Engine harness

S

swilson

New Member
May 20, 2008
16
Gunpowder River
Boat Info
2004DA
Engines
5.0 BIII
Starting a few weeks ago, when running at cruising speeds my smartcraft alarm began beeping (2 beeps every 60 seconds) until I turned the boat off and restarted. This happened twice. Then on a short trip back from Fairlee creek I hear another beep and the smartcraft tach display restarts with an error (Engine Data Bus) and the engine cuts out. This happens several times over the last couple weeks, but only at cruising speeds. Also, my fuel pump now continues to run after the engine is off and until the battery is turned off.

I took it to MM Gunpowder Cove and after 1 hour computer diagnostics (found no codes) and 1 hour sea trial, they were unable to replicate the alarms/stalling, but did experience the fuel pump issue. They did say the engine harness loses power at the quick disconnect. Spread pins and still loses power. The want to replace the engine harness and believe this is the root of the issues.

2 hours Diagnostics @ $95/hr
Engine harness (865454A01) $712.34
3 hours installation @ $95/hr
1 hour post installation "Water Test" @ $95/hr :huh:
Total after environmental surcharges and shop supplies = 1350.98:smt089

1) I did some searching on these symptoms prior to taking it to MM and found some information, but nothing really relevant to my situation. Hopefully this info will help someone else.

2) I am a new boat owner and by no means a mechanic. Does replacing the engine harnes sound legit? I already told them to go ahead with the repairs, but for some reason, I don't feel confident that this will fix the problem.

Thanks!
 
I'd be a little upset that a "non-moving", essential part would fail so quickly into the boat's life, especially for that amount of $$$$. It's one thing if there's wear and tear on something.
You may want to Call SeaRay Customer Service and describe the diagnosis and see if they think you should expect these kind of repair costs every 3-4 years.

I'll be curious to hear what their response is.

Best of luck
 
I'm troubled by your post, mostly because I have the same engine, same year. Most 5.0 owners report their engines to be pretty-much bullet proof if properly maintained. Any more info you can shed or other symptoms? Did someone take apart anything on the engine/electronics? My WAG would be the ECM, not the harness. I don't hear of harnesses going bad like yours apparently did, especially on later year boats.
 
gerryb said:
Any more info you can shed or other symptoms?
Click to expand...

Only thing I didn't mention was the RPMs drop (smartcraft protection?) just before the engine cuts out, but it happens so fast you can't tell what happened until after your sitting in the water wondering why the boat just stopped. :huh:

gerryb said:
Did someone take apart anything on the engine/electronics? My WAG would be the ECM, not the harness.
Click to expand...

I'm the second owner and can't speak to prior maintenance other than the winterization that was done last year. I purchased the boat in May. Boat had 60 hrs. and was kept in a hi and dry shed. very clean boat and engine, appeared well kept. Surveyed as excelent from a well regarded surveyer.

I guess used boats are like a box of chocolates...
 
Can you have the dealer try an ECM from another boat or parts inventory to further diagnose the issue? Easier to swap an ECM vs. a complete harness first.

I agree with Gerry that your problem sounds more like an ECM vs. a harness issue.

Doug
 
No, unless the batteries were wired backwards, or there was a recent screw drilled through it, then your harness is fine.

Sounds to me like the smart craft is cutting out when there is more vibration occuring on the boat, especially the motor.

On top of the intake manifold you will find a dead end harness that has a black cap on it. Inside the cap sits the 3 20a fuses that the smart craft runs off of. The are the smaller fuse, than your normal spade(can't think of the name)

It is possible the catches on the fuse connections are no longer tight and the fuse is losing connection with its contact as the motor vibrates more.

Try prying them in a bit so its makes a better contact. Look for and clean for corrosion as well.

If you need me to take a picture of exactly where it is I can tomorrow.

-Chris
 
Sean;

Same Boat, Same year 207 Hours. at about 160 hours my smartcraft was going out on my boat. Had MM check the boat over and the first thing they did was what Chris (SR Tech) recommends. one of my fuses was blown, tech replaced it and it Blew almost immediately.

It later turned out that the Fuel Pump was bad and was cuasing smartcraft to blow the fuse (weird). but the Tech managed to get the boat running in about 2 days for the grand total of $25 (6 year extended warranty at work).

I would have to agree with the rest of the folks. Even with Salt Water abuse and over 200 hrs I can't find any major falts or corrosion on my harness.
 
My buddy had a 2002 280 dancer that acted the same way. He bought the boat new and had the problem a couple months later. After four weeks and 3 or 4 techs including a Merc factory tech, they decided it was the harness. When the local tech came out to replace the harness he found a ground wire broke off of the ground buss behind the motor.(in a spot that is almost impossible to see or get to) He put a new lug on it and that corrected the problem. They never but the new harness on and the boat run great after that.
 
From your initial description of the problem with the SmartCraft alarm and the intermittent beeping, I would have suspected the IAC valve. They tend to fail at 100 to 125 hours on the 5.0 engines. Mine did and alot of people have had it happen. The result of the failure usually causes a no idle and then no start condition in the engine. The engine can be started by placing the shift in neutral and disengaging the shifter, applying some throttle and starting the engine. However, the engine will stall upon returning the shifter to neutral. If you are near the 100 hour mark, you might try replacing the IAC. You wil probably need to do that soon anyway. The IAC is easy to replace. The cost of the part is about a $100.00.

Good luck
 
This is more of a general comment about harnesses. I had a problem on my 8.1s that are smartcraft capable but mine is an early 2002 so no smartcraft. The engine would crank but I could not get full rpms so I thought it was in guardian mode. Long story short after 9 hours of work, without a diagonoistic computer, we unplugged the harness and claened all the pins and replugged it. Problemed solved and no issues since then. My point is these newer electronic engines with all the sensors can appear to have major problems when realy it can be very simple issues and these harnesses are prone to malfunctions due to the enviroment then are in. Check the simple things first and make sure your marina has the proper tools. My marina has now purchase the appropriate computer hardware and software to check engines.

And before you ask, yes I did pay them for the 9 hours of service work. They have since treated me very well on other service issues.
 
Ouch^^

Yeah that diagnostic computer makes things so easy.

Tell's you wants wrong, where it is, and how to fix it.

But I've always had more fun with the old carb/distributor
setups.
 
I take it this is using the MEFI puter? These Delphi pins are very delicate when diagnosing. I have found some techs using paper clips when checking terminals and those make the intermittents worse. These ECM terminals are made for up to 12 insertions, or detaches in their lifecycle, and they don't tolerate oil or grease well since they don't usually carry much current..

Grounds and powers probabaly count for more trouble than anything else. Most new equipment installs forget the need to upgrade the (-) side too!

DG
 
Well, it looks like the harness replacement fixed my issues. I talked to the mechanic. prior to replacing the harness, he was able to recreate my issue by taping the wires while underway. He also said he called Merc to confirm his diagnoisis and when he told them about the fuel pump coming on with the battery, they stopped him and immediatly said replace the harness, as if it was a known issue. Unfortunately, they were unable to give me an explanation as to why it would have failed being only 4 years old, other than the standard, "things fail", corrosion, etc... I did get the old harness back, but haven't looked at it yet...

I picked it up from MM on Friday and ran down to the inner harbor and then back up to middle river without any issues. :thumbsup:

I haven't called S.R. customer service, but I doubt I'll get very far anyway. I guess its worth a shot though.

Everyone, thanks again for your help!:smt038
 
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