2002 Johnson Chk. Engine Alarm

[Beachbum49]

New 2002 Wellcraft 210 CC. 150 Johnson has been back to dealer 4 times. Runs good for 30-45 minutes then the check engine alarm goes off. They have replaced everything from the pick up tube to the engine. The bulb never gets really pumped up and if it is checked after alarm goes off it is really soft. Any ideas? Thanks.

 

[clanton]

Re: 2002 Johnson Chk. Engine Alarm

Sounds like you have a restriction between the bulb and tank. The 2 easy things are to remove the remote fuel filter if it has one and the anti-siphon valve for a test run. Sears has vacumn guage for about 25.00, Discount auto has plastic Ts for automotive vacumn hose, or hardware store for brass fittings, Start at sensor hose nipple, full throttle in water loaded, should be about 4/5 inches vacumn, keep moving guage toward tank, check at primer bulb, at remote filter, at anti-siphon valve. All hose 3/8 inside diameter, all fittings 9/32 inside diameter. You can check fittings with a 9/32 drill bit, or 9/32 steel ball.

 

[Beachbum49]

Re: 2002 Johnson Chk. Engine Alarm

Thanks for the help. It has now been to two other Johnson cert. mechanics who both say it is something in the tank. The dealer is going to separate the hull to get the tank out. This is making me very nervous. Any advice on what to check after they get it back together? Is it common for a dealer to have to take a hull apart?

 

[Beernutz]

Re: 2002 Johnson Chk. Engine Alarm

If it's truly necessary to remove the tank, there should be an indented outline on the floor of the boat. They should cut along that line and remove a section of the floor, then replace it after replacing the tank.<br /><br />That boat should have a plastic tank. If I'm not mistaken, you should be able to unscrew and remove the pickup tube to check for a restriction. Most have a screen on the tube that can clog if the tank gets contaminated during construction. There shouldn't be anything else wrong internally with the tank.<br /><br />Why do they insist on removing the tank? That's pretty drastic, and uncommon, unless the tank is leaking. I'd check the vent before going any further. That's external to the tank.

 

[clanton]

Re: 2002 Johnson Chk. Engine Alarm

Why dont they pull pickup tube and fuel sender? and take a look? You probley could look in the tank with bore scope.

 

[jegervais]

Re: 2002 Johnson Chk. Engine Alarm

Geez, before they go to all the trouble of tearing up the floor, I hope someone had the good sense to check the vacuum switch on the engine. I've seen a flakey switch cause false fuel restriction alarms on those engines. Did these "cert mechanics" hook up a vacuum gauge to the fuel supply and verify this restriction???<br /><br />-John

 

[Beachbum49]

Re: 2002 Johnson Chk. Engine Alarm

Today they told me it was because they found "crossed PVC runners"so they didn't have to separate the hull. I'm picking the boat up this weekend and using all your suggestions to fix it myself. I'm also going to have a long chat with Wellcraft about their quality control and their dealer network. I got screwed 12 years ago by buying a Bottomliner. If I got screwed this time it was by a boat builder that has a better rep than they deserve. Guess I'll just have to break down and buy a Contender. <br />Hey honey, we need to spend just a little more...

 

[Beernutz]

Re: 2002 Johnson Chk. Engine Alarm

What are "PVC runners"? Shouldn't be any PVC in a fuel system, or anywhere else in your boat, for that matter.