Continuing Problem with 2021 VP 250 hp 4.3 DI

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
Previous post I thought I'd fixed a bad fuel problem. ...the engine problems are sticking.
Clean fuel, new fuel filter. Continued rough operation idle through WOT, intermittent alarm beeps, 1/2 or less power at hole shot and at plane. Strong gasoline smell in exhaust at no wake. It seems to be guzzling gas. No engine bay gas leaks. No Diacom DTCs other than random misfires which I already know.
The engine is under VP warranty until August. Hoping for a self fix before the 4th of July weekend. I shared the symptoms with the dealer service mgr asking for self help or useful input if I have to haul it in. He focused on fuel transfer pump pressures, saying too high could be a problem. He mentioned a clogged screen in the flow. Quick look at the shop manual doesn't show any screen. The boat has run like a beast until splashing after the last winter layover. Winterized each year with 50:1 premix through the fuel system.
I'll check transfer pump pressures tomorrow and recheck DTCs.
Does anyone know the location of this screen? Any other suggestions?
Thanks, Dave.
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
I'm not aware of any screens in this system, other then in the injectors. Your phone contact might have been thinking about older systems with the fuel pressure regulator on the fuel rail.
Yes, 1st step is to check the 2 pressures at the pump.
top port is 60 ± 5 PSI
bottom port is 10–40 PSI

Couple of questions, does this engine have catalysts? When you pumped the old fuel out of the tank, did you suck it out the fuel line or pull the sending unit and suck it dry from the lowest corner of the tank?

Diacom record files might be helpful. If you would like to post them, I would be happy to look at them.

If you would like my advice on how to do a recording, here it is:

Start with a cold engine and the boat in the water.
1. Connect Diacom
2. Turn on batt switch, turn on key switch -- but don't start engine
3. Start Diacom recording -- let run for 30 seconds to one minute
4. Start engine
5. Check that Diacom is still recording, it's not uncommon for it to have lost communication during starting. If it did, save that recording and start another one.
6. Run the boat gently at idle to 1500 RPM until up to operating temp
7. Run the boat up to full speed --- take your time, looking to get data here so advance the throttle slowly (spend one to two minutes) now slow back down to minimum wake and idle in neutral for awhile. Use the trim as you normally would.
8. Do a "ski start" -- full throttle all the way to full speed and trimmed out, now back to idle fairly quickly.
9. Drive boat back to the dock/ramp and shut off
10. Stop recording and name the files

Volvo is "special" when it comes to recordings. There can be a few monitors that need their own separate recordings. Here is what you might see.

1751346240190.png


Start with Engine Data and try and get O2 Feedback, Misfire, Fuel Control and Injector.

To use Diacom for anything more then a code reader is a learning curve and will take some time depending on how much knowledge about EGC diagnostics you have.

Happy to help if I can.
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
Also according to the Volvo website, you have an open recall?

Your product is subject to a recall campaign. Please contact your Volvo Penta service dealer to schedule an appointment. State your serial number as a reference.

Might want to ask your dealer about this.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
I'm not aware of any screens in this system, other then in the injectors. Your phone contact might have been thinking about older systems with the fuel pressure regulator on the fuel rail.
Yes, 1st step is to check the 2 pressures at the pump.
top port is 60 ± 5 PSI
bottom port is 10–40 PSI

Couple of questions, does this engine have catalysts? When you pumped the old fuel out of the tank, did you suck it out the fuel line or pull the sending unit and suck it dry from the lowest corner of the tank?

Diacom record files might be helpful. If you would like to post them, I would be happy to look at them.

