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Old 08-11-2008, 12:01 AM
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boofer boofer is offline
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Fuel Pump 101

Okay, I am starting this post to help educate ourselves and possibly get to the bottom of the MC fuel pump problem. I have included a gazillion pictures. So, please bear with me.

Is there a problem with the MC fuel delivery system? I think so. An unofficial poll on another website showed that MC has a 4 to 1 failure rate compared with other ski/wakeboard boats. Visit the other boat manufacturers forums and type in "fuel pump" and you will get only a handful (if that many) results. Do the same search on this forum and you will be reading for hours. In an email reply to my questioning the problem, the representative said, "Federal Mogul did make a pump body change to help with recurring pump failures and high warranty claims." "Recurring pump failures" and "high warranty claims?" Sounds like a problem to me!

MC did extend the warranty from one year to two for the fuel pump. And, they added a "warning" to the manual of NEW boats about running with less than 1/4 of a tank. Any sane person will tell you that this does not fix the problem. IMO, MC should of engineered a fix and done a 100% recall. It is the only fair thing to do for the 1,000's of people who paid top dollar for the best.

Okay, so let me get started with the pictures. The pictures are more or less to help those who have never seen a fuel pump module in detail. The entire process of removing the module and taking it apart was a learning experience. I have posted quite a few times regarding this fuel pump issue and I have been wrong in some assumptions. But, I am learning.

Well, here is the fuel pump module from the outside.
NOTE: the 12 bolts that mount the pump to the tank should be torque to 49 inch pounds (thanks JimN for the info).


Remove the 12 bolts, the vent hose, and the wiring harness and it comes out like this.


I removed the fuel line to the motor with a special tool. This allows the module to come completely out.

Remove the 3 screws on the metal sleeve and this is what you see on the inside.


The fuel pump is held in by a plastic support at the bottom of the module. The smooth black fuel hose is quite rigid and in my module it was kinked (quite a bit IMO).

Here is the underside of the top portion with the hose already removed. The clamp on this hose is a one-time usage clamp.
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Last edited by Team MC; 08-25-2012 at 08:42 AM.
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Old 08-11-2008, 12:12 AM
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boofer boofer is offline
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The round thing on the top of the module is the regulator. The pump sends fuel to the regulator at a certain pressure. The regulator decreases the pressure to match what the motor requires. This means that there is more fuel going to the regulator than is needed by the motor. Any excess fuel is squirt back into the tank.


A clear view of the pump inside the module.


Remove the 4 screws holding in the pump bracket and here is the pump (culprit?).


Nice QC (quality control). Look at the rubber bushing. Geezus!
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Last edited by boofer; 08-11-2008 at 01:22 AM.
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Old 08-11-2008, 12:19 AM
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boofer boofer is offline
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The bottom of the module.


The black hose on my pump was quite twisted and kinked. It is hard to see from this photo. But, my hose is kinked enough to reduce the allowable flow of fuel at least 30%.


Add a little more bend and you get NO flow.


The pump.



The nomenclature on the pump is not a serial number or anything like that. It is a manufacturers number and cannot be crossreferenced (I tried).
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Old 08-11-2008, 12:28 AM
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boofer boofer is offline
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Now here is the bottom of the module. It has a circular disk on the bottom.


I am not sure why it is there. It is buoyant and has the 3 channels that you can see. When it is "up" the pump can draw fuel. When it is down fuel cannot be drawn by the pump.

Here is a picture of the picture of the top of this disk. The small rubber tab in the middle goes into the small hole at the bottom of the module.


Here is a side view of the small disk. This is actually from the new module and it is shaped differently than the old one. The old one does not have the 2 different diameters.
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Last edited by boofer; 08-11-2008 at 01:24 AM.
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Old 08-11-2008, 12:42 AM
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The bottom of the module without the small disk.


Now, some observations. The new module has a corrugated clear hose to the regulator.


It retains its shape even when bent. But, somewhere on this board, I read a post (with pictures) from a new owner who had these types of hoses burst. I haven't the time to look it up.

The small black bypass hose on the outside does not line up with the groove made for it. You can even see a mark where it should be. What is up with this? Piss poor QC in my book.


I tested the small disk. It is buoyant. Almost like a piece of cork or wood.

I was very curious about the filter and how quickly fuel will pass through it. I poured some gas in a pan and placed the filter in the gas. The filter filled up quickly. So, there is virtually no restriction to the flow of gas through this filter. I had originally thought that the 10 micron filter was too restrictive. Not true. The only problem (if you want to call it one) with the filter is that due to its shape, it cannot draw gas from lower than the bottom lip.

A so so picture of the filter.
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Old 08-11-2008, 01:20 AM
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So, what is the problem with this design? I really do not know.

1. Gas flows through the filter fine. No poblems here.

2. I submerged the module with the small disk installed and it did take an inch or so of gas to "unplug" the hole (which leads to the pump). I would really like to know the purpose of this small disk. Problem? Possibly.

3. The kinked fuel line to the regulator. It was definitely kinked more than it should be. It would be creating a fairly significant restriction to the flow from the pump. Would this "back" pressure harm the pump? I do believe that it does.

4. The pump itself. I am almost certain that it is a poorly designed pump.

In my reading, it appears that this rotary vane style pump had too small of tolerances and prone to failure. Read this from Carter. http://www.carterfueldelivery.com/fu...CarterFTS9.pdf I would really like to know if GM issued a recall regarding these pumps. If so, then I think that we should get the same recall.

