4 Tec no start unless WOT

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seanlashbrook

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Hey Guys, Kind of a Newbie poster here, normally I am able to read my way on these forums to my solution, but this one has me stumped.

My wife and myself went for a little after dinner boat ride the other night on our 2008 Challenger 180. Dropped the boat in the water, fired right up and I let it idle to warm up for about 5 minutes then gradually worked the throttle up to about 1/2 throttle. It was running fine, no stutter, lights or anything when out of no-where there was a loss of power and it started to stutter. I backed the throttle off and it stalled. I opened the engine compartment, checked the coolant and oil, both were good. I tried to start it, but it would turn over, but not fire up - seemed to turn over a bit slower. I assumed I must have sucked up a weed or something, so I put it back on the trailer and had a look only to find that the impeller was perfectly clean.

I had it in my mind that there must be some sort of restriction in either the exhaust or the intake system so I started there. I removed the muffler from the exhaust manifold and tried cranking it over - no change. I removed the air filter, tried again, nothing. I tried starting while holding throttle linkage on the throttle body wide open and it would start revving itself right up. As soon as I slowly idle it down, it stalls, impossible to keep it running unless revving it right out. Still having it in my mind that I must have some sort of restriction, I removed the hose between the supercharger and the throttle body, started again with no change - however verified that supercharger is pumping lots of air. I hooked up the hose as not to overheat, started the engine at WOT, then turned on the hose thinking it may backflush any restrictions, but my exhaust temp light come on after a few minutes and I had to shut it down.

After alot of reading, I figured I may have an intercooler issue, so I decided I might as well pull it to have a look. I couldn't get it out but 3/4 of the way as the fuel tank and hull of the boat are in the way and I didn't want to pull the complete intake, but what I can see, there are no signs of water or damage. There is a light coating of oil on the outside of the coils which I'm unsure if it is normal or not.

At this point I'm at a loss, not really sure where to look next short of changing plugs and or digging into the fuel system, but I can't wrap my mind around these as I must have enough spark / fuel as the unit does run at WOT using more fuel/ spark. I feel that whatever it turns out to be will be so trivial as it was running like a top, but just stopped.

Hoping maybe someone has experienced something similar or maybe has some insight as to what to check next! Any help would be greatly appreciated!
 
Changing the plugs is always a good thing. Rarely can it hurt. It should like to me that you have a fuel issue. But,,, I would get a spark tester and confirm spark. If the spark and compression are good, I think you should check the Fuel Pump Pressure. If it is good, and assuming you KNOW you have good fuel, I'd pull the injectors and check them.


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Thanks for the response Joe! I pulled the spark plugs today and I'm still in a bit of shock, but I found the middle plug cathode is bent right over and now the engine doesn't even turn over even with all the plugs out. I'm afraid that my original testing may have made things worse. I've taken a flash-light and can see the middle piston is at the very top.

At minimal it looks like I'm into an engine rebuild or replacement...... afraid my season may be over

Thanks again!
 
Chances are, your additional cranking didn't make it any worse than what it was. Plugs don't just bend for the heck of it.

Get a flashlight and look at the top of the pistons. See if things are beat up If they are, you will likely be pulling the head.

As far as the engine not cranking, if the voltage has dropped on your battery, the starer could be stuck engaged.

Also,,, there is a chance that the bearings on the shaft have seized. If so, the engine will not crank.
So,,, you have some work in front of you to figure out where to head next..


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When I hear a story like that the hair on my legs, back of my neck and arms stand straight up. I'm afraid you have a serious problem and it will take a small fortune to fix. I'm truly feel terrible about your situation. I think you threw a rod on cylinder #2. Read this link on this website, http://www.seadooforum.com/showthread.php?77241-Sad-News-Blown-Engine&highlight=post+xintersecty This could be your problem. Please read the whole post of three pages. Very informative.
 
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Dude, sorry to hear about your plug bent over. That's a solid indication something physical got on in the engine and not in a good way.

1) Check the battery voltage and make sure the starter has enough energy to turn over
2) If it does not crank, then there is something physical. You can pull the pump and eliminate that variable.
3) Castlejoe might be right a bearing or something worse.

Yeah, my post above is a boating horror story. It's getting closer to a resolution. Just as a warning, these engines are not very accommodating because of the aluminum body and bearings. :-( A good rebuild is expensive.
 
Thanks for all of the input and responses guys! After I found the bent plug on Saturday, I loaded the wife camper and dog up and dissappeared for a couple days. Didn't want to be stressing over this thing all weekend. Xintersecty, you have some great 'engine porn' on your tear down, and it was very informative! Bit of a nightmare though!

Some background on my boat, We purchased it last August and as a matter of fact it has already had a rebuilt longblock installed by the dealer by the previous owner. There was a parts and labour warranty good for 1 year until this past May. I havn't got the original receipt of the engine, but I would be surprised if there are 13 hours on the boat since the job. I've got a call into the original owner of the boat to see what the symptoms were at the time of the first engine; once I have that I'll be having a 'strongly worded' conversation with the dealer who installed this thing. I don't want to pull much more apart until I know where this goes if anywhere, but I figure its worth a shot. 1 year on an engine seems a little light, I know most car/truck long blocks carry a minimal 2 year warranty.
 
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