If you would like my advice on how to do a recording, here it is:

Start with a cold engine and the boat in the water.
1. Connect Diacom
2. Turn on batt switch, turn on key switch -- but don't start engine
3. Start Diacom recording -- let run for 30 seconds to one minute
4. Start engine
5. Check that Diacom is still recording, it's not uncommon for it to have lost communication during starting. If it did, save that recording and start another one.
6. Run the boat gently at idle to 1500 RPM until up to operating temp
7. Run the boat up to full speed --- take your time, looking to get data here so advance the throttle slowly (spend one to two minutes) now slow back down to minimum wake and idle in neutral for awhile. Use the trim as you normally would.
8. Do a "ski start" -- full throttle all the way to full speed and trimmed out, now back to idle fairly quickly.
9. Drive boat back to the dock/ramp and shut off
10. Stop recording and name the files

Volvo is "special" when it comes to recordings. There can be a few monitors that need their own separate recordings. Here is what you might see.

View attachment 409162


Start with Engine Data and try and get O2 Feedback, Misfire, Fuel Control and Injector.

To use Diacom for anything more then a code reader is a learning curve and will take some time depending on how much knowledge about EGC diagnostics you have.

Happy to help if I can.
Thanks muc, I was hoping you'd pick up on this one.
Answers to your questions: This is a rare no-CAT engine. I used my electric fluid extractor on bucket to pump the tank. I removed the tank supply hose from the transfer pump and threaded the tube into the thank. I think it bottomed. About 14 gallons which seemed about right. Fuel gage was pegged empty. There could have been a little gas still in the tank. Then I added five gals of fresh gas to get to the gas dock. A little stutter at first but then smooth operation. After another 10 gals at the dock it ran fine for 1/2- 1 hr. Then the alarm and misfiring returned. Previous WOT was about 5.2K. Now about 4.4K. With the factory 21P it would hit the limiter at 5.8K, so I'm running a 22P to hold it at 5.2K with nearly the same top GPS speed of 52 mph. ....maxing at 38 mph now.
I changed the fuel filter when the problem first showed, before I pumped the tank. I changed the filter when the problem returned. No help.
I'll record data today per your instructions. ....dang laptop screen is very hard to read in the sun.
VP sent me notification about a possible fuel test schrader valve under torqued. Nothing else, but I'll recheck for more.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
How fast is that 4.3 spinning to get 250hp, 6500 rpm?
Still it would be a pretty weak Hole Shot.
It is limited to 5.7-5.8 which I got with the OEM 21P prop. I'm running a 22P now @ 5.2K at about and GPS 48 mph. Boat jumped on top of the water w/in three seconds, maybe 10 seconds more to 5.2K. Yesterday I reckon over 30 seconds to max at 4.4K, 38 mph. ....seemed half power at best.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
I'm not aware of any screens in this system, other then in the injectors. Your phone contact might have been thinking about older systems with the fuel pressure regulator on the fuel rail.
Yes, 1st step is to check the 2 pressures at the pump.
top port is 60 ± 5 PSI
bottom port is 10–40 PSI

Couple of questions, does this engine have catalysts? When you pumped the old fuel out of the tank, did you suck it out the fuel line or pull the sending unit and suck it dry from the lowest corner of the tank?

Diacom record files might be helpful. If you would like to post them, I would be happy to look at them.

If you would like my advice on how to do a recording, here it is:

Start with a cold engine and the boat in the water.
1. Connect Diacom
2. Turn on batt switch, turn on key switch -- but don't start engine
3. Start Diacom recording -- let run for 30 seconds to one minute
4. Start engine
5. Check that Diacom is still recording, it's not uncommon for it to have lost communication during starting. If it did, save that recording and start another one.
6. Run the boat gently at idle to 1500 RPM until up to operating temp
7. Run the boat up to full speed --- take your time, looking to get data here so advance the throttle slowly (spend one to two minutes) now slow back down to minimum wake and idle in neutral for awhile. Use the trim as you normally would.
8. Do a "ski start" -- full throttle all the way to full speed and trimmed out, now back to idle fairly quickly.
9. Drive boat back to the dock/ramp and shut off
10. Stop recording and name the files

Volvo is "special" when it comes to recordings. There can be a few monitors that need their own separate recordings. Here is what you might see.

View attachment 409162


Start with Engine Data and try and get O2 Feedback, Misfire, Fuel Control and Injector.

