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Hyundai i800 2.5 2011 - Injector failure #

Posted by Andrew Stephenson on April 21, 2016, 11:07 pm

Year of Manufacture *: 2011
Engine Size and Code *: 2.5
( Optional ) Scanner Used: snap-on verus
( Optional) Fault Codes: none

Could use some advice on this one fellas, 2011 ('61 plate) Hyundai i800 came in as a non start, cut out on the road with a cloud of smoke. Scanned ..... no fault codes present. Fault traced to low rail pressure due to cyl 3 injector stuck open. Here's where my problem starts ! Brand new set of genuine Delphi injectors fitted, now starts & runs albeit not very well. All injectors coded in except cyl 3 .....(the location of original fault) will not accept the coding ??? tried swapping out injector but still won't accept coding with two different injectors ?? wiring from injector to ECU continuity checked & load tested, scoped injector current waveforms. The questions are 1) Is this a possible ECU fault caused by the original injector failure. 2) Will these not run right until the injectors are coded. 3) Does anyone notice anything untoward with the waveforms ? cyl 3 is looking different to me ??
Any input always appreciated

Re: Hyundai i800 injector failure

Posted by Graham Bullock <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2744' width='330' height='300' border=0 style='border:none;'> on April 21, 2016, 11:48 pm, in reply to "Hyundai i800 injector failure"
Graham Bullock

I am having a guess here and thinking out loud, I know sod all about Hyundai systems.

If injector 3 stuck open could it have caused damage by hydraulic lock?

If so, is it now trying to compensate for lower power on that cylinder by commanding a different injection compensation on that cylinder?

Would the coding for cyl 3 fail if smooth running control reaches or exceeds the limit (but why no code set)?

Can you do a relative compression check with scope or gauge? Can you check smooth running compensations?

Graham

Re: Hyundai i800 injector failure

Posted by Andrew Stephenson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3615' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 6:43 am, in reply to "Re: Hyundai i800 injector failure"

Thanks Graham, I forgot to mention that was also my first fear once I found the injector had stuck open so a mechanical compression test was done before I took the plunge & ordered the new injectors. All cylinder compressions were 400 psi. I would also of thought a code would set for a non programmed injector ? Unfortunately I appear to have no live data to check smooth running compensations !

Re: Hyundai i800 injector failure

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 8:06 am, in reply to "Re: Hyundai i800 injector failure"
Aidan Birley

Hi
Could there be a problem with the scanner software regards coding no 3 injector.?

Aidan

Re: Hyundai i800 injector failure

Posted by Antony Powell <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3923' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 8:34 am, in reply to "Hyundai i800 injector failure"

Hi Andrew

Never worked on one of these but can make the following general diesel comments....

1) We have had a large number of injector faults that show no codes stored
2) We have had plenty that have had mechanical issues with injector fault codes stored
3) We have had injector programming issues with several scanner tools

What scanner are you using

have you tried a different scanner

have you confirmed your different scope trace is on no 3 cylinder for sure

hth

tony

Link: Seized Injector and Glow plug Specialist Removal Services

Re: Hyundai i800 injector failure

Posted by Andrew Stephenson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3615' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 9:42 am, in reply to "Re: Hyundai i800 injector failure"
Andrew Stephenson

Thanks chaps, using the snap-on verus pro with the latest updated software. Spoke with snap-on tech yesterday who suggested trying to code as another vehicle with the same engine code which made no odds. I have also tried with the Launch to no avail. The different scope waveform is cylinder number 3 from timing side (the uploads are in cylinder order).

Re: Hyundai i800 injector failure

Posted by Antony Powell <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3923' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 11:07 am, in reply to "Re: Hyundai i800 injector failure"

Hi Andrew

Have you made sure when you enter the injector code you don't get any 1's and I's mixed up or 2's and Z's Etc

tony

Link: Seized Injector and Glow plug Specialist Removal Services

Re: Hyundai i800 injector failure

Posted by Andrew Stephenson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3615' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 11:17 am, in reply to "Re: Hyundai i800 injector failure"
Andrew Stephenson

Thats the first thing I double checked as these are a 20 digit code, I tend to take a photo to avoid any confusion with iffy handwriting etc

Re: Hyundai i800 injector failure

Posted by Kevin Apps <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2589' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 2:56 pm, in reply to "Hyundai i800 injector failure"
Kevin Apps

Andrew

Get it on G Scan or even auto-com . Snappy are far from the best.

Kev.

Re: Hyundai i800 injector failure

Posted by Andrew Stephenson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3615' width='330' height='300' border=0 style='border:none;'> on June 12, 2016, 12:07 pm, in reply to "Re: Hyundai i800 injector failure"

Update to whats not so rapidly turning into a nightmare..... Agreed with customer to send this to Hyundai to have injectors coded to rule out as the problem. After doing this engine was still running rough so customer requested Hyundai to take a look seen as it was with them. A report generated by Hyundai suggested internal engine damage, EGR valve faulty & blocked DPF filter all a result of the initial injector failure!! After returning the vehicle to me, upon customer request (against my better judgement) we have carried out the repairs as advised (engine re-conditioned, genuine EGR valve & DPF filter).
Still I have a rough running fault

If anyone can offer ANY thoughts on what to scope, probe or check that I may not have done already please chip in

Re: Hyundai i800 injector failure

Posted by Andrew Stephenson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3615' width='330' height='300' border=0 style='border:none;'> on June 12, 2016, 8:45 pm, in reply to "Re: Hyundai i800 injector failure"

Can anyone offer an opinion on this cam Vs crank Vs injector 1 waveforms ? injection phase looks out of sync to me

Re: Hyundai i800 injector failure

Posted by Tim Watts <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3942' width='330' height='300' border=0 style='border:none;'> on June 18, 2016, 10:13 am, in reply to "Re: Hyundai i800 injector failure"
Tim Watts

Hi.
I presume the fault still applies to injector 3 after all the new work.
Is it possible that the ground return wire is shorting to earth in the loom and holding the injector open/no coding.(assuming pull down circuit)
Are you scoping at injector or ecu, might be worth running two channels simultaneously and comparing.
Have you tried cutting wires at both injector and ecu, then replacing with jump leads.
Not unknown for injectors to cross signals if shorted especially in a pull down system.
Also are there any signs of carbon i.e. oil contamination or exhaust soot anywhere.
Hope you sort this before the sleepless nights get the better of you..

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