engine holder /adaptor. Take the covers off the lower leg and under the powerhead is the engine holder through which seawater coupled with lotsa lovely hot exhaust gasses find their way . Port side you will find a mild steel plug which looks just like the sorta thing you would find in a domestic radiator.
THIS STEEL PLUG IS SCREWED INTO THE ALUMINIUM ALLOY CASTING!
NOW WHICH DESIGN ENGINEER THOUGHT THAT WAS A GOOD IDEA ??
Unsurprisingly this little cocktail of dissimilar metals and a corrosive atmosphere rots the aluminium alloy around the plug and hot exhaust gasses find their way into the hood and the map sensor is doing its job and lettimg ya know. Run with the hood off and the gasses disperse. The parts are sommat like £700 or so plus VAT
The casting has been modified a number of times( to eliminate the steel plug ??) I wonder why?.
However Suzuki did not want to know! Nor would they admit it was a problem of their making. Reminded me it was out of warranty (which it is by a long way). Waffled on about anode replacement during servicing. My mechanic is first class and, as a professional skipper of bigger vessels I know full well the need to replace engine anodes and its all been done.
Extremely disappointed with Suzuki's attitude and looking on the net it seems to be their policy on this matter in the US as well as here.
Was surprised that the "experts" on here gave the wrong info and had not heard of what seems to be an issue so well known to the guys in the trade .
We fixed it by cleaning up the corroded hole after the stud had been removed. Fixed a stainless patch over the hole fixed by a couple of s/s self tappers and bedded down into plastic metal. I know of another engine repaired like this and running commercially every day with no further issues
DF140-hole in exhaust
My Johnson's Fixed!
Engine holder problem anyone else