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Hi everyone, my 2000 Dauntless stopped running a couple weeks ago. It is pretty evident I'm not getting fuel into the engine from the gas tank. At first I thought the bulb was bad because I couldn't get it firm so I replaced with an OEM Mercury bulb and replaced the fuel filter while I was add it. I also added about 5 more gallons of fuel to the tank just to be sure. I'm still not getting fuel into the engine and the primer bulb still doesn't get firm. The only other thing I can think of is the pickup that must suck fuel up from the tank isn't working. I can't figure out how to pull that out and check it though.
Any suggestions on how to resolve this problem? Am I overlooking something obvious? Is there a way to pull out and remove the part of the gas tank that connects the fuel hose to the water separator to see if it is clogged or something?
1. bad fuel pump on the engine. To find out, plug in an external fuel source from an on-deck tank with a good hose and bulb. If that bulb gets firm, with plenty of fuel being supplied, and the engine still won't run, you need a new fuel pump. If it does run properly, go to #2, since you now know the engine is good and boat's supply source is bad.
2. Make sure you don't have an air leak in your fuel line system. Be sure fuel fittings and hose clamps are tight, with no slits in the fuel line, no fuel leaks.
3. Ethanol fuel may have destroyed your fuel hoses. During the period of your rig, Mercury's silver fuel lines were later discovered to not hold up, with internal separation clogging/blocking fuel flow. To find out, disconnect your fuel line at the engine connection, so you have an open line. Using the primer bulb, squeeze fuel into another container. If you get a strong flow, the lines are good, and the fuel pump is still your problem. If no flow, and junk comes out, the hoses need replacement.
4. If the above don't provide solution, the tank pickup is the only thing left, which probably means your tank is filled with crud. The pickup fitting is easy to pull out, and the tank may need to be flushed out.
#1. Ok, I haven't tried that since I don't have a deck tank, but I'll buy one. I figured the bulb would still get hard even if the pump was bad.
2. Pretty sure this is good
3. Nothing comes out when I pump the bulb, so I replaced the bulb and hoses with new mercury OEM ones. The fuel filter did have a bunch of orange, crystal looking crud in it. I thought I read on a a forum that was caused by either the tank or the fuel lines breaking down.
4. I couldn't figure out how to remove the pickup fitting. I removed the large plastic nut holding it on, but still couldn't get it out. I can't tell if it is threaded or not. How does it come out? If it does need to be removed and cleaned, what type of company would provide that service?
Your fuel filter situation indicates your problem may indeed be the tank or the pickup. First be sure the hose from the tank to the filter is good. That would be 3/8" A-1 grade black heavy wall fuel hose installed by the factory, and it should still be good. Or you can just replace it for preventative maintenance.
Most fuel pickups that I have seen are threaded, but I do not have knowledge of the Dauntless setup. If the fuel hose from tank to the filter is good, the problem is definitely the tank or a clogged pickup. As you mention, you may have ethanol phase separation in the tank, which means it needs to be drained and flushed out. Any good boat dealer should be able to refer to someone locally who can provide that service. It tends to be expensive.
I would look into all of the above before buying a deck tank for an external fuel source.
Your fuel filter should not have crud like that in it.
