Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

OldNBold51

Petty Officer 2nd Class
Joined
Apr 19, 2010
Messages
169
Guys, here are my symptoms:
Boat is a 95 wellcraft 232 with 7.4L carbed engine with thunderbolt ignition serial # OF437981. Over the last 6 hrs of run time, spread over 3 outings it began to have intermittent firing problems, now it's full time. Initially after a 10 minute warmup/idle cruising the boat began to misfire badly then died, not backfiring but misfiring. A quick restart and normal run for a few seconds then repeat the misfire and die. After several starts with me allowing a longer and longer rest in between starts the misfire symptoms cleared up( I also opened the hatch and just jiggled wires looking for any loose ones etc) and ran the rest of the evening without problems/symptoms. In an effort to rule out water in the gas I changed my fuel separator and added STABIL ethanol boat treatment but I didn't specifically check for water in the gas. Next outing (1 week later) the boat starts fine but i can hear spark arcing, although the idle is fine and and while inspecting I see no arc, just hear it (broad daylight). This is a fast spark arc, not a slow one like you'd hear from a single grounded plug wire. The arcing noise goes away after a few minutes, the boat runs great for 10 minutes and then repeats the symptoms stated above and I finish the night without incident. Last night was different. The boat started fine but had the spark arc noise but as always that went away. After a 5 minute cruise at slow idle the above symptoms turned up but never went away. I limped in as the boat would start and I could get about 5-10 seconds of normal run then misfire/die. Restart 5 seconds/die. fortunately I was smart enough never to get far from the dock.

Another symptom possibly unrelated: Prior to this problem, my alternator gauge started showing weird numbers. Upon startup, it took the alternator (according to the gauge) a minute or 2 to show that it was charging over 12V's. The gauge reads 12.5-13.5V's at idle up to about 1200 r's then the reading falls off to about 12V or less when cruising at 2K rpm's. I have not put a multimeter on the alternator to check actual voltage.

Guys, what steps do i need to do to isolate my problem and in what order?
 
Last edited:

V-Tech

Seaman Apprentice
Joined
Oct 14, 2010
Messages
32
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

How old are the spark plug wires? I would think you are hearing a high voltage spark jumping to ground. The coil wire is part of the spark plug wires too. If not spark plug wires (and that would be my 1st guess) it might be the ignition coil has insulation issues.

The alternator belt might be slipping.
 

OldNBold51

Petty Officer 2nd Class
Joined
Apr 19, 2010
Messages
169
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

So today the boat ran fine for 30 mins on the muffs. Upon checking the alternator for voltage, i found the voltage at the output orange wire to be 14.5 volts. when you raise the rpms to 1500+ the voltage went all over the board, In a span of 30 seconds you got readings of 14.88--14.5--12.5--10--8---6---15---12--. You get the picture, up and down etc.

so i know i have a problem with the alternator/regulator. Will this fluctuation in voltage affect my ignition firing?
 

OldNBold51

Petty Officer 2nd Class
Joined
Apr 19, 2010
Messages
169
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

anyone?
 

V-Tech

Seaman Apprentice
Joined
Oct 14, 2010
Messages
32
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

Your alternator should only put out DC current. If it is putting out AC current this can affect how the ignition system works since it only works on DC. Put a volt meter on the battery while engine is running. Set voltmeter to the AC setting, it should show less than .5 volts AC current. If it shows more, you have a bad diode in the alternator. Replace alternator
 

grendelsniper

Petty Officer 3rd Class
Joined
Jul 18, 2011
Messages
84
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

I would do a tune up on this as well, plug wire cap and rotor, the dist cap might have a crack in it and temp might be expanding and contacting the cap which then you can here the arcing noise, you might see it if was completely dark, if you can here it than it almost definetky is coming from the dist.
 

turbotadd

Recruit
Joined
Feb 11, 2012
Messages
1
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

Did you ever figure out what the culprit was?
I am having similar issues with a '93 7.4l. I've replaced the plugs, cap and rotor and coil, but still misfiring.
Hopefully replacing the plug wires is the ticket.
 

grewvin1

Petty Officer 2nd Class
Joined
Apr 2, 2012
Messages
189
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

Just went through same issues with 7.4L engine on buddies wellcraft, did all the fuel stuff filters at carb, water separator checked all fule line connections for blockage. All good but engine ran then started to miss fire became a chase game. Changed coil cap set timing at night took spray bottle and misted the wires while running to check for arching wires. If you check many of Don's posts check the colour of the spark of the coil wire at against the block look for dark blue to purple not yellow arch. Our problems were solved with the new cap and coil you should add wires to your mix. Maybe try the water mist of wires at night, dis. cap too.
 

OldNBold51

Petty Officer 2nd Class
Joined
Apr 19, 2010
Messages
169
Re: Help! 7.4L intermittent then fairly constant misfiring/stall/die problem

Honestly i don't remember this issue at all. It must have disappeared on it;s own. I've had the coil go out since then, but I've put about 120 hrs on it with pretty trouble free results.
 
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