To use Diacom for anything more then a code reader is a learning curve and will take some time depending on how much knowledge about EGC diagnostics you have.

Happy to help if I can.
I have the .rec files ready. I tried attaching them here, but the file type isn't supported. Also tried a pm here. Unable to attach. Requesting your email via pm, and sharing mine.
Thanks,
Dave
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
Hey Dave, I don't know how to post them on iBoats. But it can be done.
Here is a recent post.
I'm sorry, but I don't do anything outside of the board. Maybe one of the Mods or one of the posters that have posted .rec files can help?
I like these types of forums that can have multiple sets of eyes looking at the problem.

I do have another question, I can't quite follow your description of how you sucked out the fuel. When you say -transfer pump- do you mean the fuel feed pump mounted on the engine? Did you get any fuel pressure readings today?
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
Hey Dave, I don't know how to post them on iBoats. But it can be done.
Here is a recent post.
I'm sorry, but I don't do anything outside of the board. Maybe one of the Mods or one of the posters that have posted .rec files can help?
I like these types of forums that can have multiple sets of eyes looking at the problem.

I do have another question, I can't quite follow your description of how you sucked out the fuel. When you say -transfer pump- do you mean the fuel feed pump mounted on the engine? Did you get any fuel pressure readings today?
I used my engine oil extraction pump. Three bucket dumps.
I spent a few hrs analyzing the data graphs. I couldn't access the fuel pump Schrader valves easily, so I moved on to recording data. My observations:
Engine off, key on 22 psi. I assume the high pressure sensor is accurate at low pressure. If so the transfer pump pressure looks very low.
Engine running fuel, rail pressure increases from 710 psi no wake idle to over 2k psi at WOT, which is about 600 rpm lower than good performance.
TPS actual increases proportional to engine RPM.
Injector pulse width maxes at 15.3 ms at throttle up, drops, climbs to 4.5 ms at 4200 rpm, then drops to 3.7 ms at 4700 rpm.
Injector pulse width seems to hang under 4 ms through higher throttle demand. This seems to me to be a factor in the low power and random misfires.
Misfire data shows only one or two cylinders. ...haven't graphed all six yet.
I haven't dug into the O2 data much because I don't know what to look for. But with the strong gasoline odor in the exhaust I'm wondering if the ECM is dialing back the fuel delivery to compensate for rich exhaust. If a fuel, leak it seems engine internal. Engine bay smells OK. I'll give the engine oil dipstick a check for making oil, and gas smell.
Your thoughts and next checks are appreciated.
Thanks.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
Hey Dave, I don't know how to post them on iBoats. But it can be done.
Here is a recent post.
I'm sorry, but I don't do anything outside of the board. Maybe one of the Mods or one of the posters that have posted .rec files can help?
I like these types of forums that can have multiple sets of eyes looking at the problem.

I do have another question, I can't quite follow your description of how you sucked out the fuel. When you say -transfer pump- do you mean the fuel feed pump mounted on the engine? Did you get any fuel pressure readings today?
Hey Dave, I don't know how to post them on iBoats. But it can be done.
Here is a recent post.
I'm sorry, but I don't do anything outside of the board. Maybe one of the Mods or one of the posters that have posted .rec files can help?
I like these types of forums that can have multiple sets of eyes looking at the problem.

I do have another question, I can't quite follow your description of how you sucked out the fuel. When you say -transfer pump- do you mean the fuel feed pump mounted on the engine? Did you get any fuel pressure readings today?
I just saw your Zip file reference. I'll try this...tomorrow. Thanks.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
Hey Dave, I don't know how to post them on iBoats. But it can be done.
Here is a recent post.
I'm sorry, but I don't do anything outside of the board. Maybe one of the Mods or one of the posters that have posted .rec files can help?
I like these types of forums that can have multiple sets of eyes looking at the problem.

