Chap 60

start
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

By James D. Halderman
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OBJECTIVES:
After studying Chapter 60, the reader should
be able to:
Prepare for ASE Engine Performance (A8)

certification test content area C (Fuel, Air
Induction, and Exhaust Systems Diagnosis
and Repair).
Describe how to check an electric fuel pump
for proper pressure and volume delivery.
Explain how to check a fuel-pressure
regulator.
Continued

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OBJECTIVES:
After studying Chapter 60, the reader should
be able to:
Describe how to test fuel injectors.

Explain how to diagnose electronic fuel
injection problems.
Describe how to service the fuel injection
system.

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KEY TERMS:
graphing multimeter (GMM)
IAC counts
noid light
peak-and-hold injector pressure transducer
saturation

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PORT FUEL-INJECTION PRESSURE

REGULATOR DIAGNOSIS
Mostportfuelinjectedenginesuseavacuumhoseconnectedto
thefuelpressureregulator.Atidle,thepressureinsidetheintake
manifoldislow(highvacuum).
Manifoldvacuumisappliedabovethediaphragminsidethefuel
pressureregulator.Thisreducesthepressureexertedonthe
diaphragmandresultsinalower,about10psi(69kPa),fuel
pressureappliedtotheinjectors.
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Totestavacuumcontrolledfuelpressureregulator:
1. Connectafuelpressuregaugetomonitorthefuelpressure.
2. Locatethefuelpressureregulatoranddisconnectthevacuum
hosefromtheregulator.
3. Withtheenginerunningatidlespeed,reconnectthevacuum
hosetothefuelpressureregulatorwhilewatchingthefuel
pressuregauge.Thefuelpressureshoulddrop(about10psi
or69kPa)whenthehoseisreattachedtotheregulator.
NOTE: Ifgasolinedripsoutofthevacuumhosewhenremovedfrom
thefuelpressureregulator,theregulatorisdefectiveandwillrequire
replacement.
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4. Usingahandoperatedvacuumpump,applyvacuum(20in.
Hg)totheregulator.Theregulatorshouldholdvacuum.If
thevacuumdrops,replacethefuelpressureregulator.
NOTE: Somevehiclesdonotusea
vacuumregulatedfuelpressureregulator.
Manyofthesevehiclesusearegulator
locatedinsidethefueltankthatsuppliesa
constantfuelpressuretothefuelinjectors.
Figure 601
If the vacuum hose is removed from the fuel-pressure
regulator when the engine is running, the fuel pressure
should increase. If it does not increase, then the fuel
pump is not capable of supplying adequate pressure or
the fuel-pressure regulator is defective. If gasoline is
visible in the vacuum hose, the regulator is leaking and
should be replaced.
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Pressure Transducer Fuel Pressure Test

Using a pressure transducer and a graphing multimeter (GMM) or digital
storage oscilloscope (DSO) allows the service tech to view fuel pressure
over time, Figure a. Note the fuel pressure dropped from 15 to 6 psi on a
TBI-equipped vehicle after one minute. Normal pressure holding capability is
shown in Figure b, when pressure dropped about 10% after 10 minutes.
(a)
(b)
Figure 602 (a) A fuel-pressure graph after key on, engine off (KOEO). (b) Pressure drop after 10
minutes on a normal port fuel-injection system.
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DIAGNOSING ELECTRONIC FUEL-INJECTION

PROBLEMS USING VISUAL INSPECTION
Allfuelinjectionsystemsrequiretheproperamountofcleanfuel
deliveredtothesystemattheproperpressureandthecorrect
amountoffilteredair.
Thefollowingitemsshouldbecarefullyinspectedbefore
proceedingtomoredetailedtests.
Checktheairfilterandreplaceasneeded.
Checktheairinductionsystemforobstructions.
Checktheconditionsofallvacuumhoses.Replaceanyhose
thatissplit,soft(mushy),orbrittle.
Checkallfuelinjectionelectricalconnectionsforcorrosion
ordamage.
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NOTE: UseofanincorrectPCVvalvecancausearoughidleorstalling.
Figure 603 A clogged PCV system
caused the engine oil fumes to be
drawn into the air cleaner assembly.
This is what the technician
discovered during a visual inspection.
Checkthepositivecrank
caseventilation(PCV)
valveforproperoperation
orreplacementasneeded.
Checkforgasolineatthevacuumportofthefuelpressure
regulatorifthevehicleissoequipped.Gasolineinthevacuum
hoseatthefuelpressureregulatorindicatesthattheregulatoris
defectiveandrequiresreplacement.
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Stethoscope Fuel Injection Test - Part 1

A common test for injector operation is to listen to the injector using a
stethoscope with the engine at idle speed. All injectors should produce the
same clicking sound. If an injector makes a clunking or rattling sound, it
should be tested further or replaced.
Figure 604
All fuel injectors should make the same sound
with the engine running at idle speed. A lack of
sound indicates a possible electrically open
injector or a break in the wiring. A defective
computer could also be the cause of a lack of
clicking (pulsing) of the injectors.

