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Author Topic: Kia Fuel Injection Problems William Hooper Phenomenal Film Handler Posts: 1879 From: Mobile, AL USA Registered: Jun 99 posted 06-24-2003 01:31 AM                        quote: Has anybody ever messed with an AUDI with the mechanical fuel injection system? I think it was a mid eighties series. The 1967-68 Triumph TR-5 had mechanical fuel injection by Lucas. In the US, it was available only w/ SU carburettors, & called the TR-250. A few TR-5's were imported to the US by enthusiasts who became some of the first ECT patients in US mental hospitals.  |  IP: Logged Bruce McGee Phenomenal Film Handler Posts: 1776 From: Asheville, NC USA... Nowhere in Particular. Registered: Aug 1999 posted 06-24-2003 07:44 AM                     My dad owned a 5 cylinder Audi 5000. Owned is the word. He rarely got to drive it. It lived in the dealer shop. He sold it, moved back to GM and Oldsmobile, and never looked back.  |  IP: Logged Per Hauberg Jedi Master Film Handler Posts: 883 From: Malling, Denmark Registered: Jul 2000 posted 06-24-2003 12:57 PM                        What about room for a DP70 in a KIA ? That car doesn't fit a man of Your format, Mark ! p.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 06-24-2003 07:55 PM                     Actually Per, I have had a DP-70 head in the back of my KIA a couple of times. Thats probably what contirbuted to blowing up the engine. I guess you could call this KIA an expanded format KIA Sportage. When it comes to cars I've always been cheap! Except for the Dodge V-10 pickup I once had. 10 DP-70's in the back of that truck and you'd never know it . You would just stop and fill up at every cheap gas station on the planet! Mark  |  IP: Logged Per Hauberg Jedi Master Film Handler Posts: 883 From: Malling, Denmark Registered: Jul 2000 posted 06-25-2003 07:57 AM                        With a DP in back of a Kia You just might risk the same complaint from road police as i did, when having loaded 2 70mm and 8 35 mm prints of My Fair Lady in back of the Volvo: I was stopped and told that my headlights were dangerous to the air traffic ! p.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 06-25-2003 09:47 PM                     Today, I first double checked the timming belt to be sure I was not one tooth off and found it to be where it belonged. Then I proceeded to tear down the intake side and when I removed the PLENUM I found this.......I put the dam gasket on backwards (Yellow Arrows) !!! I'm pretty sure this must be the problem, and one could certainly equate this finding to the CODE 17 I was getting back from the ECU as a feedback loop error...it was also the only error it spit out at me...fortunately. With the gasket between the Plenum and the intake manifold on backwards the EGR passage between the EGR valve and the Plenum was not sealed. Not only would this affect the EGR operation, it would also cause a vacuum leak into the plenum. Couldn't see it though as the plenum comes up and over the injectors to the throttle body that you can see at the top. So it was hidden. This definately proves that haste makes waste! In this case had I not hurried through putting it back together and had paid more attention to what I was doing I wouldn't be wasting my time troubleshooting it. Will report back in a day or so as I now have to get some new gaskets from the dealer! Mark  |  IP: Logged Sam Hunter Jedi Master Film Handler Posts: 779 From: West Monroe, LA, USA Registered: Jan 2002 posted 06-26-2003 10:45 PM                     The last time I rebuilt an engine I had a piston left over Gotta take your time on those things Mark, That should fix your problem when you get that vacuum back to normal.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 06-27-2003 06:41 AM                     Yea, thats pretty amazing Sam that you guessed the problem!! I'll pick up the parts today and put it together tonight. While its apart this far I'm also replacing the "O" rings on the injectors and cleaning them with the back flushing method. Mark  |  IP: Logged Sam Hunter Jedi Master Film Handler Posts: 779 From: West Monroe, LA, USA Registered: Jan 2002 posted 06-27-2003 08:52 AM                     Should you mess with the injecters at this point? Touchy little bastards you know.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 06-28-2003 04:24 PM                     The gasket was the problem. While I was waiting for the local KIA dealer to get a part he didn't have in stock I took the injectors in and had them professionally done. It was 19.50 per injector which wasn't much cionsidering that KIA gets $300.00 each for them. Never beieve a KIA dealer when they say maintainance is also cheap . At a pro fuel injection shop the injectors were first flow tested and the spray pattern analyzed. With my 4 injectors the flow rate was off almost 20% on one of the injectors while the other three were within 12% of each other. There was no leakage at all. The injectors get disassembled as far as plastic injectors do and then they are ultrasonically cleaned while cleaning solution is run thorough them and the coil is pulsed. They are then put back together and new filters and "O" rings are installed. They're then checked again for flow matching, leakage, and spray pattern. Before I tore down that side of the engine I did a visual of the spark plugs, and took some readings off the O2 sensor with a DMM. The look of the plugs and the readings I was getting hinted at a lean running engine. Anyway, a mismatch of even 10% is not satisfactory for fuel injectors! Mine now match with in .5% and what a difference it makes in the way the thing runs. It idles so smooth now you'd think it was a V-8. Now I can have it inspected and I'm pretty sure it'll pass. Mark  |  IP: Logged

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