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Author Topic:   1992 Outrage 19 II Fuel Tank and Hoses

yellowlab posted 10-11-2014 10:01 AM ET (US)
[I have extensively edited this article as it seemed in its original form to repeat itself over and over. The boat was not identified in the original article, but I believe it is a 1992 Boston Whaler OUTRAGE 19 II, based on some prior postings by this author. It is a good idea to clearly identify the boat when asking for advice. One should not rely on readers being able to remember what boat an author owns--jimh]
I have a 1992 aluminum [fuel tank made by] Florida Marine Tanks. Can someone offer a suggestion or a diagram for the location of the fuel line and vent hoses on this tank and or how they are accessed?
I don't have evidence of leaking fuel. The boat has been trailer-kept and has the original Florida Marine Tank of 0.125" thickness. Should I consider replacement of the tank? It seems to be a point of failure.
[The engines on my 1992 Boston Whaler OUTRAGE 19 II] suddenly lost power and both engines were fuel-starved from something kicking loose. It was running well prior to the removal of those throttle cables the previous day. However, I have a disconnected fuel line that starved the delivery of fuel from the tank to the fuel water separator. I am unable to get fuel to prime and suspect something came loose when I removed two throttle cables for a kicker motor which was routed above the tank. It had run well prior previous to the removal of those throttle cables. However, the water test yesterday also ran well for several miles and then it gave way. On-water diagnosis couldn't identify the loss of fuel pickup. The result was having to tow it back to the launch by some helpful boaters, good thing I was on the lake not the sound!
jimh posted 10-11-2014 11:36 AM ET (US)
As I recall, I don't think there are any on-deck access plates that will give you access to the fuel tank connections and hoses on a 1992 Boston Whaler OUTRAGE 19 II boat.
I believe to gain access to the fuel tank, the fuel pickup access plate, and the hoses attached to it, you may have to cut the deck open. Boston Whaler has a procedure that explains how to do this. Contact Boston Whaler Customer Service for more advice. Boston Whaler Customer Service can supply you with the drawings you need, and with the detailed repair procedure that is needed to cut open the deck, remove the portion of the deck covering the fuel tank, and gain access to the fuel tank pick-up plate and hoses.
I would rely on advice from Boston Whaler Customer Service on this procedure. I do not recall any reports from an owner of a c.1992 Boston Whaler OUTRAGE 19 II boat having performed the procedure.
jimh posted 10-11-2014 11:39 AM ET (US)
Regarding whether the fuel tank in a 1992 Boston Whaler OUTRAGE 19 II should be replaced in 2014 on the basis that it might fail in the future, I suggest that you will be better able to assess the condition of the fuel tank once you have gained access to it by cutting away the deck. With the tank finally revealed, you should be in a better position to make a decision on fuel tank replacement.
martyn1075 posted 10-11-2014 02:56 PM ET (US)
If there is no access to the tank at all then the answer is not going to be all that favorable about a quick fix on a hose or sender unit which is common issue. It still could be the problem but it sounds like you need to cut the deck open. The fact that its an aluminum tank rather then a plastic gives at least some hints that corrosion may play a part in the tank or fittings condition especially if its over 15 years. Not a big fan of the glassed in tanks but if they are plastic it makes a bit more sense. Most tanks that are fully enclosed are then designed to have one or more access panels somewhere that gives access to the hoses connections and send unit(s) Im surprised a high end builder Boston Whaler did not design the boat without at least one access panel to the fittings.
If it was me and I needed to cut open the deck I would replace the whole unit top to bottom because its a big job and you don't want to seal everything up only to find out something else has rotted out a few moths or even year or two later. Then a good idea to locate where the fittings are and instal some quick plastic round panels something the company should have done in the first place.
Martyn
jimh posted 10-13-2014 08:49 AM ET (US)

quote:
I have a disconnected fuel line that starved the delivery of fuel from the tank to the fuel water separator.
I don't understand what "disconnected" means in the above.
acseatsri posted 10-16-2014 08:02 PM ET (US)
After just going through replacing the tank on a 1992 21 WA, the thing that sticks out in my mind is that the tank corroded from the inside out, leaving only a tiny pinhole in the bottom of the tank visible from the outside when it was wet. I'm still dealing with the aftermath of the particles of corrosion (aluminum oxide?) plugging the fuel system on a new Honda BF250. The particles were fine enough to make it through a Racor 10 micron filter and eventually partially plugged up both the fuel strainer and the high pressure 1 micron filter inside the engine. The 1 micron filter was plugged with white powder. Right now I'm waiting on a new filter that will allow the engine to run above 4000 RPM (used to be 6200 RPM).
Other people with older boats at my marina have encountered this same problem (filters plugging up) with Yamaha 4 stroke fuel injected engines as well. If nothing else, I would at least change the high pressure fuel filter every year if you have an older tank with a fuel-injected engine, especially if the boat sat un-used for long periods of time without fresh fuel.
PS- When I called Whaler about how to change the tank, they had no answer other than ask me to share the procedure to change it after it was done. They had no engineers left there from that era.
jimh posted 10-17-2014 01:51 PM ET (US)
The instructions for removal of the fuel tank from an OUTRAGE 19 II have been posted here for so long that I forgot they were available. See
http://continuouswave.com/whaler/reference/18Outrage/ 19_II_OR_FuelTankInstructions.pdf
yellowlab posted 10-17-2014 06:08 PM ET (US)
Thanks Jim, looks like the same instructions that Whaler emailed me.
jimh posted 10-17-2014 08:29 PM ET (US)
The instructions I linked to (see hyperlink above) have the imprimatur of Boston Whaler.

