www.iFourWinns.com

I own a 2000 210 horizon with a 5.0GI. The motor seems to be running out of fuel. I have replaced the fuel filter and checked the anti siphon valve. How do i remove the fuel pickup to check the screen in the fuel tank. It always happens over 3000 rpm also the fuel pumps start to whine when its acting up. Also how do i check the breather line into the tank. Any help will be greatly appreaciated. Herb

Herb, you can try running it without the fuel cap on to quickly see if it a venting or anti-siphon valve issue. Sounds like this is what it could be judging by the fuel pump noise...

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Alec

2006 Horizon 190
VP 4.3GL/SX, Sunsport

The EFI engines have two fuel pumps (low and high pressure). The whining sound is often made by the high pressure pump. It's possible that it is failing. This could be caused by several things including:

1) clogged fuel filter (low pressure pump not getting enough fuel to the high pressure pump)
2) low pressure pump going bad (again, not getting enough fuel to the high pressure pump)
3) the high pressure pump failing

Another component to consider is the fuel regulator on the injector rail.

The replacement of the fuel pumps is a complete assembly (filter, housing, water fuel cooling canister, low and high pressure pumps). Cost not installed is @ $800 US. Regulator is @ $235 US. I just had a failure of the low pressure pump on one of my engines causing the high pressure to whine and not allow the engine to go above 2000 RPMs - it would then backfire and stall.

My total bill with diagnostics, parts and installation labor was just south of $1,600 US. I have don allot of research on Volvo Penta fuel pump failures and there are plenty. My marina received five of the $800 jewels from VP and they were gone the next day by folks around the area purchasing new assemblies. In addition to your fuel filter, there are 10 micron filters in each of the fuel pumps (which are difficult clean) and the fuel regulator. All of them had very small black particles on them - so where does the black particles come from? My theory is the housing is painted with black paint (including inside the fuel filter mounting plate (where the fuel filter rubber gasket seals with the flat surface). The ethanol in our fuel reacts with the paint and small pieces come off and cause damage to the components mentioned earlier. Ironically, the new Volvo Penta pumps assemblies are not painted. This does make one wonder.

There should be class action against someone and a recall. If you search the internet, there are hundreds of postings. The other problem with the design is that the fuel pumps run VERY HOT. They are designed to be mounted inside a gas tank like our cars where the fuel cools the pumps. This is not done for obvious reason in a boat thus the fuel pumps are mounted to a very warm engine and cook themselves to a premature failure as well. I learned this from a GM engineer.

Of course ethanol is a major issue on your entire fuel system - phase separation and attraction of water.

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2002 Vista 298 VP 5.0Gxi

Should have seen this forum and the post before purchasing my 2006 Four Winns with 183 hours on it. We were told just a possible fuel pump issue given a new one by the boat broker(are we surprised) and fixed a loose connection and the boat performed beautifully on our almost hour ride from one harbor to final berth. Of course next time we took it out had the backfiring and "throbbing noise of th engine" Had the fuel filter replaced took it out again and still not running right-at one point lost power to one of the engines.Jimggled some of the wires and it magically started.

Sounds like we need to replace shift cables based on what I have read as those area BIG ISSUE ALSO next question is sounds like the pumps are the next replacement issue. Not sure that the fuel filter was even a problem. New gasoline in the engine so not an issue.

We did find some crimped wires looks like someone had worked on the engine in the past. We are inboard, Crusader engine boaters with one of the issues I am seeing here with these Volva Penta's mainly at this point the starboard.

Need some direction why does Four Winns which we like the boat in general put in an engine that appears to have sooo issues?

You have a 5.0 GL then you should also pull the float bowls off of the carb(4 screws). Contaminates in fuel, and modern fuel containing ethanol (alcohol) can leave a white powdery residue in the float bowls creating passage problems especially when the engine is started or under load when the flow increases. If you do not have any debris in the float bowls, nor any white residue then the filter in the fuel tank can be checked, essentially remove all sources of ignition, remove battery cables, and/or battery, remove wires from the sender, remove bolts (carefully) and then you can remove the entire float/filter inlet screen, clean inspect and reassemble. Check the cintered fuel filter in the inlet to the carb as well because these little devils have caused more problems due to clogging and limiting the inlet fuel. The good thing is these cintered filters can be cleaned (if necessary) but I always replace them , and often.

Parts list : 2 bowl gaskets $1-$2 ea (2-spares there cheap)
cintered inline filter $2-$3
Fire extinguisher handy because you never know...

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2000 H190 5.0GL

Chalk up another victim of the failed government mandated ethanol program.

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Current Boat: 2000 Four Winns 298 Vista
Previous Boat: 2000 Carver 406MY

My 2006 Four Winns - Penta 5.7Gi-F High pressure pump started whining under load, then started even whining at idle too. I just made it back to the boat ramp before it start running rough and stalling at idle. The next day I pulled the Fuel Pump assembly which includes the Fuel Filter, low pressure pump and high pressure pump. Upon removal of the fuel filter I found bubbling in the black coating and flaking where the rubber seal meets the pump housing which really surprised me to see this black painted like coating on the inside. Next I pulled the high pressure pump and upon examination I found particles in the screened inlet area clogging the pump. After getting these black particles out and rinsing the assembly I put it back together and installed it back on the engine. A week later I had the same problem!!!

