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05-18-2015 10:42 AM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

We have a 2002 Four Winns 268 with a 5.7 carb Volvo Penta. We had the same type of issue. The mechanic said we had a corroded distributor cap, and wires, so he did a tune-up. Worked for a day and started doing the same thing. He then said it was water in the gas. He drained 60 gallons and filled the tank. It worked for a day. Finally I took it to another dealer and two of his mechanics took her for a sea trial. It turns out it was a loose wire on the high pressure side of the fuel pump. He repaired it and, $1500 in total, she has been running fine ever since.
08-03-2012 04:08 PM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

..........New racor on order now....bypassed the unit til it arrives, new fuel line from tank to engine, and can at least get out to grab some wind....once we're done the fuel system will be refitted.

07-30-2012 10:24 AM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

Thanks for the updates, our engine is working fine, but this all adds to the knowledge base when we have problems.
07-27-2012 02:54 PM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

The parts arrived today!!

Special thanks go out to Rodger Stickland at Marine Parts Express in Maine for tweaking my order, and getting it to me within a week, (considering it was shipping from U.S. to Canada and had to clear Customs...)

Look for:
Excellent customer service, and great prices, you have to check them out.
We'll use them again for sure.

We'll look at the install over the weekend and I'll keep you apprised of the sitch.

07-19-2012 07:07 PM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

Sounds like your on the right path.
Fair winds
07-19-2012 01:05 PM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

So, an update for you all...
We continued to have issues, and the mechanic came back.
This time, it would not start for him, and then stalled shortly afterwards.
He re-bled the system, and thought that perhaps he had not done so
adequately when he serviced.
It was running fine.
We continued to test it over the next few days, and had no issues.
So, we set out on our first overnight sail, our destination some 3 to 4 hours away by sail with good wind.
All was well until we decided to start the kicker to help avoid a sudden cloudburst started, labored and stalled again.
It did this continually til we reached destination, and we were able to get it into the dock.
On the way home, 9 miles out from our departure point, it just died.
We limped home in 18 knot gusters, and 2 meter swells = about 6 ft.
I helmed back, and was having a ball!!!!!
Sorry, lost track there....
That being said, we had to get a tow into the marina, and waited all day the next day for another mechanic to no-show/no-call. Our lovely slip mate and bordering neighbors got down there and tore the engine open.
Looks like the fuel line and possibly the pump are the culprits, allowing air.
We tested with the engine disconnected from the fuel line, and a jerry can of diesel being sucked straight in. Purred like the proverbial kitten.
We are ordering new parts from the pump back to the tank, and will hopefully have some resolution to the issue.
Will let you know.
Thanks for all of your suggestions!!
07-11-2012 03:05 AM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

Originally Posted by HBBurlington View Post
Hi Guys,

Need your help, please!
We were having trouble with our engine stalling in low while under load and in neutral.
It's probably fouled injectors, but..

Just curious: You've checked the idle speed?
07-10-2012 07:57 PM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

Try the seafoam at 100%. All you have to do is empty the fuel filter of diesel and fill it w/ seafoam. Reinstall the filter, fire it up for a minute, shut it down for 15 mins. and then fire it up again. My 2003t had the same problem and seafoam cleared it up. Easy fix if dirty injectors is the problem.
07-10-2012 09:14 AM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!


Thanks for the suggestion...we've added fuel injector cleaner, and checked the filters.
No improvement.
Mechanic has visited again, not found the core problem, and is still guessing at bad gas.
All I know, is that this is giving ME bad gas....

Obtaining a 2nd opinion, hopefully, today.
Trying to avoid the expense and downtime of fuel polishing, plus, we haven't found anyone that can perform this service in the Burlington, Ont. area.

I read the specs on the Seafoam, and it sounds very interesting.
Have forwarded your message over to my hubby, too.

We are dock bound til this is resolved, because I don't have confidence in the engine performance, especially for when we are going out and coming back in from the dock!

07-10-2012 07:50 AM
Re: Volvo Penta 2002 - Stalling and rough idle - HELP!

You could try cleaning the enjectors w/ seafoam. You need to use it at 100% to work.
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