2014 red kia rio 1.6 GDI M/T busted dreams

[AndreyB]

TL,DR
https://github.com/rusefi/rusefi/wiki/Hellen-Hyundai-PB


rusEFI has GDI but TCU torque management is pain. Norman says he needs a solution for Hyundai PB platform https://en.wikipedia.org/wiki/Hyundai-Kia_small_automobile_platforms

Meet 2014 kia rio busted headlight / busted dreams.

Smells funny and coolant got pretty hot for a moment on the highway - smells like a head gasket leak.

Something is weird with first coil and there was water sitting in second coil tunner.

Battery is new but wrong kind thus the car has died on my 2 miles from my place... Perfect test mule!

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[Dron_Gus]

Capture! Dump! Take a short of oscilloscope! Write down a partnumber! Pleeeasaaseee.

[AndreyB]

Write down a part number!

37180 1W000?

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[AndreyB]

https://www.bosch-mobility.com/en/solutions/sensors/electronic-battery-sensor/
Connector 2-pin AMP/Hirschmann will take picture later

[AndreyB]

hello electric oil pump?!

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[AndreyB]

Connector 2-pin AMP/Hirschmann will take picture later

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[AndreyB]

Any chance that this kia is a 60/1?

https://rusefi.com/online/view.php?log=1226

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[mck1117]

it's 60/2 that needs to be inverted (if VR, swap wires)

[mck1117]

look at how the gap ratios are 1.0, 2.1, 0.84, 0.54, 1.0

For N-M wheel, gap ratios expected are 1.0, (M + 1), (1 / (M + 1)), 1.0

[AndreyB]

https://github.com/rusefi/rusefi_documentation/blob/master/OEM-Docs/Kia/2012-kia-rio-ub-service-manual.pdf

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[mck1117]

both the IAT and CLT are the "bosch" presets we have in the firmware

[AndreyB]

This time vnld5090 would not do it, this time it would need peak&hold valve control?

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[AndreyB]

https://www.motorreviewer.com/engine.php?engine_id=17

The high-pressure fuel pump is driven by an additional four-lobe cam on the exhaust camshaft.

[AndreyB]

Battery sensor seems to be fancy 20K LIN version 2?

https://github.com/rusefi/rusefi_documentation/blob/master/OEM-Docs/Kia/2013-battery-sensor-LIN.logicdata

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[AndreyB]

P0302 error code indicates that cylinder two is misfiring and not receiving enough spark to its spark plug.

Having fun with oscilloscope compression check - with spark plugs cranking with signal disconnected

[AndreyB]

These were brand new 40 miles ago. 1 and 2 look same kind of cleanest, 4 is by far the dirtiest. No 2 and 3 COPs are brand new so hopefully not COP issue on No 2. Clogged injector maybe?

All gaps are more or less 1mm, no 4 gap is not huge like it seems on the pic.

Ordered compression tested 12mm adapter.

[AndreyB]

TL,DR: stuck rings on cylinder #2? maybe thermostat? yes I am hoping it's not head gasket.

Open question why I am trying to fix it but it's kind of fun and relaxing.

Two symptoms: P0302 misfire cylinder 2 code, and on my way home it has overheated on the highway. Changing gear/lowing RPM has lowered temperature and allowed me to get home.

Let's focus on misfire cylinder 2 for now.
Dry compression test results: 130/70/120/120
Wet compression test results: 200/200/200/200

WOW, does this clearly point at rings not blown HG?

Put 100gm of diesel and 100gm of ATF into cylinder two. Will let it sit for 24 hours.

[mck1117]

Open question why I am trying to fix it but it's kind of fun and relaxing.

Sometimes regular wrenching is therapeutic. I'm almost looking forward to the eventual timing chain job on our F150.

[AndreyB]

Exactly!

[AndreyB]

Will let it sit for 24 hours.

Obviously I do not have patience for 24 hours. Bumped starter just to move things 9 hours into the soaking and added more liquid. With total 18 hours of soaking I've cranked for a bit and then drove around the block.

WOW?! No check engine so far?! 120 compression?!

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[AndreyB]

Pictured different kia GDI harness - I've noted the twisted wires. Also a bit of tape to hold the twist in place?

[AndreyB]

Looks like 4 lobes?
dark blue trace is cam sensor
yellow trace is white HPFP wire
light blue is brown HPFP wire

[AndreyB]

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[AndreyB]

HPFP coil resistance is 0.5ohm

Ohms Law says 24A if that would be continuous flow.

GDI4 defaults for pump control are peak 5A hold 3A, I wonder if this pump wants above default values?

[AndreyB]

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[AndreyB]

https://github.com/rusefi/rusefi/issues/5320 maybe fixed
https://github.com/rusefi/rusefi-hardware/issues/209
https://github.com/rusefi/rusefi/issues/5321

[AndreyB]

Another issue https://github.com/rusefi/rusefi-hardware/issues/210

[AndreyB]

Matt has fixed GDI4 start-up and there are now signs of life!!! https://rusefi.com/online/view.php?msq=1485

[mck1117]

Matt has fixed GDI4 start-up and there are now signs of life!!! https://rusefi.com/online/view.php?msq=1485

vids or it didn't happen

[AndreyB]

Yesterday i definitely had high pressure. with manual hack/control pump clicks were pretty loud

today pressure does not build. same 0.5 ohm on the pump solenoid, with manual control it makes a very quiet humming noise. actually let me double-check pump current settings

anyway it starts even without high pressure