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Stethoscope Fuel Injection Test - Part 2

With the engine still running, place the end of the stethoscope probe to the
return line from the fuel-pressure regulator. Fuel should be heard flowing
back to the fuel tank if the fuel-pump pressure is higher than the fuelregulator pressure. If no sound of fuel is heard, then either the fuel pump or
the fuel-pressure regulator is at fault.
Figure 605 Fuel should be heard returning to the

fuel tank at the fuel return line if the fuel-pump
and fuel-pressure regulator are functioning
correctly.

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Quick and Easy Leaking Injector Test

Leaking injectors may be found by disabling the ignition, unhooking all
injectors, and checking exhaust for hydrocarbons (HC) using a gas
analyzer while cranking the engine (maximum HC = 300 ppm).

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SCAN TOOL VACUUM LEAK DIAGNOSIS

Ifavacuum(air)leakoccursonanengineequippedwithaspeed
densitytypeoffuelinjection,theextraairwouldcausethe
followingtooccur:
Idlespeedincreasesduetotheextraairjustasifthethrottle
pedalwasdepressed.
TheMAPsensorreactstotheincreasedairfromthevacuum
leakasanadditionalloadontheengine.
Thecomputerincreasestheinjectorpulsewidthslightlylonger
duetothesignalfromtheMAPsensor.
Theairfuelmixtureremainsunchanged.
Idleaircontrol(IAC)countswilldecrease,therebyattempting
toreducetheenginespeedtothetargetidlespeedstoredinthe
computermemory.SeeFigure606.
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Figure 606
Using a scan tool to check for IAC counts or percentage as part of a diagnostic routine.
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Oneofthebestindicatorsofavacuumleakonaspeeddensityfuel
injectionsystemistolookattheIACcountsorpercentage,usually
15to25.Areadingoflessthan5indicatesavacuumleak.
Ifavacuumleakoccursonanengineequippedwithamassairflow
typefuelinjectionsystem,theextraaircausesthefollowing:
Theenginewilloperateleanerthannormalbecausetheextra
airhasnotbeenmeasuredbytheMAFsensor.
Theidlespeedwilllikelybelowerduetotheleanerthan
normalairfuelmixture.
Theidleaircontrol(IAC)countsorpercentagewilloften
increaseinanattempttoreturntheenginespeedtothetarget
speedstoredinthecomputer.
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No Spark, No Squirt
Most electronic fuel-injection computer systems use the ignition primary
(pickup coil or crank sensor) pulse as the trigger for when to inject (squirt)
fuel from the injectors (nozzles). If this signal were not present, no fuel
would be injected. Because this pulse is also necessary to trigger the
module to create a spark from the coil, it can be said that no spark could
also mean no squirt. If the cause of a no-start condition is observed to be
a lack of fuel injection, do not start testing or replacing fuel-system
components until the ignition system is checked for proper operation.

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PORT FUEL INJECTION SYSTEM DIAGNOSIS

Todetermineifaportfuelinjectionsystemincludingthefuel
pump,injectors,andfuelpressureregulatorisoperating
correctly:
1. AttachafuelpressuregaugetotheSchradervalveonthe
fuelrail.
2. Turntheignitionkeyonor
starttheenginetobuildup
thefuelpumppressure(to
about35to45psi).
Figure 607 Checking the fuel
pressure using a fuel pressure gauge
connected to the Schrader valve.
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3.
Wait20minutesandobservethefuelpressureretainedinthefuel
railandnotethepsireading.Thefuelpressureshouldnotdrop
morethan20psi(140kPa)in20minutes.
Ifthedropislessthan20psiin20minutes,everythingis
okay;ifthedropisgreater,thereisapossibleproblemwith:
Thecheckvalveinthefuelpump
Leakinginjectors,lines,orfittings
Adefective(leaking)fuelpressureregulator
Todeterminewhichunitisdefective,performthefollowing:
Reenergizetheelectricfuelpump.
Clampthefuelsupplyline,andwait10minutes.Ifthepressure
dropdoesnotoccur,replacethefuelpump.Ifthepressuredrop
stilloccurs,continuewiththenextstep.
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CAUTION: Donotclampplasticfuel
lines.Connectshutoffvalvestothefuel
systemtoshutoffsupplyandreturn
lines.
Figure 608 Shutoff valves must be used on vehicles

