Changed fuel filter in FCC, now boat won't start

[Ski_Keuka]

2002 196

Am in process of winterizing boat and wanted to change fuel filter. Unscrewing the canister was every bit as hard as others have described, and fuel filter was stuck in canister when removed (I had to push through the bottom to get it out).

Put in new filter, all back together with pipe-dope and grease, and now it won't start. This even after cycling the ignition.

Boat could start right up until the time I did this; what could I have done to cause this, and how can I troubleshoot?

[teamseal]

Take your canister back apart and check that the pump wires did not come disloged from their terminals.

[Ski_Keuka]

If the wires were dislodged would I still be able to hear the pump running (for a few seconds) when I cycle the START/STOP button?

I do have a suspicion that the hose on the pump got disconnected or cracked (on canister removal), as I've seen other posts mentioning checking the hose for cracks -- is this possible?

[nms1991]

As Teamseal said pull your fcc canister off and check your wires, the noise you are hearing is the low pressure pump running when the computer commands it to when you turn the key on.

[2004196]

Fuel canister

I also fill the canister w/ gas when I re-install it, have not had any issues. Hopefully you find it is a loose/unhooked wire or hose issue. Good luck! Let us know

[DanielC]

You probably will not hear the high pressure pump run, it is inside the FCC, surrounded by Gasoline, and effectively isolated from every thing by the filter.
Does your boat have a Ford or the GM engine?

[keukawake]

You could also see if there is resistence on the pump circuit (to see if it has come unclipped). Just open the connector and use a mutimeter (continuity or resistence) on the two wires on pump side.

If the wires seem attached, plug connector back together and disconnect low pressure pump. Then turn on, you can still hear high pressure pump if low pressure is not plugged in (obviously have hatch open!!, even better if you have someone else at helm and you listed to pump).

You also may simply need to reprime the FCC with a few cycles.

[Ski_Keuka]

OK checked fuel pressure on the rail, 0 psi. Opened the FCC again and presto! - black/red wires were disconnected from the top of the FCC unit. Must have occurred when I removed the FCC to change the filter.

But now I have another question... which way do the black/red wires go on? The connections to the HP pump were still on, so they should be correct -- but what about the connections to the FCC top?

[DanielC]

Again, Ford or GM engine?

There is probably a connector on the cable going into the top of the FCC. disconnect it, and on the engine end of the connector, determine the wire that is positive, with a test light, or a volt meter. When you first turn on the ignition, without trying to start the boat, you should get a voltage for about 1 second.

The same color of wire should be coming out of the FCC.

Carefully examine the high pressure pump. Ideally, there will be an mark on it indicating the polarity.

If there is no mark, you just have to put it together, and try it. If there is no fuel pressure, reverse the two wires and try again.

Be very careful with gasoline, and electrical connections.

[Ski_Keuka]

It's a Ford GT40; I'm going out to the boat to see if there are markings for polarity now.

[DanielC]

You can download the GT-40 service manual from the downloads section of this site.
On page 282 of the PDF service manual is a diagram of the fuel pump electrical circuits.
Here is how you check the fuel pressure on a GT-40 without having to run the engine:
http://www.planetnautique.com/vb3/sh...=Fuel+Pressure

[Ski_Keuka]

OK to close out this thread and for future reference I took apart the FCC for a 2nd time and yet again the wires were disconnected from the spade connectors on the FCC top. Most likely what had occurred is when I removed the FCC the first time, it twisted the pump/wires (due to filter expansion); then I put the FCC back together w/o noticing the wires weren't connected to the FCC top. Result: boat wouldn't start.

Since the wires were twisted off their spade connectors during the 1st removal, they didn't make a tight fit when I put them back on. After checking the FCC a second time I pinched the terminals (with pliers) and clipped them back to the spade connectors, *ensuring they made a better connection this time*. Also, as I screwed the canister back on I watched to ensure the wires weren't getting twisted again. PROBLEM RESOLVED!

Hopefully the terminals will hold during use in the water I'll see what happens next spring Thanks to all for the suggestions...

[skinautique]

Here's an easier way to check it, so that you aren't taking off and putting the canister on so much:

Turn the key to accessory, and listen to hear if the fuel pump cycles up, if you hear it, you need to cycle the key a couple of times and you will be set.

If you don't hear the fuel pump cycle, you knocked wires off, more than likely.

Hope this helps others out there!