2009 4.3 TKS engine alarm

[Y Knot]

I've been fighting this for a while now, any help would be great!:huh::smt100

I have a 2009 4.3 vortec V6 TKS (Turn Key Start) carbureted motor on the port side.

I have brought it to Sea Ray and they say the only sensors this motor has is for low lower unit oil (in the reservoir jug on the engine), high engine temp, and low engine oil pressure.
-They said they cannot plug in the motor due to it not being fuel injected.
-I was told to disconnect the lower unit oil jug and see if the alarm sounds. IT DID
-I was told to disconnect the temp sensor, I did and the alarm still sounded. (I replaced it anyway to give that a try, waste of $25)
-I disconnected the oil pressure sensor and the alarm system wouldn't even sound when the key is turned. It must have broken the circuit (it only has one wire and not two like the others).
-I replaced the alarm "buzzer" just to see if that was faulty and it wasn't that either.

The engines both run 170 (by the gauge and the mechanic's heat gun), oil is close to 60 when running (on both motors) and the lower unit reservoir is full to the line. (The boat runs great and starts right up, knock on wood)


The alarm does not sound at idle or hull speed. Once I get the boat on plane it goes off for a few seconds and shuts off (this is not every time either, it's completely random). This is repeated randomly throughout the trips. I took the boat to the bay (3 hours each way) and the boat ran great. I got it on plane and left it the same speed and RPM (about 3400, 22 knots). The alarm went off after an hour (the gauges hadn’t moved on both engines and they showed proper readings). It shut off on its own after about 10 seconds. It went off again sporadically the rest of the trip. I wasn’t turning the boat and did not have a wake or waves to deal with so the boat was calm and running straight.
Mercruiser says the alarm will sound for only these three issues and the alarm will either be full on or beep. Whether it beeps or full on doesn’t mean anything because it is not fuel injected.

The only relief I have had is when I disconnected the "buzzer" and ran the boat.

 

[Toolman334]

My 4.3 manual states that the fault warning may be transmission fluid temperature too hot, engine oil pressure is too low, engine temperature is to hot, seawater pressure is to low or the transmission pressure is low. None of the fault warning indicated for the 4.3 TKS are contineous sounds. One is one second on one second off in six second intervals, six on six off six on sixty off then to 1/2 second sounds. Emmision system would be 5 on sixty off 1/2 second the sixty followed by 1/2 second again. You should be able to test the warning system by turning the ignition switch to on without cranking the engine. The alarm will sound if the warning system is functioning correctly

 

[Y Knot]

According to Sea Ray " seawater pressure is to low" is not one of the alarms equipped on the motor. I don't have transmissions so that's out. Any other ideas?

 

[Lazy Daze]

What you were told is correct in regards to the (3) things the alarm will sound for. Also, that a scan tool can not be plugged in (only on fuel injected models).

I'm not sure why disconnecting the bottle caused the alarm to sound. It should only sound if you touch the two wires together. Disconnecting the wires should disable it.

Try this: Take turns running for a day or two (unless the alarm sounds earlier) with one sensor unplugged at a time. At least this way it you should be able to narrow it down to which system is being flaky. Be sure wrap open electrical connections with a sufficient amount of electrical tape.

Unless I'm mistaken, these three sensors are not "in line", so disconnecting one won't affect the other two's ability to work. The reason your alarm normally sounds when you first turn the key "on" is that you have no oil pressure (since the engine isn't running, of course).

EDIT: Oops, forgot you have a carb'd engine. Has your alarm ever sounded when you turn the key to "run"? I was under the impression that it won't, unless it's a fuel injected engine. At least, that's been my experience.

 

[Y Knot]

The alarm sounds when I turn the keys on before the engines start. By disconnecting the jug the alarm still sounded (while on plane as usual, not because the jug was disconnected.) I did exactly as you said, pulled one sensor at a time and the alarm is still sounding at random. I'm at a loss, any other ideas?

 

[Lazy Daze]

Well, hmmm... In that case I would pull all three. Could it be an alarm from something else? Depthfinder? High water bilge alarm?

Add: If you pull all three and you run hours and hours w/o the alarm sounding, then you're back to taking turns with each installed - you'll just have to run a longer time to narrow it down.

 

[jamesgang]

I had a problem very similar to yours. Turned out to be a failing port engine water circulating pump. Replaced that part and no alarms since. My 5.7's are fuel-injected however.

 

[juma]

change the alarm buzzer with a 12 volt red light until you figure the problem that way it won't scare you or your friends.(red one is if you cruise at night the glow will not affect your vision,it will still be visible at day time)

 

[Y Knot]

"Could it be an alarm from something else? Depthfinder? High water bilge alarm?"
--The bilge alarm is different and the depth sounder is on my gps. I can't pull the oil sensor as it shuts the whole alarm down. It won't sound with the key with the wire pulled, it must break the circuit.

I'd hate to change engine parts already, it's only got less than 50 hours on it.