I do have another question, I can't quite follow your description of how you sucked out the fuel. When you say -transfer pump- do you mean the fuel feed pump mounted on the engine? Did you get any fuel pressure readings today?
Here are the compressed .rec files. When you click to open this should show up in your downloads folder where you can open it to see the four individual .rec files.
Please let me know if you have trouble opening, and if you need more data.
 

Attachments

  • O2 feedback Volvo DI ETC 4G 07 01 2025 15 19 08.zip
    201 KB · Views: 2

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
@muc More info. I checked the transfer pump pressures. High pressure =50 psi. Low pressure/internal pump pressure = 8 psi.
Not good. Hopefully it explains the problem. I've noticed erratic O2 trims, closed loop switching to active and back erratically. An generally low injector pulse widths.
Thanks.
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
Hi Dave, What did you connect the oil extractor to?
Were these pressures checked with the engine running under moderate load?
Assuming this was a valid pressure test and you have confidence in your fuel pressure tester, yes that's a little low. Because it's just a little low I would be checking for air suction leaks and/or a restriction in the boat side before thinking about fuel cell replacement.

I started to look at the .rec files you posted, but don't see a running engine data file. But at this point the fuel pressure issue must be corrected before anything else can be diagnosed.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
I removed the fuel inlet at the transfer pump and threaded the extractor tube down into the fuel tank. Maybe a splash of fuel remained.
After refueling and getting the .rec files, I connected the gauge to each schrader valve and tune the engine to 'on'. The transfer pump cycles for about 8-10 seconds, reaches pressure and stops. I was up, dry on the lift. I started the engine briefly to get a reading. 8 psi on the low side vs 10-40 psi spec. 50 psi on the high side vs. 55-65 psi spec. Idle load only.
I'll get Diacom engine data running, and also each pressure. If the pressures are still low I'll see if the dealer will warranty a new transfer pump. ....else I have to wait several weeks before he can get to it.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
Hi Dave, What did you connect the oil extractor to?
Were these pressures checked with the engine running under moderate load?
Assuming this was a valid pressure test and you have confidence in your fuel pressure tester, yes that's a little low. Because it's just a little low I would be checking for air suction leaks and/or a restriction in the boat side before thinking about fuel cell replacement.

I started to look at the .rec files you posted, but don't see a running engine data file. But at this point the fuel pressure issue must be corrected before anything else can be diagnosed.

@muc
I rechecked fuel pressures today from idle to WOT.
Low pressure 10-11 vs spec 10-40. High pressure 65-70 vs spec 55-65. Little to no variation as load increased......hopefully close enough for you to take another look at the .rec files
I re-ran all .rec files attached. Recorded from idle through a moderate/hard acceleration to WOT.
Thanks for your time and help.
 

Attachments

  • Volvo DI ETC 4G 07 03 2025 13 16 50.zip
    83.9 KB · Views: 3

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
ok, I'm not 100% sure on this. But I have had more then a few customers that would tell me "Maybe a splash of fuel remained" or I drained the tank completely dry". But from their description of the symptom, it sure sounds like a bad fuel issue. So I question them about how did you drain the tank? And more often then not they describe some version of removing the fuel line from the pump and sucking it out. But the trouble with doing it like that ---- it doesn't work!
See, the problem is that a 17' to 23' I/O runabout will have a below the floor keel tank. So on all the boats I've worked on, there will be an anti siphon valve screwed into the fuel withdrawal tube and that tube will have 90° fitting at the top. So it's improbable that the tube you pushed down the fuel line toward the tank was able to make it past the stainless steel check ball and spring and then make it around the 90° fitting. Now in your case I might be wrong as I haven't worked on a small new runabout in over a decade. I suggest you follow the fuel line all the way to the tank to check. On small boats you can sometimes see in the engine compartment, but usually you will need to remove an round access plug in the floor or under the seats.

I see that you posted while I'm making this post. I'll finish this post and then hopefully later tonight I'll have time to look at the files.

