:
Hi. My suggestion isn’t nearly as clever as the guys above…but having a similar engine myself…I can tell you that a dodgy kill switch lanyard system can do this exact thing. With that failing or loose, you won’t get the pump priming or ignition…but it will turn over the engine. I use this very thing to prime the engine with oil (without it starting) each time before I let her fire up…just because I only use her a couple of times a year.
Click to expand...
I will give it a try tomorrow. Man do I hope this is it!
 
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QBhoy

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BombKnox said:
I will give it a try tomorrow. Man do I hope this is it!
Click to expand...
Hope it works for you man. Other hopeful solution, would be a battery connection. But I’d try the lanyard off then on and see what happens.
 
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BombKnox

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alldodge said:
Suggest give Bob a call of what you've found and test done, he might be willing to look again for discount or other. Its worth a call
Click to expand...
I email Bob this morning. He's recommend trying to find another MEFI 4 to try.
 
alldodge

alldodge

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Your getting the 2 beeps, gauges come alive when the key is turned so its not the kill switch.

Wouldn't have thought Bob would have said try another MEFI 4, like their everywhere right. (n)
 
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