equipped with plastic fuel lines to isolate the cause of
a pressure drop in the fuel system.
Repeatthepressurebuildupoftheelectricpumpandclamp
thefuelreturnline.Ifthepressuredroptimeisnowokay,
replacethefuelpressureregulator.
Ifthepressuredropstilloccurs,oneormoreofthe
injectorsisleaking.Removetheinjectorswiththefuelrail
andholdoverpaper.Replacethoseinjectorsthatdripone
ormoredropsafter10minuteswithpressurizedfuel.
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TESTING FOR AN INJECTOR PULSE

Oneofthefirstcheckstoperformwhendiagnosinganostart
conditioniswhetherthefuelinjectorsarebeingpulsedbythe
computer.
Properpulsingoftheinjectorisalsoimportantindiagnosinga
weakordeadcylinder.
Anoidlightisdesignedtoelectricallyreplacetheinjectorinthe
circuitandtoflashiftheinjectorcircuitisworkingcorrectly.
NOTE: Thetermnoidissimplyanabbreviationofthewordsolenoid.
Injectorsuseamovableironcoreandarethereforesolenoids.Therefore,a
noidlightisareplacementforthesolenoid(injector).
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Touseanoidlight,disconnecttheelectricalconnectoratthefuel
injectorandplugthelightintotheinjectorharnessconnections.
Crankorstarttheengine.Thenoidlightshouldflashregularly.
Figure 609 (a) Noid lights are usually purchased as an assortment so that one is available for
any type or size of injector wiring connector. (b) The connector is unplugged from the injector
and a noid light is plugged into the injector connector. The noid light should flash when the
engine is being cranked if the power circuit and the pulsing to ground by the computer are
functioning okay.
(a)
(b)
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Possiblenoidlightproblemsandcausesincludethefollowing:
1. ThelightisoffanddoesnotflashTheproblemisan
openineitherthepowersideorgroundside(orboth)
oftheinjectorcircuit.
2. ThenoidlightflashesdimlyAdimnoidlightindicates
excessiveresistanceorlowvoltageavailabletotheinjector.
Boththepowerandgroundsidemustbechecked.
3. ThenoidlightisonanddoesnotflashIfthenoidlightis
on,thenbothapowerandagroundarepresent.Becausethe
lightdoesnotflash(blink)whentheengineisbeingcranked
orstarted,thenashorttogroundfaultexistseitherinthe
computeritselforinthewiringbetweentheinjectorandthe
computer.
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CAUTION: Anoidlampmustbeused
withcaution.Thecomputermayshowa
goodnoidlightoperationandhavelow
supplyvoltage.
Figure 6010 Use a DMM set to read DC volts to check

the voltage drop of the positive circuit to the fuel injector.
A reading of 0.5 volt or less is generally considered
to be acceptable.

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CHECKING FUEL INJECTOR RESISTANCE

Theelectricalbalancetestinvolvesmeasuringtheinjectorcoil
windingresistance.Forbestengineoperation,allinjectorsshould
havethesameelectricalresistance.
Tomeasuretheresistance,carefullyreleasethelockingfeatureof
theconnectorandremovetheconnectorfromtheinjector.
NOTE: Someenginesrequirespecificprocedurestogainaccesstothe
injectors.Alwaysfollowthemanufacturersrecommendedprocedures.
Withanohmmeter,measuretheresistanceacrosstheinjector
terminals.Besuretousethelowohmsfeatureofthedigital
ohmmetertoreadintenths(0.1)ofanohm.
SeeFigures6011and6012.
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Measureresistanceofall
injectors.Replaceanythat
donotfallwithinthe
resistancerangeofthe
specification.
SeethechartonPage
723ofyourtextbook.
Theresistanceshouldbe
measuredtwiceonce
whentheengine(and
injectors)arecoldand
aftertheenginehas
reachednormal
operatingtemperature.
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Ifanyinjectormeasuresclosetospecification,makecertainthat
theterminalsoftheinjectorareelectricallysound,andperform
otherteststoconfirmaninjectorproblembeforereplacement.
Figure 6012 To measure fuel-injector
resistance, a technician constructed a short
wiring harness with a double banana plug that
fits into the V and COM terminals of the meter
and an injector connector at the other end.
This setup makes checking resistance of fuel
injectors quick and easy.
Figure 6011
Connections and settings
necessary to measure
fuel-injector resistance.
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MEASURING RESISTANCE OF GROUPED