I emailed MC and inquired about fuel pump failures. The first replay sent to me basically said that MC was not aware of any fuel pump problems. I replied with disagreement stating the unofficial poll I ran and the multitude of posts on their own website. Their reply stated that there was a design problem with the Carter pumps. It also said that they (MC) was working with 2 pump suppliers "to reduce the failure rates, and durability regarding low fuel situations." Apparently these 2 suppliers are Carter with their turbine style pumps and these Milinium pumps. I have asked if my new module contains one of the new pumps. I have not yet received a reply.

I am upset that MC is not being more proactive with this situation. And, apparently the situation has been around for many years. I opted for MC over the other boats because I was willing to dig for the cash to have the best. I would not trade my boat for anything. But, I feel somewhat let down. Instead of getting the engineers off of their butts, MC has done what they can to skirt the issue.

I am going to visit a Federated auto parts store hopefully this week. I went to 3 major auto parts stores and no one could get a cross referenced pump to replace the Carter one. The fellow I spoke to at Federated said he wanted to help me out. He has 18 years in the business and has had his own dealings with hard to find parts. As many of you might know, a call to Carter/Federal Mogul will get you nothing. MC has forbid them to give out any details/specs with regards to these fuel system modules.

Okay, for now my brain is fried. I got 2 nasal douches out on the water today and my eyes are starting to hurt from looking at this computer screen. Please feel free to chime in. I will update as soon as I get by Federated and if I hear anything else from MC.
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Old 08-11-2008, 10:41 AM
BearCreek BearCreek is offline
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Great, job Boofer. I would have to say that a big part of the problem is the cheap plastic fuel line between the pump and module. This is very clear because, that seems to be the only thing they changed. WOW!!! That new line looks like a even bigger problem, waiting to happen, you would have thuaght they would have spent the extra money to do it right. When I replaced my hose I think it totaled approx. $3.00 bucks. Two hose clamps and about 8" of high preasure fuel line. I just made a small loop and connected it to fuel pump then regulator, and it has plenty of room to move with out kinking.

I would suggest anyone told they need a new module as I was. They should first look at replacing that line. My MC dealer said the pump runs but no preasure, pumps bad $450.00. Sound familiar? Actually, I would replace that line before it causes you problems. I have a $740.00 tow bill, because that stupid little hose.

After looking at the link to the GM fuel pump issue, it appears to me that the wireing harness is to blame not used on MC. If you close at the picture of the new GM module you will see a thick black fuel line in their module, HHHMMM very intersting.
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Old 07-17-2017, 10:22 AM
90 Lowrider 90 Lowrider is offline
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I would agree. I have spent a lot of time trying to understand this problem and after removing the fuel pump module on my 2004 Prostar (Indmar Predator) I can see the kink in that plastic line. I have to believe this would cause the pump to work too hard and shorten its life. I bought a Carter P74083 pump and it seems to fit well. I am now looking into a replacement for that plastic line. Auto Performance Engineering has lines with 8MM ends. Does anyone know if these fit both the pump and the regulator? What length? 7.4" or 7.6"?
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Old 07-17-2017, 10:50 AM
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wheelerd wheelerd is offline
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I pre-emptively replaced the pump on my 05 this spring. I read this whole thread back to front and front to back. Here's my experience:

- The short answer is that the pump nipple and the pressure regulator nipple are two different sizes -- 5/8 and 1/4 I believe. So the APE hoses are problematic. It is really difficult to try to expand the end of a smaller-diameter plastic hose to fit over a larger nipple.
- Some guys have made the APE hose work by keeping the smaller diameter end of the original hose on the nipple and sliding the larger diameter of the APE hose over it -- sort of a sleeve.
- You can get fuel-submersible rubber hose at most auto parts stores. (Note: Must be SAE 30R10 rated since regular rubber hose will degrade when submersed in fuel.) Get the size to fit the smaller nipple. Using a heat gun or blow dryer and a drop of oil on the larger nipple, it can be gently slid on.
- Prior to doing my replacement I purchased a couple of lengths of the APE hose as well as 12" of submersible rubber hose so I would have everything I needed if the OEM hose came apart. Fortunately, I was able to reuse the OEM hose so didn't need to worry about this.

- You will read about guys having issues with leak-back if the hoses aren't clamped tightly since the diameter is really small for a gear-clamp to provide even sealing pressure. I used Oetiker clamps (aka. ear clamps) like the OEM and have not had a problem.

Hope this helps.
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  #10  
Old 07-30-2017, 10:35 PM
skiman66 skiman66 is offline
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2006 X30

I have been having trouble with fuel pressure since the end of last season (Sept. 2016).

Read through this whole post and decided to take the fuel pump assembly module out and set up a bucket with five gallons of gas and using my compressor blew air back through the top of the regulator to the fuel pump. Low and behold I had a hole in the hose at the connection to the nipple on the fuel pump. The hose clamp was connected at the bottom of the hose and not close to the barb on the nipple.

I adjusted the hose and clamp and placed it right on top of the barb and but the air back to it and ta-da it held pressure. Hooked it back up and put the fuel gauge back on the rail and hit the key, it held pressure.

Took the boat out to the lake and had the fuel pressure gauge on the rail and pressure never wavered.
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