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Old 04 August 2015, 08:56   #1
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Problems New Suzuki DF90A

Hoping someone can help; I purchased a new Suzuki DF90 last year for my Rib 5.3mtr.
All went well until my 2nd trip this season when it stated misfiring and popping and smoking till it eventually died; we had to be towed in!!

Took it back to the Suzuki agent and he could not find the fault logged and suggest we replace the timing sensor. This done we tried again after 5 mins the same thing happened, luckily no tow needed this time. But now engine wont start
Engine will not start but after trying gives 3 beeps of the warning buzzer. No fault code generated.
The engineer has looked at the engine and says the fuel pressure is showing twice what it should be and now thinks the fuel pressure regulation sensor is at fault. This means another 2 week wait while the parts come form Germany.
ps Fuel line checked and new fuel tried.

Any of you guys have any ideas, I am not that hopeful that the fault has been correctly diagnosed.

Really disappointed in Suzuki; had my old Mariner for 10 years and it never let me down!!


Thanks for looking

Phil
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Old 04 August 2015, 11:08   #2
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Originally Posted by philwaterboatman View Post
Hoping someone can help; I purchased a new Suzuki DF90 last year for my Rib 5.3mtr.
All went well until my 2nd trip this season when it stated misfiring and popping and smoking till it eventually died; we had to be towed in!!

Took it back to the Suzuki agent and he could not find the fault logged and suggest we replace the timing sensor. This done we tried again after 5 mins the same thing happened, luckily no tow needed this time. But now engine wont start
Engine will not start but after trying gives 3 beeps of the warning buzzer. No fault code generated.
The engineer has looked at the engine and says the fuel pressure is showing twice what it should be and now thinks the fuel pressure regulation sensor is at fault. This means another 2 week wait while the parts come form Germany.
ps Fuel line checked and new fuel tried.

Any of you guys have any ideas, I am not that hopeful that the fault has been correctly diagnosed.

Really disappointed in Suzuki; had my old Mariner for 10 years and it never let me down!!


Thanks for looking

Phil
It shouldn't be taking 2 weeks to get parts, they should be available next day, have they offered an explanation as to why it takes so long? I can't say that I've been over impressed with Suzuki support in the short time I've owned my DF140a. The engine itself is fine, but I'm having nmea2000 issues & they aren't interested.
Strange how the Etec knockers are notable by their absence when it's a Suzi at fault
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Old 04 August 2015, 11:48   #3
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Should have gone BRP! Always had replacement parts for my Evinrude next day

Sorry I cant help, but with all the BRP bashing I get when I have a fault I have to take the opportunity when I have one.
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Old 04 August 2015, 16:11   #4
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If fuel pressure is twice the operating amount then surely the fuel pressure regulator is at fault purely because this is what controls the line pressure to injectors.
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Old 04 August 2015, 17:53   #5
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The smoke is from over fuelling.maybe worth checking that the return is not blocked in some way causing a build up of pressure, ie a kinked pipe or collapsed fuel line.if there is no fault codes then the ecu thinks all the various sensors are working within their parameters.as a non runner you have more chance of an accurate diagnosis than a misfire at sea.best of luck.
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Old 04 August 2015, 19:57   #6
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It does sound quite unusual they are normally extremely reliable, the only problems Ive heard have come from bad fuel.

My DF90A hasn't missed a beat over the last 4 years but I have had nmea networking issues Pikey dave mentioned. I wouldn't recommend networking them as even Suzuki over this side of the pond seem clueless to sorting the problems out, they are very good at passing the buck though.

Jon
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Old 06 August 2015, 19:05   #7
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Did he connect a pressure gauge inline to the injector rail feed? Should be about 37-38 psi.

There is no fuel pressure sensor.
There is a pressure regulator which is located within the bottom of the vapour separator (which also contains the high pressure fuel pump).
This is behind the inlet manifold which needs to be removed to access it.


I have a suzuki diagnostic interface. The software is pretty basic as best.
It wont display any error code which is not displayed on the console gauge as a flashing check engine light/buzzer.
the software is useful to see each sensor performing live.

Check the blanking plug in the exhaust manifold for signs of corrosion or cracks. This is located on the same side of the engine as the ECU, near the bottom of the engine.
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