Mopar Muscle Association UK

Pretty far removed from Mopar, but I'm struggling here...

The Kia Picanto (petrol 1.0 4cyl, 35k, 2006) we got for Daisy has developed a low rpm misfire. It was fine on the test drive and driving 60 miles home from Oswestry. Since then it's got worse every day, with the engine warning light on permanently, sometimes flashing. On advice I replaced the plug leads, no improvement. I then got a diagnostic tool on it which pointed to the coil pack. I've replaced that, no improvement. I've done lots of research and have found that there was 'an inherent manufacturing fault' with the crank pulley bolt, resulting in lots of claims against Kia. The fault allows the pulley wheel to move throwing out the timing. If not sorted in time it can knacker the crank. Symptoms described on Kia owners forum, etc, exactly match our car. Ours is outside the affected chassis number range but so are many others affected.
A receipt from July 2015 states 'Warning light flashed up on the dash Friday but not been on since. Trace to possible coil or crankshaft bolt'

Is there anything else that could cause a misfire which started as a slight stumble and within 100 miles has gone to utter crap below exactly 2000rpm.

O2 sensor is always a favourite but this should show up on an OBDII diagnostic tool.

When the Crank Position Sensor (CPS) went on my Durango it would not run at all, and when the Camshaft Position Sensor played up it would continue to run but with an engine management light up.

Sorry I forgot to mention the warning light, post now amended.

I used to work on hyundais which had the same engine as the kia. We had to replace a few engines due to this problem. The original fault if I remember correctly is incorrect torque of the crank pulley bolt. Leading to wear on the woodruff key totally ruining the crank. There was a recall to remove the bolt and inspect for wear and then replace the bolt with modified washer etc..
I also remember one of them having a snapped crank but still running. It made a rumbling sound though. The AA diagnosis was alternator bearing gone.
Hopefully for you this isn't the case.

Thanks Ed.

These are pages from the Kia repair bulletin someone has stuck online, and a pic of a knackered crank pulley.

Yes that's it. Seeing that has reminded me of a kia we did a few years ago at a non franchise garage I work at. Similar story to this really, customer with misfire, I vaguely remember the old hyundai problem. Took the bottom pulley off to find the worn pulleys and crank etc. Tried it with new pulleys ,sprocket and bolt etc and fingers crossed. But it didn't fix it. BUT, even though the car didn't have a full kia service history and was out of warranty , after the customer complained to kia customer services they did fix it.
It may be too far out of warranty now to even consider it, but it might be worth a call if the car has a good service history and low mileage. Even if they only offer a contribution to repair..
Unless you think the car isn't worth the hassle.. is the rest of the car in good condition? I don't suppose it's worth much money now it's 10 years old.

Also known for breaking wires in the injector loom,normally gives a misfire over whole rev range.

Thanks.
The car's is in such good nick apart from this, it's a damn shame!
It's been looked after by one dealer since new. I don't have all the service evidence but I've contacted them and they're looking up their records.
It's a very long shot but I will try Kia.

I just got a laptop-based OBD reader on it:
Address 11 (Engine): 1 Fault Found:
P0336 - Crankshaft Position Sensor (G28): Missing Tooth

99.9% certain now

I guess you now know why they sold it, sorry chap.

I take it the car is distributorless - as in no other place you can pick up any timing signals.

Correct Pete.
It may be but all the signs were good.
One old lady owner, had it maintained/ MOT'd at the dealer where she bought it. All MOT's and some service docs all proving the mileage, etc.
I had a good long test drive, no issues. Drive it 60 miles home, no issues.
The seller may have known about it the problem, but tbh I doubt it.

Can you not just tack weld it in the correct position? Had to do that a couple of times on Fiat Punto's that had lost drive due to the crown wheel spinning on the carrier because its not bolted, just an interference fit Few tacks and it's fixed...

Try the plugs

Do what Blue said, run the mig round it. Not really worth a lot of investment at that age.

Yes that would most likely fix it. At the moment we still have the option of taking it back for a refund and cutting our losses. If he finds a way of wriggling out of that (he's been cool so far...) then the mig might be coming out.
Mind you the sensor is knackered too -£132!

db wrote:Yes that would most likely fix it. At the moment we still have the option of taking it back for a refund and cutting our losses!

Sadly id be doing this.........Fix one thing and so it begins.

Also unknown what other potential issues may arise from this one.

Not sure id' want my daughter/son/wife driving something that may leave them stranded. Trust in a car is worth its weight in gold.