2002 opti no power, @ wits end

[phinphan]

Don or anyone who can help,
My 2002 200hp Opti has been in the shop for a month and a half for a problem with lack of power @ wot. 2000 bucks later the mechanic has told me he is @ wits end. He has spent 2.5 hrs on phone with merc and they don't know. Computer says everything is fine but can barely get up on plane, sometimes. Cleaned 6 fuel injectors, changed plugs, tried separate fuel source, rebuilt pulse pump, and most recently changed HP fuel pump. They are admittedly changing parts @ this point. I'm running out of cash. In truth it ran better b4 I took it in. Max RPM is about 4000, sometimes much less.
Just hoping someone has seen something different. I am just about ready to drive to Don's shop from northern Indiana so I can still salvage the motor which only has 50 hrs on it.
Thanks

[crizzel]

Is there another dealer in the area? I'd be taking it somewhere else if there just changing parts to "try" to get it to run...

[phinphan]

I am thinking the same thing. When I was told that Merc said the next item to replace was the HP fuel pump, I was forced to go with it since I was leaving on a trip in two days and no other dealer could turn it around that fast. I have heard other horror stories from another Merc owner in my area. Hard to find someone good and who cares at the same time.
My question is, How can Merc not have a solution besides replace parts?

[EuropeanAM]

<table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by phinphan &raquo;</td></tr><tr><td class="quote">My question is, How can Merc not have a solution besides replace parts? </td></tr></table>

Unfortunately, the guys and gals in Fond du Lac just don't a have a "crystal ball" that tells them what's wrong.

They must rely on the information given to them by the dealer you choose.

Have the BASICS been checked?

-Compression test
-Spark test (ALL SIX cylinders)
-AIR and FUEL PRESSURE TESTS, and Air/Fuel Pressure Leakdown Tests?

REEDS been inspected?

Any PRINTOUTS available from the Computer Diagnostic System?

[phinphan]

BTW This started with breakdown and replacement of gray fuel line then rebuilding of Pulse pump as described in separate post 2 mo. ago.
The things that the shop did during repair were as follows:good compression on all cylinders, good fuel sample, dropped 1 cylinder @ a time, changed fuel filter, checked tps, pulled and checked intake assbly and reeds, checked exhaust tuner,good and constant fuel and air pressure, changed plugs,sent fuel injectors to have cleaned and calibrated (supposedly way over spec and overfueling, rust over port side injectors and water signs in rail assmbly, cleaned vst(float ok),cleaned all and purged fuel lines, replaced injector o rings. Suggested have Direct injectors sent in next(are there two sets of injectors)?

[EuropeanAM]

Yes, there are two sets of injectors: Fuel injectors (this is Stage 1) and Direct Injectors (these are Stage 2).

Both must function properly. The BEST method of handling this is to send the RAILS, FUEL INJECTORS, and DIRECT INJECTORS at the SAME time.

Rails can be cleaned/inspected for carbon, damaged diaphrams, broken springs, etc.

Injectors can be cleaned, flow tested, and checked for proper balance between the set (and appropriate flow rates).

As stated earlier, I would also recommend a VOLTAGE SWEEP TEST of the TPS, as it plays a VERY CRITICAL ROLE in the delivery of the proper amount of fuel, proper timing, etc. Without proper TPS inputs... the PCM is left "at the end of the runway, flapping it's doors".