Ok back to why this might be important to you. The fuel withdrawal tube in your gas tank will stop well short of the bottom of the tank, anywhere from 1" to 5". So when you "run out" of gas while driving the boat, there will be anywhere between 3 to 5 gallons still in the bottom of the tank. In a gas tank the bad fuel and crud will always be at the bottom. It will stay there until the boat starts moving around and then get sucked up.
What concerns me is, first it sounds to me you are dealing with a "bad" dealer. I base this off of your comment that they are "several weeks before they can look at it" If this is the dealer you bought the from -- that's unacceptable. A good dealer will find a way to get you taken care of. If it's a dealer you didn't buy the boat from -- that's normal this time of year and I have worked for dealers that wouldn't do ANY warranty work on boats that weren't purchased from us. If you do have bad fuel, this is something that's not covered under warranty. So if that's the case it might be best for you to correct it. If you decide to do this, post some pics of the tank and I'll walk you through how to get all the bad gas out.
I'm not there and diagnosis over the internet isn't easy. The picture you posted of the fuel is from the wrong angle. Only you can determine if you have bad fuel. But your symptoms fit. Now that I see the new fuel pressures you just posted --- I'm 50/50.

I'm out of time, will try to complete my thoughts later.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
@muc. Reply to your last post.
Fuel story: Unknown bad winter leftover fuel. Topped off w/10 gals before splashing.
Immediate symptoms from ramp to lift. Removed and drained filter and saw too yellow fuel with a little crud. Dissected filter showed small amounts of crud.
Pumped tank. Empty on gauge. Boat sets slightly stern down on the lift. Extracted volume w/in one gallon of total est. leftover plus 10 gal add.
New filter and 5 gal of fresh land gas plus 2+ oz Red Line cleaner. Ran normal to gas dock for 10 more gals fresh gas. Ran normal for 1 hr+. Out with family on chop. Symptoms return.
Another new filter and 10 gals of gas. ....25 gals total after pumping. No joy.
New transfer pump pressures and .rec files recorded and forwarded.
Point is any residual bad gas is very diluted. I cut previous filter apart and no crud in the folds.

Boat is driveable with poor performance/alarms. All helm gauges are good with no new DTCs, so I feel safe. I expect to take on another 15+ gals gas and more Red Line cleaner over the Fourth w/family.

New .rec files (latest Diacom update) show better injector pulse width response to throttle. 4.53 ms vs < 3.9 and closed loop status seems more in line with other inputs.
I'll pull a few spark plugs tomorrow...although with no latest misfire events I expect good plugs.

So assuming good fuel, please take a look at the latest .rec files and see if you can see an anomaly that I can't see.
Thanks again.
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
I've had a chance to look at the files and I need better files.
What I see so far is you have the MIL light on, a soft warning horn and a octane rating of 50%. This usually will set a code. There are sometimes valid reasons for why this happens. We need to find out why no code is setting. Well not the 50% octane --- no code for that.

I should have been clearer about the files I need for this issue.
When I said This model of Volvo is special, it's because of all these different monitors. I'll try to explain why this causes problems.
This EGC has many timers in it. Let take for example the fuel pump. You seem to think that at key on the pump runs until a set pressure. No, it runs for a programed amount of time and then stops until the EGC tells it to turn back on. And this fuel pump is different from past engines --- past engines the pump was either on or off --- But this engine the EGC controls the pumps with PWM (pulse width modulation) so it's turning the pumps on/off many times a second. There are many more timers. Most of what the EGC does (injector on time, spark advance and throttle plate position) when the engine is running is based off of these timers, baro, temp, RPM, load and how good the fuel is. So many things that only happen when for a set amount of time all these conditions are meet. Lets take something as simple as the misfire counter, for this counter to even become active and start counting. The baro/intake pressure, engine temp, RPMs, load and octane must ALL be between certain parameters (not to high or too low) and be stabile for a set amount of time. Just about everything this EGC does is like this, including setting a warning horn or DTC (digital trouble code). So because of how you're running these recordings there either isn't enough time at these certain parameters or the sensor reading that triggering horn/light or would set a DTC. Note the time to set is different for all this stuff.
Next up is all these different monitors that you need to record. Each monitor only looks at certain data. So the tech often has look at different monitors at the "same time". Diacom doesn't let you do this. So we have to look at the files one at a time and try to compare what's happening at certain times. This is almost impossible when the operator records these files under different conditions. They need to as close as possible to each other.
This is why I asked you to start with a cold engine running the data monitor. Note that this could take 15-30 minutes because we need to meet all these timers and allow the engine to go thru the 4 stages of open loop to closed loop. After a good data monitor run the rest of the files can be run in less time (no need to go from cold to hot). Note that each of these should take about 8 minutes or more. The files you posted are all different lengths and it appears you were running the boat differently for each of them. Heck one the most important misfire files was only 15 seconds long! that's not long enough for any of the timers.
Please follow the instructions I posted earlier on how to do .rec file. What we have so far isn't enough for someone like me who is sitting at a computer and not at the boat.