INJECTORS
Manyvehiclesareequippedwithaportfuelinjectionsystemthat
firestwoormoreinjectorsatatime.
AV6maygroupallthreeinjectorsononebanktopulseonatthe
sametime.Thentheotherthreeinjectorswillbepulsedon.This
sequencealternates.
itisofteneasiesttomeasureeachgroupofthreethatiswiredin
parallel.Theresistanceofthreeinjectorswiredinparallelisone
thirdoftheresistanceofeachindividualinjector.
Injectorresistance=12ohms()
Threeinjectorsinparallel=4ohms()
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AV6hastwogroupsofthreeinjectors.Ifbothgroupsmeasure4ohms,it
islikelyallsixinjectorsareOK.However,ifonegroupmeasuresonly2.9
ohmsandtheothermeasures4ohms,itislikelyoneormorefuelinjectors
aredefective(shorted).
Figure 6013 (a) The meter is connected to read one group of three 12-ohm injectors. The
result should be 4 ohms and this reading is low, indicating at least one injector is shorted
(low resistance). (b) This meter is connected to the other group of 3 injectors and indicates
most injectors are shorted. The technician replaced all six injectors and the engine ran great.

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MEASURING RESISTANCE OF INDIVIDUAL

INJECTORS
Thefirsttestistomeasuretheresistanceofthecoilinsideand
compareittofactoryspecs.Iftheinjectorsarenotaccessible,check
serviceinformationforthelocationoftheelectricalconnectorfor
theinjectors.
Unplugtheconnectorand
measureresistanceofeach
injectorattheinjectorside
oftheconnector.
Figure 6014 Measuring injector resistance
using a DMM and an injector connector. This
setup was made by the technician and makes
measuring injector resistance fast and easy.
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Equal Resistance test

All fuel injectors should measure the specified resistance. However the
specification often indicates the temperature of the injectors be at room
temperature and of course will vary according to the temperature. Rather
than waiting for all of the injectors to achieve room temperature, measure
the resistance and check that they are all within 0.4 ohm of each other. To
determine the difference, record the resistance of each injector and then
subtract the lowest resistance reading from the highest resistance reading
to get the difference. If more than 0.4 ohm then further testing will be
needed to verify defective injector(s).

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PRESSURE DROP BALANCE TEST

Thepressurebalancetestinvolvesusinganelectricaltimingdevice
topulsethefuelinjectorsonforagivenamountoftime,usually
500msor0.5second,andobservingthedropinpressurethat
accompaniesthepulse.
Ifthefuelflowthrougheachinjectorisequal,thedropinpressure
inthesystemwillbeequal.Mostmanufacturersrecommendthat
thepressuresbewithinabout1.5psi(10kPa)ofeachotherfor
satisfactoryengineperformance.
Thistestmethodnotonlyteststheelectricalfunctioningofthe
injector(fordefinitetimeandcurrentpulse),butalsotestsfor
mechanicaldefectsthatcouldaffectfuelflowamounts.
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Thepurposeofrunningthisinjectorbalancetestistodeterminewhichinjectorisrestricted,
inoperative,ordeliveringfueldifferentlythantheotherinjectors.Replacingacomplete
setofinjectorscanbeexpensive.
Thebasictoolsneededare:
Accuratepressuregaugewithpressurerelief
Injectorpulserwithtimecontrol
Necessaryinjectorconnectionadapters
Safereceptacleforcatchinganddisposingofanyfuelreleased
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Thetestingprocedure:
Step#1Attachthepressuregaugetothefueldeliveryrailonthe
supplyside.Makesuretheconnectionsaresafeandleakproof.
Step#2Attachtheinjectorpulsertothefirstinjectortobetested.
Step#3Turntheignitionkeyto
theonpositiontoprimethefuel
rail.Notethestaticfuelpressure
reading.
Figure 6015 Connect a fuel pressure gauge

to the fuel rail on the Schrader valve.
Step#4Activatethepulserfor
thetimedfiringpulses.
Step#5Noteandrecordthe
newstaticrailpressureafter
theinjectorhasbeenpulsed.
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Step#6Reenergizethefuelpumpandrepeatthisprocedurefor
alloftheengineinjectors.
Step#7Comparethetwopressurereadingsandcomputethe
pressuredropforeachinjector.Comparethepressuredropsofthe
injectorstoeachother.Anyvariationinpressuredropswill
indicateanunevenfueldeliveryratebetweentheinjectors.
SeethechartonPage725ofyourtextbook.
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INJECTOR VOLTAGE DROP TESTS

