Re: Volvo 5.0 GL 2002 Fuel system
OK now
I went round and round with this for some time
Finally found out the issues.
The fuel pump was having periods of time where it would go out.
That in turn caused a failure of the green alternator connection.
It might have been the other way around I am not sure.
final fix is to replace the fuel pump and the alternator.
Here is how to trouble shoot the problem for anyone that has this issue.
1. Boat stopped without warning. Cannot Restart
2. No gas to the carb
3 first check to see if you are out of gas
4. Check the 7.5 amp fuse located in the master engine fuse case. Were the 50 amp breaker is. (replace it if it is blown) There are 4 fuse case located in the master breaker area. 2 are a live fuses, and 2 are spare fuses not in use. If you have never used them there is 1- 7.5 amp fuse and 1- 40 amp fuse (for the starter relay)
5. On the fuel pump there is a connection wire. It has a metal clip that holds it in place. Make sure the connection is tight and the contacts are not corroded.
6. Just to the side of the fuel pump is a relay. It is used to supply power to the fuel pump. (It uses the same relay that the trim and tilt uses. You can buy one online for 7 bucks or west marine for 18)
You may have 2 relays here. One is a spare. Switch them if you have a spare, or pull the relay out and make sure the connections are good and clean.
7.You should have an access panel to the fuel level gague under a panel, near the motor. It will be round with 6 screws. Remove them and look at the smallest fuel line that runs to the engine. Where it connects to the engine, there is a L type connector. Screwed into this is an anti siphon valve.
Disconnect the hose from this line, and unscrew this antisiphon valve.
Inside this connector, there is a metal ball. It should move freely back and forth when suction is applied to the outlet.
If you cannot get air to pass through, then it is bad.
If you can get air to pass through going inward and outward it is bad.
It should be a one wave connection, Gas can go out but not back in.
8. If nothing has worked so far. Check the starter relay located where the 50 amp breaker is. "The big red button". same thing. It is a relay, uses the same one as the trim and tilt but has a place to ground it to a metal point. You can replace it with a standard trim and tilt relay. Chances are this is not the problem since if the relay is bad the starter wont turn.
9 If your still stuck, get 2 wires. Connect one to the positive side of the battery the other to the negative. Touch the 2 electrical connection points on the fuel pump where the wire goes in.
Just because it "spins" with power does not indicate it is working.
This at least tells you if you can test your wires.
10. Now take the fuel pump relay out of the connector. There is a red wire that goes into one of the connector points on the relay holder, and there is also a yellow red and green wire that share one of the connector points on the relay.
Have the fuel pump connected to the wire from the relay.
Take a jumpper wire, and touch the red wire connector to the the yellow red and green connector.
The pump should "spin". This tells you the connection wire is good. It also tells you the ground is good.
If the fuel pump does not "Spin" you either have a bad connector for the relay, or a broken ground wire somewhere. Trace the black wires back to the engine block main ground to make sure it is not broken or loose.
Of course you may have also blown the 7.5 amp fuse. Make sure you check this often.
11. If nothing is working still, prime the fuel pump by jumpping the red and yellow/red and green wires again. also put just a bit of gas in the carb
Try and strart the engine. If starts and runs, then your problem is with the power to the pump before start. The power comes from the starter selonoid.
There is a yellow red wire that leads to the starter relay, at the main 50 amp breaker. Trace that line back to the selonoid. If broken replace it.
If not conside replacing the selonoid. They are 35 to 89 bucks online.
If it does not run after primed then you have a problem with the power coming from the alternator. When you have an alternator power failure to the fuel pump, the pump will not prime when started so you cannot rule out selonoid failure without a vollt meter to check.
If you have made it this far, I would replace the fuel pump. The cheapest online it $150
I would also replace the alternator, since both the fuel pump and alternator have had issues.
My final resolution that worked was to replace the fuel pump and alternator.
Cost a total of 320 bucks and its easy to do.
Hope this helps somebody.
