200hp HPDI Won't idle

[markbob]

I have a 2001 HPDI that won't idle and "bogs down" when given gas in neutral. When in gear it runs poorly like it is fuel starved and surges when running or doesn't plane at all. I have run a direct line to fresh fuel, replaced fuel filters, injectors were sent away and inspected, new plugs, VST inspected last fall. Near the end of last season while running WOT it suddenly lost it's top end and ran about 800 less RPM's. Here's the YDTS results when I was able to get it into gear on the cuffs and keep it running. While at poor idle momentarily it shows #1 and #4 on only. Thought four cylinders were supposed to light up at idel? I know just enough about my motor to be dangerous and no dealers anywhere nearby. Any suggestions on where to look next? Thanks in advance if anyone has any thoughts. Any four strokes for Sale? Mark
p.s. The injectors were sent off after the 26 code and had run great up until the last several hours. Code was not reset


Save date March 01 2009
ECM No.: 68F8591A03

Diagnosis
Code Item Result Condition
13 Pulser coil Normal
14 Crank position sensor Normal
15 Water temp sensor Normal
18 Throttle position sensor Normal
19 Battery voltage Normal
22 Atmospheric press sensor Normal
23 Intake temp sensor Normal
25 Fuel press sensor Normal
26 Injector Normal
27 Water in fuel No
28 Shift position switch Normal
44 Engine stop lanyard switch Off

Diagnosis Record
Total hours of operation 457
Code Item Occurred
26 Injector 400.3

Engine Monitor
Monitor Item Result Unit
Engine speed 1575 r/min
Fuel pressure (5.0±0.8) 4.8 MPa
Fuel pressure (725±116) 696.07 psi
Atmospheric pressure 809.4 HPa
Atmospheric pressure 24 inHg
Ignition timing BTDC 4 deg
Battery voltage (12-16) 13.18 V
Oxygen sensor voltage (0-1.0) 0.88 V
TPS voltage (0.5-4.5) 0.83 V
Throttle valve opening (0-90) 6.8 deg
Fuel injection duration 0.92 ms
Water temperature (below 90) 54.5 °C
Water temperature (below 194) 130.1 °F
Intake temperature (below 70) 28 °C
Intake temperature (below 158) 82.4 °F
Electric oil pump Low
Firing of cylinder #1 Yes
Firing of cylinder #2 Yes
Firing of cylinder #3 Yes
Firing of cylinder #4 Yes
Firing of cylinder #5 Yes
Firing of cylinder #6 Yes
Starter switch OFF
Engine stop lanyard switch OFF
Over-rev control release lead OFF
Main switch ON
Shift position switch OFF
Water detection switch OFF
Oil level switch (remote tank) ON
Oil level switch1(engine tank) ON
Oil level switch2(engine tank) OFF
Oil level switch3(engine tank) OFF
Water temp switch (over heat) OFF
Dual engine system switch OFF

Data Logger[Engine operating hours according to engine speed]
Engine speed Time[h]
- 1000 r/min 205.5
1000 - 2000 r/min 70.9
2000 - 3000 r/min 2.6
3000 - 4000 r/min 59.5
4000 - 5000 r/min 101.8
5000 - 6000 r/min 16.9
6000 - 7000 r/min 0
Total hours of operation 457

Data Logger[Data comparison graph]
Engine speed[r/min] Fuel pressure (5.0±0.8)[MPa] Battery voltage (12-16)[V] Oxygen sensor voltage (0-1.0)[V] TPS voltage (0.5-4.5)[V] Water temperature (below 90)[°C]
700 4.65 12.52 0.02 1.72 50.5
450 4.61 12.96 0.19 0.86 49.3
350 4.49 12.74 0.72 0.86 54.5
600 4.65 12.67 0.65 1.84 57.5
400 4.3 9.3 0.08 0.88 20
900 4.72 11.43 0.26 1.84 24
450 4.57 12.16 0.27 0.8 40
350 4.65 12.16 0.07 0.78 49.7
950 4.76 12.16 0.1 0.8 51.5
350 4.57 12.08 0.29 0.8 52.3
350 4.49 12.82 0.03 0.88 62
600 4.65 11.35 0.1 0.84 38
400 4.61 12.16 0.15 0.82 42

[markbob]

Yes, I don't get it. Only showing #1 and #4 at idle and all light up when I get it in gear. All the numbers seem good on the Diagnostics. #2 and #5 supposed to drop out at idle I heard? Sure wouldn't be able to idle on two. Surges with a burst of power intermitantly almost like it's ready to take off when it does get on plane

[boats.net]

The TPS voltage seems to be way off but don't know where you have throttle lever when running engine.
Check compression, fuel pressure test and diaphrams in fuel pumps.

[markbob]

I'll do that. Thanks! I have messed with linkage and the TPS has gone bad before. Appreciate it.

[markbob]

Looks like the TPS is good. Throttle was just in it's almost off position. Any thoughts on the other two cylinders not lighting at idle? Can an ECM be tested. I always like to start with the most expensive stuff first and work backwards. I'll check all of the connections on the motor next and make sure nothings loose. Sure seems intermittent while running and a slight miss when it is. Idle is consistently not working. I replaced the diaphragms on the fuel pumps when I tested the injects and replace the inline filter over the vapor tank as well. Lost in Colorado, Mark

[jb123]

why wouldnt you start with the most COMMON stuff like fuel supply ?

[markbob]

Still checking on that and other angles. Fuel bulb, lines, etc. I'm a little bit dramatic. Probably also looking for an excuse to buy a new motor, but not in the budget. I'll keep plugging away. Thanks to all for your suggestions.

[markbob]

Well, I'm back at it. When in neutral I am only lighting up cylinders #1 and #4 according to my YDS and not the four I am supposed to have (not sure which four they should be). When in gear it lights them all. It will also stay running and ***** with no problem when in gear. If I try to throttle up in neutral it floods out and I assume it's because the other two that are supposed to be on at idle are not getting fire? When I have run down the lake I get the same fuel starved symptoms often like they may also be intermittently dropping out. I'm pretty sure I've determined it's not a fuel issue as all the filters have been changed, fuel pressures check out, run fresh source of supply, injectors check out, etc. If electrical, anyone have any suggestions where to start?
Thanks, Mark

[Hamfisted]

Was that YDS data in gear ?

Hey Mark was that YDS data report you posted done with the engine in gear? I see all the cylinders firing is why I ask, and the timing is up a bit. In neutral cylinders 3 and 4 are suppose to be OFF and the timing would be back around 5 ATDC. Also the TPS voltage should be about .62~.64 in the idle position. If that report was done in neutral I would test the neutral cutout switch there at the throttle slide area and find out if it even functions or not. If the TPS is bad the computer is not getting reliable throttle position information and can't react to throttle movements accurately.



- Mike

[markbob]

Thanks Mike.

The report I posted was in gear with a little throttle since I couldn't get it to idle in neutral. As it sits, the TPS reads .74 at idle and 4.10 at WOT. Interesting #2 and #4 are supposed to be OFF at idle and instead I'm ONLY getting two cylinders, #1 and #4 ON at idle and that's it. The rest of the cylinders must be as confused as me. Not sure what's going on there. I will test the neutral cutoff switch for sure. I actually have a spare in the package. I can also do the TPS if needed. I didn't know if it would have any relevance to the lighting up the cylinder problem, but I may even have several unrelated ghosts. Thanks for your quick reply and help. Lake Powell is only a three hour drive from here, so if you get bored.

Mark