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hi, i have a 03 df140 w 1800 hrs.
i had no problems since i owned the motor from 1100hrs thru 1700 hrs. i left the boat in the water fishing longer than normal last season prior to hauling it out in march, with no issues. upon launch prep, i discovered that the engine wouldn't turn over. i brought it to a mechanic, who found a frozen lower crankshaft bearing, and was eventually able to destroy the bearing with heat and remove the lower unit. he cleaned it up, machined the lower unit face, replaced seals, but did not replace the lower bearing calling it 'unnecessary', and i launched.
the engine appeared to work fine for about 70 hrs, when i experienced a low oil pressure alarm and rev limit cutout. i checked the dipstick and found no oil on stick. i added a quart and it brought the level to between the dots on the stick, stopped the alarm, and returned the engine to normal. checked w mechanic, who said, 'sometimes older motors burn oil, monitor it.' so i serviced the engine at 90 hours, replacing l.u. oil and engine oil/filter. the engine only drained approx 4 quarts (5.8 to fill df140). i put in 5.8qts new oil, changed filter, checked for visible leakage, all appeared fine. no smoke, no burning oil smell.
i checked the dipstick at 35 hrs, and it read low, so i added 3/4 qt to bring level back between dots. the oil is going somewhere. yesterday morning i checked the stick at 50 hrs, and it read low again, bottom of stick. i added rest of that quart, which brought oil level above lower dot. as i drove out, i notice check engine alarm, error code 1-5 on tach, and return to dock. tied to dock idling, i see sheen in water. engine stalls out. i get towed to trailer just in case, and start investigating.
i find error code 1-5 is exhaust manifold temp sensor. with engine cold, i turn key to on, still getting error code. i locate, unclip, and unthread sensor. can't find picture of what it is supposed to look like new, but it appears broken, with rough aluminum at end of threads. i put sensor back in, leaving wires unclipped, and start the engine on hose ears. engine runs fine, does not feel unusually hot to the touch, piss stream water feels normal. i continue to get 1-5 error code while sensor unclipped. while running (well) i reclip sensor wires. engine stalls out and i get overheat alarm on tach. i unplug sensor, engine starts fine, reclip sensor wires and same result, stall and overheat alarm. does this indicate that the sensor is faulty? they have this part in stock locally, so would be easy repair. why would this fail?
next, the oil leak. while engine running fine on hose, i collect some of the water that is expelled through the prop hub area in a bucket. there is obvious noticeable oil in the water. clean oil. a different mechanic suggested that the oil cooler is the likely culprit. allowing the oil to leak into the coolant water. how do i determine whether the oil cooler is bad? it apears that to check this, i must drain the oil, remove the filter, and remove the cooler for inspection? there is no sign of oil on the exterior of the cooler or filter or surrounding area.
any help would be appreciated. thanks.
i had no problems since i owned the motor from 1100hrs thru 1700 hrs. i left the boat in the water fishing longer than normal last season prior to hauling it out in march, with no issues. upon launch prep, i discovered that the engine wouldn't turn over. i brought it to a mechanic, who found a frozen lower crankshaft bearing, and was eventually able to destroy the bearing with heat and remove the lower unit. he cleaned it up, machined the lower unit face, replaced seals, but did not replace the lower bearing calling it 'unnecessary', and i launched.
the engine appeared to work fine for about 70 hrs, when i experienced a low oil pressure alarm and rev limit cutout. i checked the dipstick and found no oil on stick. i added a quart and it brought the level to between the dots on the stick, stopped the alarm, and returned the engine to normal. checked w mechanic, who said, 'sometimes older motors burn oil, monitor it.' so i serviced the engine at 90 hours, replacing l.u. oil and engine oil/filter. the engine only drained approx 4 quarts (5.8 to fill df140). i put in 5.8qts new oil, changed filter, checked for visible leakage, all appeared fine. no smoke, no burning oil smell.
i checked the dipstick at 35 hrs, and it read low, so i added 3/4 qt to bring level back between dots. the oil is going somewhere. yesterday morning i checked the stick at 50 hrs, and it read low again, bottom of stick. i added rest of that quart, which brought oil level above lower dot. as i drove out, i notice check engine alarm, error code 1-5 on tach, and return to dock. tied to dock idling, i see sheen in water. engine stalls out. i get towed to trailer just in case, and start investigating.
i find error code 1-5 is exhaust manifold temp sensor. with engine cold, i turn key to on, still getting error code. i locate, unclip, and unthread sensor. can't find picture of what it is supposed to look like new, but it appears broken, with rough aluminum at end of threads. i put sensor back in, leaving wires unclipped, and start the engine on hose ears. engine runs fine, does not feel unusually hot to the touch, piss stream water feels normal. i continue to get 1-5 error code while sensor unclipped. while running (well) i reclip sensor wires. engine stalls out and i get overheat alarm on tach. i unplug sensor, engine starts fine, reclip sensor wires and same result, stall and overheat alarm. does this indicate that the sensor is faulty? they have this part in stock locally, so would be easy repair. why would this fail?
next, the oil leak. while engine running fine on hose, i collect some of the water that is expelled through the prop hub area in a bucket. there is obvious noticeable oil in the water. clean oil. a different mechanic suggested that the oil cooler is the likely culprit. allowing the oil to leak into the coolant water. how do i determine whether the oil cooler is bad? it apears that to check this, i must drain the oil, remove the filter, and remove the cooler for inspection? there is no sign of oil on the exterior of the cooler or filter or surrounding area.
any help would be appreciated. thanks.
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