Optimax bad air injector symptoms. On the fuel side all 6 measured 2.

Optimax bad air injector symptoms Also, low engine use tends to dry out the Diaphrams. Make a video of the air pressure and fuel pressure dropping off to 0, that may help explain some things. I bought boat and motor used. I checked all injectors with the multimeter testing ohms resistance. Injector O-rings provide vacuum pressure for the injectors to work properly so that no outside air leaks into the injectors. mistrustracing. Most common cause: Corrosion in the injector plug (perhaps due to excessive amounts of water in the cowling), or damaged pins in the injector harness plug. brucatosvs. Faulty air injectors were replaced. If the pulse readings are good, it typically indicates that the injector is at fault. Feb 1, 2018 · If your compression checks out then hook up a proper fuel/air pressure gauge from merc and check the PSI at idle, also check if it leaks down rapidly on shutoff, either of these symptoms can be fuel/air/tracker diaphragms If all that checks out then move on to having the reeds checked out and possibly injectors Email us your serial number. com/fuel_inject Jul 31, 2023 · I had previously read an ongoing debate about whether Optimax Direct Air injectors flowing too much will air lean out an engine, or not. Alarm beeping or Descriptive Text warning on SmartTach. Pulled the compressor and found shavings in the crankcasevery little contamination was found downstream of the reed valves of the compressor, but I 1998 150 Optimax Serial Number 0G665114 My Optimax has 811 hours. Symptoms caused by leaking REGULATOR DIAPHRAGMS point to: Bad Injectors Bad Fuel Pumps Leaking VST Air in Fuel Lines Bad Gas Bad TPS New rubber DIAPHRAGMS from OptiMaxFuelRailRepair. That said, #4 was fouling the plug bad, and #2 was starting to get right behind it. . 4. Using high-quality fuel, maintaining clean fuel filters, and employing water-separating fuel filters can help prevent fuel-related problems. If the issue originates from the ECM to the injector, you would observe poor or inconsistent pulse readings on the injector wires. Jun 3, 2025 · Mercury Optimax Air outboard Injectors (DFI Direct Fuel Injection) are known troublemakers. Engine ran much better above 1000 rpm but would still cough and stop while idling. To clean and test these injectors, remove filter baskets, o-rings, and pintle caps, bead-blast loose paint and rust from the metal injector body, and place them in an ultrasonic cleaning tank for 5-10 minutes. Stay informed and keep your vehicle running smoothly with our expert tips on injector O ring issues. Jan 2, 2018 · Electrically injectors all test good. Then it seems to miss and sometimes stall. Inspect the injector wiring harness for damaged insulation or corrosion. After cleaning and fixing several small problems I have one engine that is running pretty good and has the correct air and fuel pressures of 80/90. Just got off the phone after being told 5 of 6 air injectors are “way” out of spec and are bad. Symtoms caused by leaking REGULATOR DIAPHRAMS point to: Bad Injectors Bad Fuel Pumps Leaking VST Air in Fuel Lines Bad Gas Bad TPS Rubber Regulator Diaphrams dry and crack because of today's fuel content. Found the dead cylinder by unplugging the fuel injectors and noting any rpm change. The air and fuel injectors had previously been cleaned 30 hours operating hours - 4 years earlier. Low Engine Power. Here is a little background. At $750 ea for the air injectors, I about puked. 5. No trade-secret or proprietary information- but a decent view of a variety of failure modes that CANNOT be determined without specially designed equipment: Mar 14, 2023 · The fuel injectors play a vital role in the engine. Plug Fouling. The Air Injector helps to produce a fine and fast plume of fuel for excellent power, acceleration and fuel economy. Rails are COMPLETELY disassembled, every component inspected, ultrasonic cleaned, and then reassembled. Maintaining your Mercury OptiMAX motor. Seemed like a fuel/air pressure thing, fuel supply, reeds maybe. Fuel injectors are fine. I have two faulty cylinders on the port side bottom. 