Fuel Delivery/starvation Help troubleshooting

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
Hey Everyone ! Im hoping for a bit of guidance here. My boat is a Four Winns Horizon 180- circa 2000/2001 (supposedly a in between model). It has a 5.7 (not original) volvo engine that was installed in 2017, the season before I bought it.

In 2018, shortly after I bought it, it gave me some trouble. Died out in the middle of the lake and wouldnt restart. A while later it started fine. I ended up figuring out that it was an electrical problem. Essentially the ground for the fuel pump was somehow not staying "grounded" - it would "lose ground" randomly. Sometimes working fine and then sometimes not at all. I "fixed" this by running a ground wire directly to the negative battery terminal. Problem was solved ! No issues for a while. Then, it started again. This time it ended up being the positive wire on the fuel pump cutting in and out. Once again I "fixed" this by running a wire straight from the battery to the positive wire on the pump- HOWEVER ! I installed a toggle switch under the dash for this wire, so that the pump wouldnt just run all the time. This switch allowed me to remotely make the fuel pump run. When she died I would just flip the switch and fire her back up. At some point I noticed the problem had stopped and I no longer needed to use that switch. I disconnected it but left the wires in place, just taped up the ends.

Last season, it started to happen again, but not as randomly. I noticed that it would straight up just die if we took too long to plane out. The high angle of the boat pre plane would cause it to die everytime. It also did not want to start after this occurred. This was also accompanied by a strong smell of fuel ?

This season I had not experienced any issues during the first few times out. But more recently it seems to have gotten much worse. I had to start using the "jumper" wire on the fuel pump once again to get the boat to start after the stalls. It happens almost everytime the boat angle is high, but also sometimes after it has successfully planed out, right when the throttle is cut back a touch. The only solution has been to just keep the rpm slightly lower and just wait for it to build enough speed to plane without increasing the throttle.

When it does die its not easy to restart even with the fuel pump jumper wire. I need to really work the throttle and once it fires it has to revved up quick and high or it just dies. Again there is always the strong smell of fuel.

I understand that the problem could either be air getting into the system from a leak of some sort or it could also possibly be the pick-up in the fuel tank. The boat has a fuel water separator filter that I changed last season. I dont think they need changed every season though. At first I suspected the pump might just be starting to go so I bought a new one, however its still in the box since I thought deeper on this and am now suspecting it might be something else.

If anyone actually took the time to read all of that and has a idea of where I should start looking PLEEEEASE help me out.

Any posts are appreciated ! Thank you
 

alldodge

Moderator
Staff member
Joined
Mar 8, 2009
Messages
42,275
Sounds like you have corrosion issius and instead of finding where its taking place your running jumpers.

Which 5.7 do you have? Original serial number would be best but at least Gi, GXi - E etc
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
Thanks @alldodge ! I want to properly diagnose this issue. I dont think it will be too difficult mechanically, but will likely take some time. Just hoping someone could recommend a good jump off point to start with. I have started to compile a list of the things I should check, Im just not sure what to start with and would prefer to not waste time.
Heres what Im thinking I should check
-Fuel Hoses and clamps (Corrosion, restrictions, cracks ?)
-Fuel Tank and pickup (Dirty, damaged ?)
-Tank Vent (not sure if it has one? clogged?)
-Water separator filter (check for leaks ?replace?)
-Fuel pump connection at inlet (check for leaks, restrictions)
-Bleed fuel system (have no idea how to do this or if its necessary, but I suppose it is a possibility

Is there something else I am missing here ? Where would you start with this list ?

Thanks again !
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
A little point by point of the condition.

-Occurs only after high angle takeoff (gas probably moving around quite a bit in the tank) OR right after the throttle is backed off post plane
-Accompanied by the strong smell of fuel (indicating a possible "flooded" condition)
-Difficulty restarting after dying. (even with throttle at WOT and also with fuel pump running on a jumper)

Hopefully this helps narrow down the possible causes
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
The serial number for the engine is something I have not been able to locate. Since its not the original engine. I have tried to find it before. Was told it would be stamped on the back of the block below the heads,- port side I believe. I have tried reaching mirrors and my cell phone back there to get a pic, but have not been successful. Im guessing it would take one of those flex cameras connected to a laptop to get a clear image of that serial #

To me, it appears like some of the components were swapped over from the 5.0 that was originally in this boat. Some of the top end parts like the heads and intake manifold looked more dirty and used than the lower end- the block, starter and oil pan all looked like new when I bought it
 

alldodge

Moderator
Staff member
Joined
Mar 8, 2009
Messages
42,275
Is it MPI or EFI?