out of time --- I'll try to finish later. If what I posted today isn't clear, please ask.
 

harringtondav

Commander
Joined
May 26, 2018
Messages
2,465
I've had a chance to look at the files and I need better files.
What I see so far is you have the MIL light on, a soft warning horn and a octane rating of 50%. This usually will set a code. There are sometimes valid reasons for why this happens. We need to find out why no code is setting. Well not the 50% octane --- no code for that.

I should have been clearer about the files I need for this issue.
When I said This model of Volvo is special, it's because of all these different monitors. I'll try to explain why this causes problems.
This EGC has many timers in it. Let take for example the fuel pump. You seem to think that at key on the pump runs until a set pressure. No, it runs for a programed amount of time and then stops until the EGC tells it to turn back on. And this fuel pump is different from past engines --- past engines the pump was either on or off --- But this engine the EGC controls the pumps with PWM (pulse width modulation) so it's turning the pumps on/off many times a second. There are many more timers. Most of what the EGC does (injector on time, spark advance and throttle plate position) when the engine is running is based off of these timers, baro, temp, RPM, load and how good the fuel is. So many things that only happen when for a set amount of time all these conditions are meet. Lets take something as simple as the misfire counter, for this counter to even become active and start counting. The baro/intake pressure, engine temp, RPMs, load and octane must ALL be between certain parameters (not to high or too low) and be stabile for a set amount of time. Just about everything this EGC does is like this, including setting a warning horn or DTC (digital trouble code). So because of how you're running these recordings there either isn't enough time at these certain parameters or the sensor reading that triggering horn/light or would set a DTC. Note the time to set is different for all this stuff.
Next up is all these different monitors that you need to record. Each monitor only looks at certain data. So the tech often has look at different monitors at the "same time". Diacom doesn't let you do this. So we have to look at the files one at a time and try to compare what's happening at certain times. This is almost impossible when the operator records these files under different conditions. They need to as close as possible to each other.
This is why I asked you to start with a cold engine running the data monitor. Note that this could take 15-30 minutes because we need to meet all these timers and allow the engine to go thru the 4 stages of open loop to closed loop. After a good data monitor run the rest of the files can be run in less time (no need to go from cold to hot). Note that each of these should take about 8 minutes or more. The files you posted are all different lengths and it appears you were running the boat differently for each of them. Heck one the most important misfire files was only 15 seconds long! that's not long enough for any of the timers.
Please follow the instructions I posted earlier on how to do .rec file. What we have so far isn't enough for someone like me who is sitting at a computer and not at the boat.

out of time --- I'll try to finish later. If what I posted today isn't clear, please ask.
Got it. Getting good recordings has a learning curve. ....and a black cursor on my laptop.
I'll record again per your instructions and my wrist watch. ....I missed the eight minute test duration, but will do this.
I assume eight minutes running before idling back and doing a 'hole shot' for each of the four monitors I have available. (?)
Ps. I pulled one 90 hr spark plug today. Image attached. A bit sooty and the gap eyeballs over the .040" spec1000000473.jpg. ...any value in replacing all before the next recordings?
 

muc

"Retired" Association of Marine Technicians...
Joined
Jul 7, 2004
Messages
2,194
Well let's see how much time I get.