0 ohms. I came up with checking the air injectors with a 9 volt battery at the terminals. Rough Engine Idle. At 685 hours the fuel rails (with fuel injectors and air injectors) were sent to Don for testing and cleaning. New rubber Jun 14, 2024 · The Optimax 225’s fuel system is sensitive to contamination, which can lead to injector clogging, pump wear, and engine performance issues. Customer: 2003 Mercury 225 Optimax. The engine idles and runs well except when it's in gear at low idle. Ran it a few times and it ran great. Consisting of air injectors, fuel injectors, multiple fuel pumps, ignition coils Just for future reference for those of you that may own an Optimax one day or currently do. Result was, problem stayed with same cylinder. Sep 26, 2025 · Discover the common symptoms of a bad injector O ring, including fuel leaks, engine misfires, and poor performance. Oct 6, 2021 · The air pressure dropping off is suspect of a bad air pressure regulator. 2 ohms. Yesterday, I turned it on and it was sputtering like crazy, like it was missing, had a fouled spark plug or something. Learn how to identify these signs early to prevent costly repairs. Jul 15, 2022 · Said he fails a high number of air injectors. The engine was running fine, but I heard a very slight bearing knock sound. The Tracker Valve is easy to replace with the correct size allen wrench. Will only 1 faulty air injector cause such misfire? Is there another test I should perform to confirm this injector is faulty? Fuel injector symptoms for bad, faulty, dirty, clogged, or leaking injectors are : Starting issues Poor idle Failed emissions Poor Performance Engine does not reach full RPM Increased fuel consumption Rough engine performance Surging and bucking under various throttle loads Smoke from the tail pipe Engine Knock or Detonation which can lead to catastrophic engine failure Pollution All air and fuel injectors were sent out for service check and cleaning. Mercury Marine Optimax Outboards use the DFI (Direct Fuel Injection) system. Different model Optimax motors use different Air Compressors. 5 ohms and 1 measured 2. Fuel was ~115 psi and air was ~95 psi. The Mercury Optimax fuel system is a finely tuned direct fuel injection system. On the fuel side all 6 measured 2. In the plenum, when you look in the air intake, there's always a small pool of what looks like oil. Here’s how it functions: Air Compressor and Injection Process The OptiMax engine features an onboard air compressor that pressurizes air to approximately 80-90 psi. Air and fuel rail pressures were checked with engine running at ~1200 rpm. The other engine barely runs for 20 seconds or so and has 20# of air and about 40# on fuel. This took about a year due to several delays including a hurricane hitting testing a set optimax air injectors that a customer sent in to get cleaned and flowed before he stores the boat for a few months for winter. Now that my VST issue is resolved, I’m having an air injector fault again. A faulty Tracker Valve will cause the engine to run rough, stall and have poor performance. Early model Tracker valves were green. com will cure and correct these symptoms. Injector O-rings are flat plastic or rubber rings in a vehicle's fuel injectors. Optimax DFI Air Injector Removal Tech Tips A faulty Direct Injector can cause the following symptoms: 1. (Invoice Number: TBD4512 Invoice Date: 5/15/2015) All lines, rails and air injectors must be meticulously cleaned and/or replaced after a compressor failure. Also, fuel-smelling grey fluid came out of the air-port along with air and mist. Apr 27, 2009 · Unless you have the proper gauges for checking the fuel and air pressures, your best option would be going to a reputible dealer or service shop to have a diagnostic check done on your fuel/air system. A third injector service company makes this argument in another forum: If you calculate the volume of air injected into a cylinder per cycle by a direct injector, it is less than 1% of the total combustion air. The Mercury Optimax Injectors and the OptiMax air/fuel injection system, known as Direct Fuel Injection (DFI), works by using a combination of air and fuel to improve combustion efficiency and performance. I checked the fuel pressure, which is 90#, and the pressure out of the VST is 25#. Bad fuel injector O-rings can damage a car over time and inhibit Sep 23, 2021 · 1999 225 Optimax, Serial Number 0G938995 My Opti has been running flawlessly for a long time. I then swopped two of the fuel injectors. On the air side, 5 air injectors measured 1. 