2004 Volvo 5.7 Gi sputters then dies...

Shark_bait99

Petty Officer 3rd Class
Joined
May 9, 2012
Messages
96
Hello, I bought a 2004 Four Winns Sundowner 225 and she has died on me on my second trip out.

Two major issues have been noted which I am not sure are related.

On the first trip (Sunday) I was having trouble shifting gears. I was easing into gear and the engine would not move from neutral to forward or reverse idle. I would apply some gas, which was followed by a loud thud and the boat would lurch forward into gear. One of these lurches sent my poor dad into 45 degree water, but fortunately just a hop away from the dock and my warm car & seat warmers. No permanent damage. Yet. This forum helped me realize that I needed to firmly place the engine into gear.

Armed with my new found knowledge I headed Out today to test my theory. Of course she slipped right into gear and cruised smoothly. After about 20 min, I slowed down to stop and as I was decelerating the clunk happened, even before going into neutral. I turned off the engine waited a few minutes then restarted. She started fine but after 30 sec she sputtered and died cut out. I waited and tried her again, and she went into a weak idle, and seemed like she was gong to stall so i tried to give some gas but she cut out again. When I tried again she would crank but not start. I switched my battery to both the deep cycle and the starter to see if a little more juice would help, but still nothing. Both batteries were reading 11v.

No one else in sight, so I used my never tested 30 lb thrust "emergency trolling motor" attached to my deep cycle to crawl all the way home. Nice save bass pro - only $100 to push a 4500lb boat into the wind!

My first though was a clogged fuel filter so that's my first step, followed by a fuel system evaluation. I read the fuel system how to, but most of the test require the boat to be running... And i have no experience working on engines, but i am handy and willing to learn.

Any thoughs on what could be wrong. Could the issues be related - damaged something from the hard shifts?

The boat is still on its first full tank of gas which was winterized by the last owner. They said they filled it up and added stabilizer before winter (sept). They suggested I might want octane booster since the fuel has been sitting for several months. We are in Canada so it obviously gets cold. Could another easy diagnostic tool be to add the octane booster and/or some fuel Cleaner to unblock the clog if it's not the filter?

Thanks for your help. I am sorry about the long post, but I think it's all relevant.
 

Shark_bait99

Petty Officer 3rd Class
Joined
May 9, 2012
Messages
96
Re: 2004 Volvo 5.7 Gi sputters then dies...

She only has 115 hours and the marine surveyor who looked over the boat, but did no in depth engine testing said she was in mint condition. Thanks again.
 

Don S

Honorary Moderator Emeritus
Joined
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Messages
62,321
Re: 2004 Volvo 5.7 Gi sputters then dies...

Might want to check the screens in the inlets of the fuel pumps. Been a lot of them found plugged up lately.
 

Shark_bait99

Petty Officer 3rd Class
Joined
May 9, 2012
Messages
96
Re: 2004 Volvo 5.7 Gi sputters then dies...

Might want to check the screens in the inlets of the fuel pumps. Been a lot of them found plugged up lately.

Thanks Don. So you agree that it sound like a fuel issue and I hopefully didn't wear out the gears when shifting improperly?

My service manuals are supposed to arrive soon, so I will start with the fuel system once I have more information than the one picture in the manual. Unless anyone has a more detailed fuel system diagram they would be willing to share? I will search the forums.

Do you think that fuel cleaner could temporarily unblock the clog? Certainly wouldn't hurt?

The mechanic says he cant even look at the boat for 3-4 weeks. I am going to call around, but its that time of year. I spent way to much on this boat to have it sit on the trailer over the May long weekend. Our summer is way to short in Canada.

Thanks again.
 

Don S

Honorary Moderator Emeritus
Joined
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Messages
62,321
Re: 2004 Volvo 5.7 Gi sputters then dies...

I don't know about the drive, but stop "easing " it into gear. You want the cone to grab quickly.

Nothing in a can is going to fix it, I'm not referring to the fuel filters, I am referring to the screen inside the inlet of the fuel pump. It's about a 1/2" in diameter.

What is the full model number of your engine, I have the OEM manuals for your engine, just need to know which ones. Year doesn't help.
 

Shark_bait99

Petty Officer 3rd Class
Joined
May 9, 2012
Messages
96
Re: 2004 Volvo 5.7 Gi sputters then dies...

I don't know about the drive, but stop "easing " it into gear. You want the cone to grab quickly.

Nothing in a can is going to fix it, I'm not referring to the fuel filters, I am referring to the screen inside the inlet of the fuel pump. It's about a 1/2" in diameter.

What is the full model number of your engine, I have the OEM manuals for your engine, just need to know which ones. Year doesn't help.

Thanks, I will get back to you with the exact model number as she is currently parked at the shop. Do you recommend the Volvo manual off their website over the seloc and clymer versions?

The second time I went out (after reading the forums), she was shifting smoothly once I firmly place her into gear. Only felt/heard the engine jerk once, after a 20 min cruise, during the deceleration. Everything went downhill shortly after, but I am hoping its just the fuel system and not my poor shifting.

Thanks
 

Don S

Honorary Moderator Emeritus
Joined
Aug 31, 2004
Messages
62,321
Re: 2004 Volvo 5.7 Gi sputters then dies...

The Volvo manual is where Seloc and Clymers get their information. They just use about 1/4 of it, and make a lot of mistakes along the way. They are great for knee pads though.
 

Shark_bait99

Petty Officer 3rd Class
Joined
May 9, 2012
Messages
96
Re: 2004 Volvo 5.7 Gi sputters then dies...

Mosquito season is coming, maybe a flyswatter as well?
 
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