I have thought about the light, i'll probably rig something like that up. I hate not having it right though. Spend all that money on a new engine and have this foolishness.

 

[Fun Times]

The alarm sounds when I turn the keys on before the engines start. By disconnecting the jug the alarm still sounded (while on plane as usual, not because the jug was disconnected.) I did exactly as you said, pulled one sensor at a time and the alarm is still sounding at random. I'm at a loss, any other ideas?

Sounds like your Tan/Blu -Warning system sense wire (Audio warning)
wire may be intermittently going to ground somewhere between the helm and the engine.

Your dealer should be willing to / able to find this issue for you especially if your still under warranty.:thumbsup:

It's closer to winter time now,,Let them worry about it, not you :wink:, They shouldn't have as much to do this time of year, so you should get a better job out of the dealer.:smt017:smt001

Good luck with it.:smt001

 

[Lazy Daze]

I can't pull the oil sensor as it shuts the whole alarm down. It won't sound with the key with the wire pulled, it must break the circuit.

I wasn't aware that it breaks a circuit, but I could be wrong. The only reason your alarm sounds with the key in the "on" position is because you have zero oil pressure. With it disconnected, there's no way to complete a circuit to activate the alarm.

Try this: disconnect it and then manually push the float inside the lube monitor bottle down. If the alarm sounds, it's as I thought. If it doesn't, it's as you thought.

Although, BoatTech - do you know the answer?

If you're still under warranty, then BoatTech's answer is the best one.

 

[Y Knot]

No warranty anymore. Are any relays or solenoids in the alarm loop? I'd rather check those then try and trace those wires from front to back!

 

[Fun Times]

I have a 2009 4.3 vortec V6 TKS (Turn Key Start) carbureted motor on the port side.

I have brought it to Sea Ray and they say the only sensors this motor has is for low lower unit oil (in the reservoir jug on the engine), high engine temp, and low engine oil pressure
-They said they cannot plug in the motor due to it not being fuel injected..

Correct. ^^^^^^^^

-I was told to disconnect the lower unit oil jug and see if the alarm sounds. IT DID.

Did you unplug both wires going to the gear oil bottle??? If you did unhook both wires and the horn still sounded, Then most likely the bottle is working fine.

-I was told to disconnect the temp sensor, I did and the alarm still sounded..
[quote]Did you unhook the Tan/blue wire going to the temperature switch, It's a single wire going to the temperature switch.


-I disconnected the oil pressure sensor and the alarm system wouldn't even sound when the key is turned. It must have broken the circuit.

This is normal.

Key on, engine off = no oil psi and would sound the horn, All you did was unhook the oil psi wire, The other two switches would still work normal if needed.

(it only has one wire and not two like the others).

The temperature switch and the oil psi switch will only have one wire, The gear lube bottle will be the only switch that has two wires going to it.

-I replaced the alarm "buzzer" just to see if that was faulty and it wasn't that either.

At least you tried

.:thumbsup:


The alarm does not sound at idle or hull speed. Once I get the boat on plane it goes off for a few seconds and shuts off (this is not every time either, it's completely random). This is repeated randomly throughout the trips. I took the boat to the bay (3 hours each way) and the boat ran great. I got it on plane and left it the same speed and RPM (about 3400, 22 knots). The alarm went off after an hour (the gauges hadn’t moved on both engines and they showed proper readings). It shut off on its own after about 10 seconds. It went off again sporadically the rest of the trip. I wasn’t turning the boat and did not have a wake or waves to deal with so the boat was calm and running straight.
Mercruiser says the alarm will sound for only these three issues and the alarm will either be full on or beep. Whether it beeps or full on doesn’t mean anything because it is not fuel injected..

It could just be as simple as a loose wire connection someplace. Carefully wiggling any and all wires around with the engine running is considered a test procedure.:wink:

The only relief I have had is when I disconnected the "buzzer" and ran the boat.

lol, I don't recommend doing that.

I'm not sure why disconnecting the bottle caused the alarm to sound.

I believe he was saying the dealer recommended he try unhooking the wires, Then run the boat and see if the horn still goes off at a later timeframe, And it sounds like he did this test and unfortunately the horn went off at some point proving the gear lube bottle is still working correctly and the bottle is not going to be the issue here.

It should only sound if you touch the two wires together. Disconnecting the wires should disable it.

Correct.

Try this: Take turns running for a day or two (unless the alarm sounds earlier) with one sensor unplugged at a time. At least this way it you should be able to narrow it down to which system is being flaky. Be sure wrap open electrical connections with a sufficient amount of electrical tape.

I agree

.:thumbsup:

Unless I'm mistaken, these three sensors are not "in line", so disconnecting one won't affect the other two's ability to work.

You are not mistaken.

:thumbsup:


The reason your alarm normally sounds when you first turn the key "on" is that you have no oil pressure (since the engine isn't running, of course).

Correct.