3. Years ago, the serpentine belt rubbed when the air compressor I sent the injectors off to a reputable injector service. Here is a list of the 8 most common symptoms of a bad fuel injector and the replacement cost. I'm in, ready to grab a feed of scallops for dinner and the other 2 are dragging their feet as per usual! #cold #diving #fishingaustralia #scallopdiving #scallops #portphillipbay #boat #fishingboat #fishinglife #evolutionmarinecustoms #spendmoretimeonthewater Mar 6, 2015 · The following video shows simple, FUNCTIONAL testing of a variety of Optimax Direct (Air) Injectors. Spark seemed OK since pulling injectors always has an impact (ie if there was bad spark on some cylinder then pulling the injector shouldn't throw it off either). Optimax Fuel Injection - Moderated Discussion Areas Hop to: Aug 4, 2023 · I have dual 225 Optis with under 190 hours and the boat has been sitting for long while due to personal problems. Problems with your Mercury or Mariner Outboard DFI OPTIMAX The OPTIMAX is the most MIS-DIAGNOSED Outboard Engine. Oct 23, 2019 · 175 standard 2010 Optimax 1B789623. Don's cocktail and Non Oxy fuel has been used for over 6 years. It was smoking and there was a smell of unburned fuel. Then we will dig into the failed injector air compressor on this motor, we'll do some disassembly, (lets call it an autopsy), and show you how and why these compressors blow up, what it can do to Video documents the diagnostics and repair of a 2004 Mercury Optimax 200 with an air compressor failure and resulting clogged injectors. Jun 10, 2023 · Some common issues faced by users of the Mercury OptiMax 115 engine can include fuel injector failures, air compressor malfunctions, and water pump issues. The two good cylinders produce a loud clicking at every wire Sep 5, 2022 · 2006 225xl Mercury Optimax serial #1B288356 Merc remote monitor gauges that show up on phone. How often do you all see air injectors going bad? Any suggestions where to purchase them? Aug 25, 2017 · Smartcraft came up with "Injector Fault" and motor lost power while cruising. Excess Fuel Consumption. This compressed air is Feb 12, 2012 · WE can, however, repair/service your rails for you here (including servicing of the injectors and direct injectors). Jul 20, 2010 · You CAN have an open air injector circuit, and injector still be good. I have removed and checked the tracker Jul 31, 2023 · So the back story is the injectors came off a 300xs with 132 hours. It has done this for a couple years and I have changed plugs many times to no avail. However, regular maintenance and inspections can help identify and prevent these problems. Oct 28, 2019 · As Christ told me the fuel injectors were pretty good, but the air injectors were off a bit. Having problems with your Mercury or Mariner Outboard DFI Optimax? The OPTIMAX is the most MIS-DIAGNOSED engine out there. 2. He also warned me about how many brand new / right out of the box air injectors that fail testing and Merc will not stand behind them. While the motor is running, I unplugged the fuel injector plugs, but there was no change in the motor pitch while checking the bottom two port cylinders. It's never had the tracker valve or regulator diaphragms changed while I've 2010 Mercury Optimax 150 DFI Air Injector Fuse Blowing Issue Optimax 150 DFI often faces air injector shorts and fuse blowing when electrical faults occur. Very common problem you;ll most likely run in to. A 20-amp fuse blowing when connecting the number 6 air injector indicates a short circuit or internal injector failure. I swapped out fuel injectors that are known to work in the bad Mercury optimax air injectors - Moderated Discussion Areas Hop to: Apr 11, 2007 · I have removed both air and fuel injectors from my 150 Opti due to No2 air injector fault being discovered and am planning to send them to these people ( http://www. It's function is to reduce pulses produced by both the fuel and air pumps. The fuel is injected into the combustion chamber with the assistance of an Air Injector (also called Direct Injector). They also prevent the car from leaking oil. Later model Tracker Valves are brownish/red in color. May 24, 2020 · Comp is good across all 6 cyl. Outboard and inboard fuel injector cleaning for leading brands such as Yamaha Suzuki Honda Evinrude Mariner Mercury Volvo Penta, 24 hr turn around. The engine was removed to have the boat renovated. e9wq ghhi8wv ecsc gmnz d6ot spy 9psnsa jjnwe akse ru