Mean while I decided to call a Volvo Penta parts dealer to see if there is a recall and they said no. So I asked if they a Fuel Pump kit in stock (part # 21608511) and they did. So I told him about the problem and he said the Penta learned from their mistakes and no longer put the black coating inside the new pumps, but he was not aware of a recall.

So next on, 7-19-2012 – I called Volvo Penta Warranty: 1-757-436-5100 (consumer relations) Josh: Gave me a line that the special coating reacts to ethanol fuel & water and causes a stripping of the coating in some instances. He said this the fault of the consumer using ethanol and sitting for long periods of time. I told asked him why there was no warning about this. He just repeated the same lame story above. SO Next I requested to talk to a Supervisor.

The Volvo Consumer Relations Suprv: Jay Koontz said the problem is due to ethanol sitting for long periods on time, collecting water then causing a reaction with the special black coating, Jay Koontz said that unless it is determined by the US Coast Guard to be life threatening defect that no recall is required.

My reply was: what about boaters out in the Gulf of Mexico, Ocean or lakes and this happens, leaving them stranded when the boat stalls due to when these specially coated fuel pumps flaking causing fuel blockage? Seems to be life threatening situation to me.

Also , I have been using 100% gasoline since I owned the boat in 2010, but regardless of what Volvo says….this is a design defect and should be a recall. This really is unfair to the consumers for Volvo Penta not to recognize this as a real defect!!!

I am sure a lawyer could get a big pay day off these guy’s lame excuses.

If you have one of these special internally black painted/coated FUEL Pump assemblies call Volvo Penta Warranty: 1-757-436-5100 (consumer relations) and complain.

Meanwhile if you don't want to get stranded, then best to replace you fuel pump kit with the new unpainted/coated version. Hope this post helps!

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Seajay-v248

Lots more stories of failed fuel pumps:

http://forums.iboats.com/Volvo-Penta/Fuel-Pump

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2004 Vista 298
Twin 5.7L Volvo Penta GXi-E

Have you been able to fix the problem yet? I've changed the pump assembly, pressure regulator and now I have sent the injectors out for servicing. After the injectors, I'm not sure where else to go.

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2004 Vista 298
Twin 5.7L Volvo Penta GXi-E

They can run it in their boats mine gets 90 Octane Rec Fuel. 3.85 a gallon is worth not having all these issues with Ethanol.

Well took the 288 Vista out for a spin on the Lake before heading off to the office, rode like a champ no engine issues nothing just great performance-we'll see how long it lasts.

Thanks for all the input Fuel filter replaced and also son-in-law went thru the wiring did find a couple of issues with that(naturally this was corrected by the dealer mechanic based on the trialrun, or so I was told). I keep getting a service evaluation form from the dealer to complete-not sure if I want to really complete . I had contacted the sales person as he had asked me to do in regard to the issues(he is also the manager) never a return call, follow-up etc.

They sent me a letter asking me to recommend them to my friends etc. - don't hold your breath guys!! I received better direction and advise from this website THANK YOU FELLOW BOATERS!

Got in the new Fuel pump kit for my 2006 Penta 5.7Gi-F. But it still has the black coating on the inside of the fuel pump. Called the parts palce and they said sorry but that pum still has the black coating and that they changed the formula to prevent the flaking.....I doubt it but what choice do i Have!!
So 7-26-12 I Replaced FUEL pump kit 21608511, but the high pressure pump still feels very hot to touch after about 60 seconds running. So ordered a Fuel Pressure Gauge to make sure the pressures are okay to prevent damage to the high & low pressure pumps.- Actron CP7838 Professional Fuel Pressure Tester
While waiting for the Fuel Pressure pump to arrive.
7-27-12 Replaced Fuel pickup and anti-flowback valve. Note that the new pickup tubes donot have a screen on the end and are about 1/2" shorter, so bought 24” pickup and cut off at a 45 degree angel at 12.5 inches.
7-29-12 Fuel Pressure Gauge arrived:
1. Checked Low Fuel Pressure and reads 15 PSI (should be around 6-8 PSI) indicating high pressure pump must be feeding back to low pressure side due to clogged fuel regulator or fuel injectors.
2. Checked High Pressure and pressure meter wiggles at around 100 PSI which is way to high (should be around 50 PSI).
3. So remove fuel pump regulator on the fuel rail and found clumps of black paint/coating on the fine screen inlet, so cleaned out screen of all the black paint/coating. Then stuck a rag in front of where the regulator is to catch the gas, then turned ignition key switch on a split second to cycle the high pressure pump to flush out the line before putting the fuel regulator back on. Then reinstalled the fuel regulator with a drop of oil on the O-rings to make it install easy (did not put on new O rings but is a good idea).
5. Cycled the fuel pressure pump several times before starting to make sure to get fuel in the lines.
4. Re-Checked low and high fuel pressure reading: on my 2006 Penta 5.7Gi-F and reading are now good: Low pressure at 6 PSI and High Pressure at 50 PSI (note high pressure pump stays cool now and does not heat up at all).

Now runs perfect! Hope this post helps!!!

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Seajay-v248

I received my injectors back from servicing, the report said the injector filters (which look like very fine screens) were very dirty. I imagine the same stuff that is clogging the fuel pressure regulator screen was also clogging the injector filters. The boat is running well now without backfiring and loss of power.

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2004 Vista 298
Twin 5.7L Volvo Penta GXi-E