Dave, you seem to be sure fuel isn't your problem --- I'm not.
Let me tell you where I'm coming from.
I've lost count of the times someone brought me a small runabout that didn't run right. Often they would tell how they or a different service provider had "pumped the tank empty" or "I added a lot of chemicals and good gas". At first I believed them. But I learned.

You tick quite a few boxes.
Transported fuel in gas cans to the boat.
Filled up at a sketchy marina.
Problem started right away or shortly after storage.
Engine computer is reporting 50% octane.

You're there and I'm not. Soooo
I looked at the pic you posted, That's a lot of crud for a filter with so little time on it. I assume it was replaced during winterization? The pic of the fuel needs to be a side view to tell anything. The bad stuff goes to the bottom.

I do know that adding ANY chemical to bad fuel can only make it worse, never better. Trying to dilute bad gas rarely works. The bad gas usually won't mix with good gas --- that's one of the things that make it bad gas.

The ONLY thing I would think about adding to gas is a good stabilizer before the boat is going to sit for more then 2-3 months
The only time I would add anything is if I had a D.I. engine like you have. I would use Chevron Techron Complete (or a comparable product that has been tested to the standards, I'm not aware of any others) if I wasn't able to fuel at least 1/2 the time at a Top Tier™ certified station. https://www.toptiergas.com

Next up is --- bad fuel isn't covered under warranty. So if you do go to dealer and they find bad fuel. Lets just say you just gave them a license to charge whatever they want.
All this over one of the easiest and cheapest tests that you can do. Costs less then plugs, car and rotor that most dealers will want to start with. You already have everything you need except 4' of soft copper tubing.

I see that you feel "safe" continuing to use the boat. Not sure why you would think that? The boat is doing everything it can to tell you to stop using it and get it fixed. Once again I'm not there --- but the question isn't if your causing more damage (you are) the only question is how much damage. You have had cat damaging misfires in the past, you don't have cats to worry about. But they just call them cat damage misfires because the cat is the weakest link and goes bad first, doesn't mean they are the only thing that gets damaged. Do not take comfort that you don't see codes. The MIL light and warning horn tell me you do. you just haven't found the right conditions to log them.

Here is what I recommend you do next.
Clear the codes with Diacom, do this before you start the engine, once complete, shut everything off including the battery switch and wait 2 minutes, power everything back up and check that all codes are gone. Next before starting the engine, clear the misfire counters with Diacom.
IMPORTANT: do NOT clear the Misfire adaptive memory that you will find in this area ONLY the counters. We will do adaptive memory once the engine is fixed.

Yes Diacom is a steep learning curve and requires knowledge of how all the engine systems work I first started with Diacom back in the MEFI days and those ECMs were pretty simple, still took me many many hours and hours to learn enough to make the job easier.

I try to carry a moving blanket to put over my head and laptop screen to cut down on the sun glare or I'll use a customer beach towel (as long as it doesn't smell too much!)

What I would like, is for it to take you 3-4 minutes to get to full throttle, hold it for 30-60 seconds and then 3-4 minutes to get back to idle. Ski start to full RPMs and hold for 30-60 seconds, back to idle keeping an eye on the stern wave. The big thing is for each recording to be as consistent as the others. Patience is a trait that all good troubleshooters have.

The picture of the plug is from the wrong angle and reading plugs on a computer monitor isn't best.
No I haven't seen any reason to replace plugs yet. Once we get some consistent misfires and fuel trims, then I would think about swapping the plugs in cylinders 1+2 with 5+6 for further testing. Do not try to check or change the gap on this type of spark plug without training. Very easy to convert a $25 plug to a $2.50 plug. Gap isn't all that critical with style ignition system.
 
Top