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Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold - Fixed #

Posted by Mike Burgess on January 27, 2011, 10:39 pm

Year of Manufacture *: 2002
( Optional ) Engine Code or CC: 1.6 16v

Hi every one

I wounder if any one can give me any ideals on this one. I have a Kia Sportage. The customer had only just brought it about 5 weeks ago. he came in to me with a petrol smell. I checked it over and found fuel was dribbling from under inlet manifold, to which I found that the fuel return pipe was disconnected. were it should have been connected to the fuel regulator there was a short pipe fitted with a bolt in, blocking it off. I removed the upper section of manifold and rejoined it with a new pipe, refitted upper manifold and started it up. When it started it would only run on two cylinders and was hard to start. I then clamped of the return pipe and it was then running OK. I removed the regulator thinking that this could be faulty, obtained a new one but it still would not run unless pipe was clamped. I have checked the fuel filter, I have also tested the fuel pressure which is giving me the correct reading via Auto Data. I have carried out compression checks and replaced with new plugs. I have also smoke tested the manifold for any leaks, checked vac system and swapped over number 1 ans 2 injectors to see if it changes, but still the same. Diagnostic checks show a random misfire when pipe is not clamped. When the pipe is clamped , on road test it runs with out any problem. I have also just removed the complete inlet manifold and checked for cracks and replaced with new gasket. Were can I go from here, any sujestions would be very greatfull

Re: Kia Sportage

Posted by dave Harney <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT2603' width='330' height='300' border=0 style='border:none;'> on January 27, 2011, 11:02 pm, in reply to "Kia Sportage"
Dave Harney

Hi Mike,
What fuel pressure did you get ?

Regards
Dave

You can trim a sheeps wool many times, but you can only fleece it once !

Re: Kia Sportage 2.0 16v

Posted by Mike Burgess <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3060' width='330' height='300' border=0 style='border:none;'> on January 28, 2011, 8:16 am, in reply to "Re: Kia Sportage"
Michael Burgess

I have told you all the wrong size engine ( working late on this one). It is a 2.0Ltr not 1.6. The fuel pressure is 3.5 bar from the pump.

Re: Kia Sportage 2.0 16v

Posted by Chris Angus <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT5111' width='330' height='300' border=0 style='border:none;'> on January 28, 2011, 9:36 am, in reply to "Re: Kia Sportage 2.0 16v"
Chris Angus

Mike, can you measure the flow, use the return pipe and collect it in a jug and measure it over a minute at idle. then post results.

Chris

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by David Davies <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT5218' width='330' height='300' border=0 style='border:none;'> on January 28, 2011, 5:57 pm, in reply to "Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
David Davies

It is a known fault on these vehicles to have partially blocked or silted up injectors.I'd suggest removing the injectors(not the easiest of jobs) and having them cleaned and tested.Apparently the contamination originates in the fuel tank and is so fine that it can pass through the filter,so it may also be necessary to clean the tank.

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Mike Burgess <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3060' width='330' height='300' border=0 style='border:none;'> on January 30, 2011, 5:02 pm, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
Michael Burgess

Hi again, thanks for the last two bits of information. I am hoping to get the vehicle back into the workshop on Monday, and carry out the tests and checks on the injectors them self. I will let you know.

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Sean Mc Gettigan <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT5291' width='330' height='300' border=0 style='border:none;'> on January 31, 2011, 7:56 am, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
Sean McGettigan

Mike the contamination is normally from a rotten fuel filler neck on these (if thats the problem).

Sean

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Jim Watson <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT5178' width='330' height='300' border=0 style='border:none;'> on January 31, 2011, 4:48 pm, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"

I remember looking at one of these for poor running and did a volume check on the fuel and got a jug half full of water, and half petrol.

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Mike Burgess <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3060' width='330' height='300' border=0 style='border:none;'> on February 1, 2011, 7:11 pm, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
Michael Burgess

I have just measured the amount of fuel from the return pipe.I can not keep the engine running at idle due to it will only run if the return pipe is clamped off. Doing it over 30 seconds I get 400cc of petrol. I have checked the fuel for signs of water but none present. I am now going to remove the injectors to get tested. One thing I did find, I took the fuel filter off and let it drain out. There was something running out that looked like melted chocolate.I did connect the pipe directly to the fuel rail, but this still did not cure the fault.

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Mike Burgess <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3060' width='330' height='300' border=0 style='border:none;'> on February 1, 2011, 9:23 pm, in reply to "Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
Michael Burgess

Hi again. I have just removed the complete manifold from vehicle.When I removed the injectors from the rail, there was brown like rust between the injector seals and rail. I will be having them tested on Wednesday to see what they are like. I checked under rear seat and found access point for fuel pump. I was going to remove it to look in tank but all 8 screws are in a poor state. The inner section of the fuel filler neck does show signs of brown staining.

Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #

Posted by Chris Angus <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT5111' width='330' height='300' border=0 style='border:none;'> on February 2, 2011, 12:16 pm, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"

Mike, you need to see about 2 litres over one minute, so you definately have a fuel supply problem, the injectors are not going to cure this.
You need to check the pump, filter and fuel lines, even the tank if it's fuel of crap and blocking the pick up.

Chris

Fixed #

Posted by Mike Burgess on February 20, 2011, 10:10 pm, in reply to "Re: Kia Sportage 2.0 16v 2002 - Petrol smell, leak under manifold #"
Message modified by board administrator February 22, 2011, 2:28 pm

Hi again, sorry I have not got back to you on this job. I had the injectors tested and they were all OK, only showing number one and two with a course spray pattern. wile the injectors were away i did try to remove the fuel pump, but the screws were ceased solid and I will have to remove the tank to get better access to them. In the mean time I have smoked the manifold, cleaned and replaced with new manifold gasket, cleaned return pipe back to tank and refitted injectors back into manifold. I was about to then remove tank but tried starting vehicle first and to my surprise it now runs OK. I would have still liked to remove pump and see inside as I now think that is were the problem lies, but it has cost me a lot of time already, and the customer would like to try it first. Up until now the customer has had it back for over a week and it is still running OK. Now is the tricky bit, how much can I charge?FIXED?

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