5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

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363coupe

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I have a 2002 Chaparral 200 SSe with 135 hours on it. It has a Volvo Penta 5.0 GL (Chevy-carbed).

When I ran it for the first time this year, it ran terrible. It would spit, spudder, and wouldn't even get on plane. I pulled the 2 barrel Holley off and rebuilt it. Carried it back out to the lake and it ran a whole lot better but now I'm having another problem. Now the boat cranks and runs great. You can cruise all day long at around 2,800 RPM's but when you get it up above 3,000 RPM's, it'll run perfect for about 30 seconds and then it'll start bogging down and eventually die if you leave it alone but you can pump the accelorator while it's doing this and it'll pick back up and run fine for a few more seconds then start bogging down again.
I pulled the fuel/water seperator out and it had a little water in it so I drained the fuel tank and put a new fuel/water seperator filter on it and a fresh tank of gas. I carried it back out to the lake yesterday and it's still doing the same thing.

The boat has a round electric fuel pump on it and I decided to check it yesterday. I pulled the fuel line off the carb and turned the ignition to the ON position and the fuel pump didn't kick on. I pulled the coil wire off and had someone turn the engine over to see if the pump would spit out any fuel but nothing came out.

I'm assuming the fuel pump is going bad but I don't understand why it'll run great below 2,800 RPM's but when you pull the fuel line off, it would pump any fuel.

Any help would be greatly appreciated.
 

363coupe

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

No, I haven't checked the relay. It never crossed my mind since it would run fine a cruising speeds but not at WOT
 

Don S

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

It's very possible you have problems in the boats fuel system, plugged up fuel tank vent, partially plugged pickup tube or antisiphon valve. Air leak in the system.
Hook up a remote fuel tank (Outboard tank) directly to the fuel filter and see if it runs better.
 

Maclin

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

From the safety angle, when the coil wire is removed there is still a spark potential trying to arc to anything resembling a ground. If that arc happened with raw fuel and vapors close by then it could combust and that would be tragic in almost all instances. Just sayin' be safe out there! ;)
 

363coupe

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

It's very possible you have problems in the boats fuel system, plugged up fuel tank vent, partially plugged pickup tube or antisiphon valve. Air leak in the system.
Hook up a remote fuel tank (Outboard tank) directly to the fuel filter and see if it runs better.

I'll definatly try that this afternoon. I forgot to mention that I carnked it on a hose before I carried it out for the first time this year and it ran out of gas. I'm thinking it may have sucked some trash through the fuel system. Thats why I rebuilt the crab to begin with.
 

363coupe

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

I pulled the fuel pump off last night and checked the screen on the inlet side. It had one small peice of trash on it. I cleaned it off and hooked up a fuel pressure gauge to it. It was holding a consistant 4psi. I think this is plenty?

I also checked the vent hose. It seemed to be clear of any blockages but it wade me consider something else. The vent tube exits INSIDE the fuel fuller area. When the fuel cap is on, it relies on the cap to vent? Is it possible the cap isn't letting it vent or draw in air?

The fuel line running from the tank to the inlet on the fuel/water seperator filter is clear as well.
 

Maclin

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

Not all gas caps are designed to vent, so you could have the wrong type on there. See what it does with the separate gas tank (be sure the vent on the separate tank is open :) )

If the wrong cap is on there then this probably should have been a problem all long unless something just now went wrong with the cap, how long have you had the boat?
 

363coupe

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

I've had the boat for 3 weeks. The cap does appear to be a vented cap. It'll be this weekend before I can carry it back out to the lake and try it.
I don't know if this matters but it will run continuously when you have it hooked to a hose. It only has the problem when it's under a load.
 

Don S

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Re: 5.0 GL Volvo Penta Cuts Out at WOT *HELP PLEASE*

You are actually a little low on the fuel pump pressure, it should be 4.9 - 8.5psi at idle.
Here is the specs of the fuel pump pressure throughout the rpm range. It may be way too low at higher rpm.

View attachment Fuel sys specs.pdf
 

Dhassan76

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I know this thread is super old but my Caravelle with the same engine is doing the EXACT same thing. Was hoping this guy found a solution.
 
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