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Hyundai Santa Fe 2.0 CRTD 2004 - Cuts out under load, code P1181 - Fixed #

Posted by Peter Rainsley on July 16, 2013, 9:01 am

Year of Manufacture *: 2004
Engine Size and Code *: 2.0 CRTD
( Optional ) Scanner Used: Maxidas/Hannatech
( Optional) Fault Codes: P1181

After wasting time on incorrect code description with both scanners, I eventually got the description for P1181 as 'fuel pressure monitoring'. The car starts instantly, and pulls very well at low and high revs, small and large throttle openings. Then, without warning, car can cut out in first or second gear when pulling away from a junction. Unfortunately it is unpredictable and unrepeatable, but always in the same manner. Code P1181 is logged. Clearing the code, or turning the ignition off for several minutes, allows the car to be re-started. Fuel supply pressure, before and after the filter head, has been 2.4 bar when this has happened. The engine fires up when the pressure reaches 1.5 bar, and can go as high as 2.9 bar. The tank and pick ups are clean. Leak off showed one injector 50% higher than the others, which were even, so has been replaced with a new one. The other three are now 30% lower than the new one! Rail pressure and drv demand, on live data, are good, but pressure drops like a stone when the engine cuts out. I am now looking for words of wisdom, though silver bullets are also accepted
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on July 16, 2013, 9:54 am, in reply to "Hyundai Santa Fe, Cuts out under load"
Mark Carter

What system is it running? and is it single or duel point control?

Mark

Modern cars, Its all wizardry and witchcraft

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on July 16, 2013, 5:02 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
the injectors are Bosch. Would you please explain single and dual point control? This looks like the words of wisdom I need,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on July 17, 2013, 8:44 am, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
dual control, drv and suction control valve? I will get another look at it today. Thanks for your interest,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on July 17, 2013, 5:25 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
Bosch pump number 0 445 010 038. No IMV/SCV. Does this help identify the system?
Thanks,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on July 19, 2013, 6:36 am, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Mark Carter

Sorry, been away for work. Its a CP1 system running single point control.

What's the DRV duty cycle at idle when warm? and how does it respond when the Rpm is raised( correlate with rail pressure rise though out the rev range)it may pay you to graph the two.

Is the rail pressure reading steady through out the whole rev range? ( I know it will alter but does it jump about)

Have you carried out a leak off test at different engine speeds?

Where did the "new" injector come from?

Modern cars, Its all wizardry and witchcraft

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on July 23, 2013, 9:39 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
thank you for your response.The only duty cycle I noted was when under full load, and it sat at 80%. I will correlate it with rpm, similar the rail pressure. I only did a leak off test at idle with the new injector, which came from Mick Ogden. You have given me more to look at, I will let you know results,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on July 26, 2013, 8:13 am, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
customer off on holiday for a couple of weeks, so will be back in touch late,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on August 19, 2013, 9:09 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Mark,
Customer is now back off holiday so I have been able to have another look at this problem. First, I have noticed an error in my original posting. The NEW injector had 30% LESS leak off than the old ones, sorry. Now, repeating the test at 2000 and 3000 rpm shows the old injectors to have 75 to 100% more leak off. DRV duty cycle, on the scan tool, and checked with a DMM, rises steadily from 15% at idle to 20% at 3000 rpm. Similarly, rail pressure rises steadily from 260 bar to 600 bar. All tests off load. I eventually managed to 'scope rail pressure against DRV switching, volts and current, as the engine cut, but am struggling to load the image onto the forum. Can I e-mail it to you please,
Many thanks,
Peter

Re: Hyundai Santa Fe, Cuts out under load

Posted by Rob Nicholson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5122' width='330' height='300' border=0 style='border:none;'> on August 20, 2013, 8:46 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"

Hi Peter,

Does this not have a pressure limiting valve on the end of the fuel rail with a small hose into the return line? if it has and it's failing (mechanical spring n ball valve type) when it's starts to leak the DRV will see the loss & back the pressure right off giving your code and stalling?

Rob

Re: Hyundai Santa Fe, Cuts out under load

Posted by Ian Baxter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1560' width='330' height='300' border=0 style='border:none;'> on August 20, 2013, 11:11 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"

Hello Peter,
If I have read your last post correctly, Its not unheard of old injectors to fail after a new one has been fitted,

this is because the pressure has now increased as the new injector has a higher leak back resistance, this in turn puts more pressure on the old ones, if you get my drift

so you may still have an injector/injectors fault

.
Ian.

Re: Hyundai Santa Fe, Cuts out under load

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on August 26, 2013, 10:18 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Mark Carter

>>> Can I e-mail it to you please,<<<

I've been on holiday myself, if you still need any help PM me with your number.

Mark

Modern cars, Its all wizardry and witchcraft

Re: Hyundai Santa Fe, Cuts out under load

Posted by Peter Rainsley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5418' width='330' height='300' border=0 style='border:none;'> on September 2, 2013, 9:14 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Peter Rainsley

Rob, I can,t see any extra relief valve in the rail. The end with the DRV has a banjo fitting underneath, joined to the injector leak-off and tank return, and a clipped in pipe on top going to the HP pump. Ian, as you say, the leak-off test is relative,and by replacing one injector, I have moved the goal posts! Mark, e-mail on it's way, thanks for the interest shown, Peter

Fixed #

Posted by Peter Rainsley on October 14, 2013, 7:23 pm, in reply to "Re: Hyundai Santa Fe, Cuts out under load"
Edited by board administrator October 16, 2013, 3:25 pm

I can finally post a fix. Persuaded customer to have three remaining injectors overhauled. A bit of a wait for the nozzles. Customer has been running the vehicle under all conditions for several weeks, and it has behaved itself. Many thanks for ALL inputs,
Peter

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