EDIT: Oops, forgot you have a carb'd engine. Has your alarm ever sounded when you turn the key to "run"? I was under the impression that it won't, unless it's a fuel injected engine. At least, that's been my experience.

Both EFI and older carbed engines should sound the horn at key up, Just EFI will turn off within a few seconds. The newer carbed engines now have a time limiter/delay in the warning horn so you don't half to hear it as long while trying to get it started.:smt038

The alarm sounds when I turn the keys on before the engines start. By disconnecting the jug the alarm still sounded (while on plane as usual, not because the jug was disconnected.) I did exactly as you said, pulled one sensor at a time and the alarm is still sounding at random. I'm at a loss, any other ideas?

Could be loose wire, wire damaged someplace, Wire touching ground someplace, Bad oil PSI switch.
My guess, it's most likely a bad oil PSI switch do to something like blockage or bad grounding do to paint, ect.

Add: If you pull all three and you run hours and hours w/o the alarm sounding, then you're back to taking turns with each installed - you'll just have to run a longer time to narrow it down.

I agree, And if it still sounds off then it would be a loose wire or damaged wire going to ground someplace.

I can't pull the oil sensor as it shuts the whole alarm down. It won't sound with the key with the wire pulled, it must break the circuit.

You could pull the oil PSI wire and run it, The other two items will still work if needed.

I'd hate to change engine parts already, it's only got less than 50 hours on it..

The only other switch to try/buy is the oil PSI switch. See number 26 in this link below. At $22.17 that is about the same price as a mercruiser warranty deductible at $ 25.00 had you still been under warranty.:wink:

http://www.mercruiserparts.com/Show...nbr=12833&bnbr=40&bdesc=Electrical+Components

I have thought about the light, i'll probably rig something like that up. I hate not having it right though. Spend all that money on a new engine and have this foolishness.

Keep working at it, You will get it.:thumbsup:

I wasn't aware that it breaks a circuit, but I could be wrong.

Unhooking one does not affect the other two.

Try this: disconnect it and then manually push the float inside the lube monitor bottle down. Although, BoatTech - do you know the answer?.

If you push the float switch down inside the gear lube bottle it would sound the warning horn, even if the other wires where disconnect it would still sound the warning horn.

If you're still under warranty, then BoatTech's answer is the best one.

No warranty anymore. Are any relays or solenoids in the alarm loop? I'd rather check those then try and trace those wires from front to back!

Sorry there are no relays or solenoids in the alarm loop to check. There's just basically switches to check, Ohm's checking wires, And wiggling some wires around.


Wow, Being it's an 09 it must just be out of warranty by a few months then?

If it turns out to be a bad wire on the boats end that should be on sea ray not merc.

Also if they have tried to fix it at one time before and it was not done correctly, You could try calling mercruiser with your engine serial number and see if they are willing to help you out still.

 

[Y Knot]

Thanks for all the input!! When I disconnected the oil psi sensor the alarm would not sound when I turned the key.? Is this normal or is this showing that is the problem? I have wiggled as many wires as I can find and still the problem.

 

[Lazy Daze]

No - it doesn't sound because it's not connected.

 

[Y Knot]

Thanks for all the input! I'll keep looking and let you know what I find out.

 

[Fun Times]

Oops sorry about the long break down on post #13, For some reason I didn't really realize it was that long and repetitive till now.:wow::smt017:smt021

Sorry about that guys.:smt001

 

[mwph]

Boat Tech - No need to be sorry. I'm sure a lot of us benefit from your posts. Thanks for taking the time to do so.

 

[Lazy Daze]

Oops sorry about the long break down on post #13, For some reason I didn't really realize it was that long and repetitive till now.:wow::smt017:smt021

Sorry about that guys.:smt001

No problem - I used my Little Orphan Annie secret decoder ring and was able to decipher it! :grin:

Seriously, lot's of good info in there - thanks.

 

[MarkD]

Your problem is really frustrating.. believe me I know. I was having the same problem during this season of boating and got alot of help from folks here. I also have the TKS 4.3 in my 2008 185 sport.
Symptoms were varied, but I did notice that when there was a throttle change (while cruising @ 3000 rpm) or heading change that required me to throttlle/trim differently it would trigger an alarm on occasion. It wasnt every time either... un-nerving when you are out with kids and wife. You end up not trusting the boat for fear it will strand you. Regardless, everone is correct about the 3 main alarms. Drive Lube, Engine Oil pressure and temp. After doing all you did with wire pulling, my issue turned out to be a faulty temp sensor in the thermostat housing. I isolated it when alarm sounded and pulling one sensor at a time... Not sure about yours, but initially i was confusing the temp "gauge" & wire with the actual temp sensor & wires. On mine, the sensor/alarm combo connects below the actual temp wire & its housing. The sensor/alarm is a weatherpak connector fitting. Once I disconnected that, my alarm woe's went away. The engine was running at 172 (verified with my thermal gun). Just wanted to insure you were clear on that. But it sounds like you have your head on straight and its just a matter of time....