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Author	Topic: 1992 Outrage 19 II Fuel Tank and Hoses
yellowlab	posted 10-11-2014 10:01 AM ET (US) [I have extensively edited this article as it seemed in its original form to repeat itself over and over. The boat was not identified in the original article, but I believe it is a 1992 Boston Whaler OUTRAGE 19 II, based on some prior postings by this author. It is a good idea to clearly identify the boat when asking for advice. One should not rely on readers being able to remember what boat an author owns--jimh] I have a 1992 aluminum [fuel tank made by] Florida Marine Tanks. Can someone offer a suggestion or a diagram for the location of the fuel line and vent hoses on this tank and or how they are accessed? I don't have evidence of leaking fuel. The boat has been trailer-kept and has the original Florida Marine Tank of 0.125" thickness. Should I consider replacement of the tank? It seems to be a point of failure. [The engines on my 1992 Boston Whaler OUTRAGE 19 II] suddenly lost power and both engines were fuel-starved from something kicking loose. It was running well prior to the removal of those throttle cables the previous day. However, I have a disconnected fuel line that starved the delivery of fuel from the tank to the fuel water separator. I am unable to get fuel to prime and suspect something came loose when I removed two throttle cables for a kicker motor which was routed above the tank. It had run well prior previous to the removal of those throttle cables. However, the water test yesterday also ran well for several miles and then it gave way. On-water diagnosis couldn't identify the loss of fuel pickup. The result was having to tow it back to the launch by some helpful boaters, good thing I was on the lake not the sound!
jimh	posted 10-11-2014 11:36 AM ET (US) As I recall, I don't think there are any on-deck access plates that will give you access to the fuel tank connections and hoses on a 1992 Boston Whaler OUTRAGE 19 II boat. I believe to gain access to the fuel tank, the fuel pickup access plate, and the hoses attached to it, you may have to cut the deck open. Boston Whaler has a procedure that explains how to do this. Contact Boston Whaler Customer Service for more advice. Boston Whaler Customer Service can supply you with the drawings you need, and with the detailed repair procedure that is needed to cut open the deck, remove the portion of the deck covering the fuel tank, and gain access to the fuel tank pick-up plate and hoses. I would rely on advice from Boston Whaler Customer Service on this procedure. I do not recall any reports from an owner of a c.1992 Boston Whaler OUTRAGE 19 II boat having performed the procedure.
jimh	posted 10-11-2014 11:39 AM ET (US) Regarding whether the fuel tank in a 1992 Boston Whaler OUTRAGE 19 II should be replaced in 2014 on the basis that it might fail in the future, I suggest that you will be better able to assess the condition of the fuel tank once you have gained access to it by cutting away the deck. With the tank finally revealed, you should be in a better position to make a decision on fuel tank replacement.
martyn1075	posted 10-11-2014 02:56 PM ET (US) If there is no access to the tank at all then the answer is not going to be all that favorable about a quick fix on a hose or sender unit which is common issue. It still could be the problem but it sounds like you need to cut the deck open. The fact that its an aluminum tank rather then a plastic gives at least some hints that corrosion may play a part in the tank or fittings condition especially if its over 15 years. Not a big fan of the glassed in tanks but if they are plastic it makes a bit more sense. Most tanks that are fully enclosed are then designed to have one or more access panels somewhere that gives access to the hoses connections and send unit(s) Im surprised a high end builder Boston Whaler did not design the boat without at least one access panel to the fittings. If it was me and I needed to cut open the deck I would replace the whole unit top to bottom because its a big job and you don't want to seal everything up only to find out something else has rotted out a few moths or even year or two later. Then a good idea to locate where the fittings are and instal some quick plastic round panels something the company should have done in the first place. Martyn
jimh	posted 10-13-2014 08:49 AM ET (US) quote: I have a disconnected fuel line that starved the delivery of fuel from the tank to the fuel water separator. I don't understand what "disconnected" means in the above.
acseatsri	posted 10-16-2014 08:02 PM ET (US) After just going through replacing the tank on a 1992 21 WA, the thing that sticks out in my mind is that the tank corroded from the inside out, leaving only a tiny pinhole in the bottom of the tank visible from the outside when it was wet. I'm still dealing with the aftermath of the particles of corrosion (aluminum oxide?) plugging the fuel system on a new Honda BF250. The particles were fine enough to make it through a Racor 10 micron filter and eventually partially plugged up both the fuel strainer and the high pressure 1 micron filter inside the engine. The 1 micron filter was plugged with white powder. Right now I'm waiting on a new filter that will allow the engine to run above 4000 RPM (used to be 6200 RPM). Other people with older boats at my marina have encountered this same problem (filters plugging up) with Yamaha 4 stroke fuel injected engines as well. If nothing else, I would at least change the high pressure fuel filter every year if you have an older tank with a fuel-injected engine, especially if the boat sat un-used for long periods of time without fresh fuel. PS- When I called Whaler about how to change the tank, they had no answer other than ask me to share the procedure to change it after it was done. They had no engineers left there from that era.
jimh	posted 10-17-2014 01:51 PM ET (US) The instructions for removal of the fuel tank from an OUTRAGE 19 II have been posted here for so long that I forgot they were available. See http://continuouswave.com/whaler/reference/18Outrage/ 19_II_OR_FuelTankInstructions.pdf
yellowlab	posted 10-17-2014 06:08 PM ET (US) Thanks Jim, looks like the same instructions that Whaler emailed me.
jimh	posted 10-17-2014 08:29 PM ET (US) The instructions I linked to (see hyperlink above) have the imprimatur of Boston Whaler.