175 HPDI Injector Driver Nightmare

[sportfish78]

Just inquiring if anyone out there can assist a fellow HPDI owner? My current problem is that I have my motor at a certified Yamaha dealership and they are having serious difficulties troubleshooting electronics.

When I first took motor in, the motor had a draw which was killing my battery and also did not run well such that there was a fuel injection problem. I discovered this electrical draw from the cranking battery by touching the negative lead from the motor to the negative of the battery post while the key to ignition was "off" and hearing a clicking (like a relay) within the motor. The dealership indicated I had a faulty injector driver assembly and thus causing intermittent troubles on #1,#3, and #5 fuel injectors and that I required a new one. All done via YDS software and injector LED's.

After having the new injector driver assembly installed and being told by the dealership that the electrical draw was repaired and boat ran well, I paid my hefty bill. I took the boat to the lake and the boat did run well for two days until I discovered my motor was still draining and killing my battery as I found before.

I went to run the boat the next weekend to discover the boat would not start and also a blown 20 Amp fuse on the PBT circuit. Having the key off to the boat, I replaced the fuse with another 20 Amp and heard a 'popping' sound. The motor then started in neutral but ran unwell.I took the boat back to the dealership and they indicated that the newly installed injector driver assembly probably had a short fault and was now blowing up fuel injector #4. They also came clean and said the draw was in fact still in the motor and is probably causing these injector driver assemblies to fail. Perfect....

Any suggestions where and why this electrical fault is causing my injector driver assemblies to fail??...I need HELP

Thanks

 

[sportfish78]

Re: 175 HPDI Injector Driver Nightmare

Would still really appreciate any advice on this situation. Rodbolt please help!

 

[yamamarinetech40]

Re: 175 HPDI Injector Driver Nightmare

What year is your motor? Saltwater or fresh? I'm obviously thinking corrosion....VERY FEW electrical problems found on Yamahas. ONLY way you could have amp draw from motor with key OFF is a faulty ign sw. or a grounded(corrosion) circuit....you have this motor directly to batt. instead of batt. switch? Do you run just one battery?

 

[rodbolt]

Re: 175 HPDI Injector Driver Nightmare

the ign setup on the HPDI uses 12V power from the starter terminal to the key switch, from the keyswitch at key on power is fed from the switch to the fuel pump and main relays.
the pump relay and main relay power up the driver,ECU and fuel pump.
and various other engine functions.
with the key off place n ampmeter or use the shunt from yamaha, inline with the poitive batt terminal and cable.
unplug the relays and fuses until the current draw goes away.
an 8 milliamp draw is rather normal.
HPDI is rather simple if you actually study it.

 

[sportfish78]

Re: 175 HPDI Injector Driver Nightmare

Thanks for responding Marine tech and Rodbolt. I really appreciated it. My motor is a 2001 and was salt water used as I purchased it from a dealer on the coast in BC, Canada. Every since I bought this motor a two years ago, it has had this problem. Should of kept my 150 OX66. My boat is now only used in fresh water in Ontario, Canada.

At the moment, the mechanic that is working on the motor is now saying he has an the identical motor (except it's a 2003) with the same symptoms which I have had. I have a difficult time believing this. He said he found a shorted fault in the fuse block of this other motor and that is likely my problem as well. They indicated they will have to replace it with a new one. I don't understand why he has to replace it. Is it not possible to see and repair this short in the fuse block? I still believe it is grounding problem that could be in the relays or wiring just like you guys said.

I will ask them if they used an ammeter to troubleshoot this current draw and if they determined that the fault proved out to be in the fuse block. I would have done this troubleshooting myself but because of this whole saga of the mechanic being responsible for this fault, I am in over my head with this Yamaha dealership.

Man, I would really love to get back on the water!

 

[sportfish78]

Re: 175 HPDI Injector Driver Nightmare

Forgot to mention I have only one cranking battery energizing this motor and it is a direct connection with no battery switch.

 

[sportfish78]

Re: 175 HPDI Injector Driver Nightmare

Dealer finally came through and fixed the problem. Apparently, there was a short in the ECU which in fact was frying the injector driver assembly and reeking havoc with the fuel injectors. Once the ECU was replaced with a new one at Yamaha Canada's expense the draw was gone and motor ran like a gem.

It is too bad they never found this sooner with better troubleshooting techniques to determine the fault in the ECU. If anybody knows of any of these tests or procedures, please don't be shy and voice your opinions. This was way too long of a repair and the last resort fix in which Yamaha Canada finally recommended.

Happy to have a running boat,

Brendan