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The engine is running on between two and three cylinders after replacing the cylinder head?

Tiny
CONECASTER
  • MEMBER
  • 2001 KIA SPORTAGE
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 113,000 MILES
This occurred after replace the cylinder head.

The head replacement is not the issue. The compression is reading between 145-155 on the 4 cylinders.

#4 has not fired at all.

The coils and wiring are all replaced back to the main plug near the firewall.

I installed new injectors, and they are all clicking.

There is a new cam sensor, and the crank sensor was replaced in the recent past, it tests at 975 ohms.

I had an extra ECM and installed it after 0604 codes. I even had a code for automatic transmission fault.

It was running on 3 cylinders. I decided to check the compression on the dead #4 and inspect the plugs. The plugs are showing rich. After re assembly it runs awful. Back to 2 cylinders. 2 and 4 are dead now.

The thing is a mess and if you can't pull the plugs without a major meltdown there is something very wrong.

I have reset the ECU every time I have disconnected components.

So, the issue is not,

compression, plugs, coils and or coil wiring, injectors, cam sensor, Crank sensor ohms, grounds to the chassis and engine no more than.02 ohms,

The diagnostic is a host of conflicting codes and they change they have included ECM error codes, 02 sensor codes. Misfire codes, auto transmission codes, inj. Codes even though the suspect injector is audible,

I must say this is the biggest cluster of an experience in automotive repair I have ever experienced.

I have done much diligence with no results.

The only good thing is my head installation is good, no bolts available, I used arp studs At 90 ft lbs.
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Thursday, May 25th, 2023 AT 3:50 AM

19 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,536 POSTS
Let remove the spark plug wire/coil and see if it is getting spark.

here is a guide to help:

https://www.2carpros.com/articles/how-to-check-for-ignition-spark

and

https://www.2carpros.com/articles/engine-misfires-or-runs-rough

Also, does this engine has an EGR this could be the cause as well. Please go over these guides and get back to us.
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Thursday, May 25th, 2023 AT 2:02 PM
Tiny
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Thank you for your response, Ken.

My evidence of no spark is based on 2 information sources 1) a consistent p0304 fault code,

2) this picture

https://photos.app.goo.gl/cRMDu1by9Ges15Pk6

The engine has run quite a bit. I have pulled the #4 plug more than once but 2 mornings ago when I checked the compression I believed it had been firing the night before when I drove it. this picture shows the plug has never fired.

It is without any ignition signs.

That cylinder tested 145lbs of compression. The injectors are new, pulling no 0204 code and I can listen to it clicking with a Stethoscope.

I have not checked the EGR valve being a fuel injected car I see nothing like that near the intake. There is a vac hose at the top of the intake manifold running to a device mounted to the wall of the engine compartment below the battery in front of the fuel filter. I presume this is the EGR?
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Friday, May 26th, 2023 AT 5:16 AM
Tiny
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  • 17 POSTS
The device I described has a broken rubber mount so it floating around. I will ensure it is plugged in.
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Friday, May 26th, 2023 AT 5:18 AM
Tiny
CONECASTER
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Is this the EGR.

You can see it's plugged in I pulled it up and held it against the manifold to shoot it.
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Friday, May 26th, 2023 AT 5:27 AM
Tiny
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Here are the plugs in order 1 through 4.

#1
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Friday, May 26th, 2023 AT 5:29 AM
Tiny
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#2
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Friday, May 26th, 2023 AT 5:29 AM
Tiny
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  • 17 POSTS
#3
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Friday, May 26th, 2023 AT 5:30 AM
Tiny
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#4
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Friday, May 26th, 2023 AT 5:30 AM
Tiny
CONECASTER
  • MEMBER
  • 17 POSTS
As you can see # 3 is the most healthy, #2 is not firing all the time and in fact has not fired since I tested the compression. Before that it was firing and running relatively well, right now I could not bank it up my driveway.
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Friday, May 26th, 2023 AT 5:32 AM
Tiny
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So, I know it has fuel and compression on #4.

Obviously it is not sparking.
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Friday, May 26th, 2023 AT 5:33 AM
Tiny
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The crank sensor is reading 975 ohms.

I have been told normal is 900.

It's hard to imagine 975 is an issue.
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Friday, May 26th, 2023 AT 5:34 AM
Tiny
CONECASTER
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  • 17 POSTS
Do you know if these cars have failed wiring harness issues?
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Friday, May 26th, 2023 AT 5:36 AM
Tiny
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I have the wiring schematics if you can't locate.
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Friday, May 26th, 2023 AT 5:37 AM
Tiny
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This is a manual 5 speed. The reader showed an automatic tranny code at one point. It also reads error quite often. This is why I changed the ECM

It had a fouled cam sensor last fall before the head was changed. I. That effort to get it running I acquired and I stalled another ECM. So, the original ECM was not the issue and I put it back in after getting these crazy codes like an auto transmission code and errors.
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Friday, May 26th, 2023 AT 5:46 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

I noticed we haven't been in touch for a couple of days. Have you been able to make any progress? We are interested in knowing.

Also, you indicated you have the wiring schematics "if we can locate." Is there something I can get for you?

Let us know,

Take care,

Joe
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Sunday, May 28th, 2023 AT 7:50 PM
Tiny
CONECASTER
  • MEMBER
  • 17 POSTS
Hi Joe,

I never saw a response from you after I explained my issues.
The question has been:

Why is #4 not firing at all
Why after I pulled the coils and checked compression it lost the 2bcylinder as well as the 4.

I checked the wire plug at the ECM, for the 2 trigger wires going to the coils. Both were passing continuity. But, they were also combined and the meter beeped when I tested the two trigger leads at the plug.
I ran a new 1-4 coil wire from the ECM to the coil connector. That did nothing.

So this morning I checked everything I could again.

Although I had installed new coils I decided to move a good coil to the #4 position and I re installed an old coil I had removed on 2-3.

Big improvement, it idled with no cel. It's obviously running on no less than 3 cylinders again.

The compression is 145 on the #4 cylinder.

When I loaded the engine to back up my driveway the cel started flashing.

It was a bit grombly but smoothed out at speed and only seems to miss under load.
I need to pull the plug to see if it's firing. Up until now it has not fired at all.

Just to give you all the info
This is a new head installation

I could not buy bolts and used ARP studs torqued at 90ft lbs using the molly lube for the nuts.

The head was well above minimum height

So with compression of 145 why is it not firing

Oh, and I replaced the injectors and they are all clicking through my stethoscope.
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Monday, May 29th, 2023 AT 8:22 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,536 POSTS
The #4 plug likes like fuel is not getting to it. I would replace the fuel injector.
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Tuesday, May 30th, 2023 AT 9:28 AM
Tiny
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The issues were:

1. Continuity between the 2 coil trigger wires.

2. Moved the working 2 coil to 4 and put in an old coil, number 3 started firing.

3. The spark plug was no good. Cleaned up an old ngr from old head and it came to life. Bosch iridium plug no good.
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Tuesday, May 30th, 2023 AT 9:36 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Wow, is everything working properly now? And if I understand, it was a faulty coil and spark plug?

Let us know.

Take care,

Joe
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Wednesday, May 31st, 2023 AT 6:27 PM

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