I'm thinking electrical, so I would start with the 10 pin engine connector. Then the rear of the block where the Negative battery cable attaches and should also be engine harness connections. Feel along the engine harness and find any grounds which come out from it to ensure they are clean and tight

Then remove relays and loog real close for the contacts are wires are clean and will make a tight connection. Same with fuses. There is also the engine connector to EFI harness. This is a 3 to 6 pin, usually flat type connector
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
Thank you sir ! Some good ideas there. I believe it is MPI. I will certainly try to check all of the things you mentioned, however I am curious why you think it might be electrical ? Especially since the condition only seems to happen with higher angle takeoffs. I can run it all day at low speed without any issues. It only occurs when I try to get on plane quickly, which is why I figured it had to be fuel related
 

alldodge

Moderator
Staff member
Joined
Mar 8, 2009
Messages
42,275
Because of your previous fixes and it being intermittent. If it was fuel it would stay that way
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
Well I took a quick glance at it yesterday. I didnt have much time to work with but pretty quickly noticed that the fuel hose that goes from the pump to the carb has a slight restriction near the pump side. Its just slightly kinked, but pretty obvious. I went ahead and ordered a new one (sierra 18-8115) -which looks like it will be a decent bit longer than the hose that is currently on there. Hopefully that doesnt mess anything up !

So you believe that a fuel problem wouldnt be intermittent ? I figured if it was some sort of air leak the problem would be irregular. I am hoping to check out the areas you mentioned in the next couple of days. I will report back here. Hopefully this thread helps out others who have the same problem.
 

alldodge

Moderator
Staff member
Joined
Mar 8, 2009
Messages
42,275
Fuel supply can weaken over time but will not just come back like there was no issue
 

mtntrogger

Seaman Apprentice
Joined
Apr 29, 2013
Messages
41
Wanted to post a quick update. I started checking around the wiring harness around the engine, while doing so I also checked the connections on my battery. They were not as tight as I would like. I tightened them and noticed that some of those wires ran behind a second battery that I keep on board in case my main died and I needed to jump.

However, this second battery isnt secured properly. Basically I have a strap that goes around the main battery that I have looped around the second battery. After looking at it for a while, I realized that it was likely that this second battery was sliding back and forth as the boat was at a steep angle during the pre plane stage. I decided to remove it. Especially since in the 4 years Ive owned this boat the battery has never given me any issues, regardless of how long I played the stereo.

I took it out after this and she ran perfect all day. Not one hiccup. Started first crank everytime and seemed to not care at all about the steep angle when we were taking off wakeboarding. I cant believe it was something so simple causing me all the headaches. Im really glad I listened to your advice and looked at the wiring first. Now I have a brand new fuel pump and hose still sitting in the box's ! Pretty sure its too late to return, but I sure am happy I got this worked out.

Thanks again for pointing me in the right direction, sincerely appreciated sir
 

rwfloberg

Recruit
Joined
May 17, 2021
Messages
3
Wanted to post a quick update. I started checking around the wiring harness around the engine, while doing so I also checked the connections on my battery. They were not as tight as I would like. I tightened them and noticed that some of those wires ran behind a second battery that I keep on board in case my main died and I needed to jump.

However, this second battery isnt secured properly. Basically I have a strap that goes around the main battery that I have looped around the second battery. After looking at it for a while, I realized that it was likely that this second battery was sliding back and forth as the boat was at a steep angle during the pre plane stage. I decided to remove it. Especially since in the 4 years Ive owned this boat the battery has never given me any issues, regardless of how long I played the stereo.

I took it out after this and she ran perfect all day. Not one hiccup. Started first crank everytime and seemed to not care at all about the steep angle when we were taking off wakeboarding. I cant believe it was something so simple causing me all the headaches. Im really glad I listened to your advice and looked at the wiring first. Now I have a brand new fuel pump and hose still sitting in the box's ! Pretty sure its too late to return, but I sure am happy I got this worked out.

Thanks again for pointing me in the right direction, sincerely appreciated sir

Was the second battery wired in, or was it just interfering with the primary battery?
 
Top