Df 140 ehaust leak code 32

[ejayt1]

Hi I just discovered my 2002 DF 140 was running rough and found a hole under the forward plug next to the dipstick. I went to my dealer and they said it is a fairly common thing to happen and that there is no recourse from Suziki, I have about 875 hours on this motor and use the side flush every time I return from fishing. They told me $2200 to repair,I am going to try to fix it with Marine TEX has anyone tried this and was it successful?

[Sirfishalot]

Temporary fix but it will work for a short time

[kmoose]

I wonder if a more viable fix could come from inside the port? Do you have any pics of where it is leaking?

[ejayt1]

Df 140 exhaust leak

I did not take a pic but the hole is under the lowest forward plug on the left side just behind the dipstick it almost looked like a hacksaw cut but more ragged. We cleaned it ou and filed it smooth er and sandes and cleaned the area and the placed a good amount of Marine Tex and will let it cure about two days. These plug are in the part referred to as the engine holder and the plug on the port side cowel is where the hole was.

[ejayt1]

Why do you say it is only a temporary fix?

[WEDOCQ]

It's temporary because if you pulled the power head off and got a look at the engine holder it will be extremely corroded. Trust me, been there.

[boatjoe]

it is always better to run your motor with a flusher after saltwater use.the repair if done right might be good for awhile untill corrossoin loosenes it

[ejayt1]

I take it you have repaired one of these before, is it something that could be done at home or should the dealer do it?

[reel compromise]

I had this problem with the so called O2 sensor boss on both my 2003 DF140s. The first one was fixed/replaced under the 3 year warranty but the second one a year later was declined. My Suzuki mechanic pulled it and had it cut out and had a local shop weld in a "cover" for total cost of $700.-that was 650 hours ago. Good luck

[nelbur]

It is my understanding that the early DF140s had a steel plug, which was in contact with the aluminum engine holder, and the water in the exhaust. This combo caused the aluminum close to the plug to corrode fairly rapidly (galvanic corrosion). The plug was redesigned, I think in '05. My '05 has what appears to be an aluminum plug. The plug was eliminated around '08.

So long as the steel plug is still in your engine, you are getting accelerated corrosion of the aluminum near the plug. The fix, as mentioned above is to remove the plug and weld in an aluminum repair patch.

[WEDOCQ]

Yes, it may be temporarily plugged, BUT most likely there is more corrosion inside that you cant see that's going to cause you problems. This is a good pic of what happened to my engine holder internally.
-Shawn

[ejayt1]

Hi did you do the repair yourself or did you have the dealer service it?

[WEDOCQ]

I am doing everything myself. It really isnt that bad with the shop manual and a good set of metric tools. When the water got into mine, it caused me to spin a bearing. I decided against rebuilding, and found a used powerhead instead. I now have 2 nearly brand new engine holders. I will sell one at half of retail if anyone is interested wedocq@comcast.net
-Shawn

[briscoe]

nope, not Al

Your 05 will have a painted (black) steel plug. I have just removed my 07 plug and it is blowed up! The end is eroded away. I wonder if this is truly corrosion, it looks like the hot exhaust gases are eroding it!