Kia Picanto: Engine Control System / Injector

Kia Picanto JA 2017-2022 Service & Repair Manual / Engine Control / Fuel System / Engine Control System / Injector

Specifications
Specification
Item
Specification
Coil Resistance (Ω)
1.43 - 1.57 (23°C)
Fuel Pressure
bar
200 - 267
MPa
20.0 - 26.7
kgf/cm²
203 - 2722.6
psi
2900 - 3872.5
Pin
2

Description and operation
Description
The GDI injector is similar to a standard injector, but sprays fuel at a much higher pressure directly into the combustion chamber and has a swirl disc to get the fuel swirling as it exits the nozzle. This aids in atomization of the fuel.The ECM controls both the feed circuits (high side) to feed voltage to the injectors and the ground circuits (low side) to energize the injectors. Also, the feed for 2 injectors comes from the same driver set. As the ignition coils are paired with cylinders (1-4 and 2-3), the injectors are also set up in pairs.

Schematic diagrams
Circuit Diagram
[A/T]

[M/T]

Repair procedures
Inspection
1.
Turn the ignition switch OFF.
2.
Disconnect the injector connector.
3.
Measure resistance between the injector terminals 1 and 2.
4.
Check that the resistance is within the specification.
Specification: 1.43 - 1.57 (23°C)
Removal
   
When removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there is potential risk of injury caused by leakage of the high pressure fuel. So, do not work on related parts immediately after engine stops.
1.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - “Release Residual Pressure in Fuel Line”)
2.
Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3.
Remove the delivery pipe & injector assembly.
(Refer to Fuel Delivery System - “Delivery Pipe")
4.
Remove the connector (A), and then separate the injector (B) from the delivery pipe.

Installation

1)
Combustion seal
2)
Rubber washer
3)
Support disc
4)
O-ring
   
Do not reuse the injector fixing clip.
Install the component to the specified torques.
Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing.
Apply engine oil to the injector O-ring.
Do not reuse the injector O-ring.
Do not reuse the bolt.
When inserting the injector, be careful not to damage the injector tip.
Do not reuse the support disc.
Do not reuse the injector rubber washer.
Do not reuse the high pressure fuel pipe.
When replacing the rubber washer, the steal plate (A) part should face the cylinder installation part and the rubber plate (B) part should face the injector body part.

Do not reuse the combustion seal.
1.
Install in the reverse order of removal.
Replacement
The injector combustion seal should be replaced with a new one to prevent leakage after removing the injector.
1.
Remove the combustion seal (A) with a wire cutter.

   
By pinching the sealing ring, carefully pull it to form a small loop and then cut it out.
Be careful not to damage the surface of the valve sleeve with the wire cutter.
2.
Before the assembly of the sealing ring, the groove must be cleaned by using a clean cloth.
By using a brass-wire brush, carefully remove all caulking from the injector sealing surface.

   
The surfaces of the new sealing ring must be clean and free of grease.
3.
Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector without damaging the injector tip (A).
Push the sealing ring (C) by thumb and index finger over the conical assembly tool until it snaps into the groove.
The complete assembly must not take longer than 2 to 3 seconds.

4.
To size the sealing ring, the injector is first introduced to the sizing tool (A) (SST No.: 09353-2B000) and then pressed and rotated 180° at the same time into the sizing tool.

5.
Pull the injector out of the sizing tool by turning it in the reverse direction of the press-in process.
   
Make sure that the seal ring is not been damaged during assembly to the injector and that no circumferential scratches are present.
Do not reuse the combustion seal.
The seal must be completely free of grease and oil.
6.
Check the combustion seal (A) installation.

Troubleshooting
Signal Waveform
The three waveforms below are taken from the #1 and #4 injectors. The top waveform is from the high side (feed side) of the #1 and #4 injectors, while the middle waveform is from the low side (ground side) of the #1 injector and the bottom waveform is from the low side of the #4 injector.
The middle waveform is the same as the top waveform because there is no ground for the circuit. With no current flowing in the circuit, the #1 injector is not energized and fuel does not flow.
The bottom waveform shows that ground is supplied and there is a voltage drop across the #4 injector. With current flowing in the circuit, the #4 injector is energized and fuel flows.

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