Thistestinvolvespulsingtheinjectorandmeasuringthevoltagedrop
acrossthewindingsascurrentisflowing.Atypicalvoltagedrop
testerisshownhere.
Figure 6016 An injector tester being
used to check the voltage drop through
the injector while the tester is sending
current through the injectors.
This test is used to check the coil
inside the injector. This same tester can
be used to check for equal pressure
drop of each injector by pulsing the
injector on for 500 ms.
Thetester,whichisrecommendedforusebyGM,pulsesthe
injectorwhileadigitalmultimeterisconnectedtotheunit. Continued
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Thiswhichwilldisplaythevoltagedropasthecurrentflows
throughthewinding.Recordthehighestvoltagedropobservedon
themeterdisplayduringthetest.
Repeatthevoltagedroptestforalloftheinjectors.Thevoltage
dropacrosseachinjectorshouldbewithin0.1voltofeachother.
Ifaninjectorhasahigherthannormalvoltagedrop,theinjector
windingshavehigherthannormalresistance.
CAUTION: Donottestaninjectorusingapulsetypetestermorethan
onetimewithoutstartingtheenginetohelpavoidahydrostaticlock
causedbytheflowoffuelintothecylinderduringthepulsetest.

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SCOPE TESTING FUEL INJECTORS

Ascope(analogordigitalstorage)canbeconnectedintoeach
injectorcircuit.Therearethreetypesofinjectordrivecircuits,
eachwithitsowncharacteristicpattern.
Figure 6017
A digital storage oscilloscope can be easily connected
to an injector by carefully back probing the electrical
connector.
Hereforanexampleofhowtoconnect
ascopetoreadafuelinjectorwaveform.
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SaturatedSwitchTypeInasaturatedswitchtypeinjectordriven
circuit,voltage(usuallyafull12volts)isappliedtotheinjector.
Groundfortheinjectorisprovidedbythevehiclecomputer.
Duetotheresistanceandinductivereactanceofthecoilitself,it
requiresafractionofasecond(about3millisecondsor0.003
seconds)forthecoiltoreachsaturationormaximumcurrentflow.
Mostsaturatedswitchtypefuelinjectorshave12to16ohmsof
resistance.Thisresistance,aswellasthecomputerswitchingcircuit,
controlandlimitthecurrentflowthroughtheinjector.
Avoltagespikeoccurswhenthecomputershutsoff(opensthe
injectorgroundsidecircuit)theinjectors.
SeeFigure6018.
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Figure 6018 The injector on-time is called the pulse width.
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PeakandHoldTypeApeakandholdtypeistypicallyused
forTBIandsomeportlowresistanceinjectors.Batteryvoltage
isappliedtotheinjectorandthegroundsideiscontrolledthrough
thecomputer.
Thecomputerprovidesahighinitialcurrentflow(about4amps)
toflowthroughtheinjectorwindingstoopentheinjectorcore,
thenreducesthecurrenttoalowerlevel(about1amp).
Typicalpeakandholdtypeinjectorresistancerangesfrom2to4
ohms. Thescopepatternofatypicalpeakandholdtypeinjector
showstheinitialclosingofthegroundcircuit,thenavoltagespike
asthecurrentflowisreduced.
Anothervoltagespikeoccurswhenthelowerlevelcurrentis
turnedoff(opened)bythecomputer.SeeFigure6019.
Continued

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Figure 6019 A typical peak-and-hold fuel-injector waveform. Most fuel injectors that measure
less than 6 ohms will usually display a similar waveform.
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PulseWidthModulatedTypeApulsewidthmodulatedtypeof
injectordrivecircuituseslowerresistancecoilinjectors.Battery
voltageisavailableatthepositiveterminaloftheinjectorandthe
computerprovidesavariabledurationconnectiontogroundonthe
negativesideoftheinjector.
Thecomputercanvarythetimeintervalsthattheinjectoris
groundedforveryprecisefuelcontrol. Eachtimetheinjector
circuitisturnedoff(groundcircuitopened),asmallvoltage
spikeoccurs.
Itisnormaltoseemultiplevoltagespikesonascopeconnected
toapulsewidthmodulatedtypeoffuelinjector.
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If Three of Six Injectors Are Defective, Should I Also

Replace the Other Three?
This is a good question. Many service techs recommend that the three
good injectors also be replaced along with the three tested defective. The
reasons given include:
All six injectors have been operating under the same fuel, engine,
and weather conditions.
The labor required to replace all six is just about the same as
replacing only the three defective injectors.
Replacing all six helps ensure that all the injectors are flowing the
same amount of fuel so the engine is operating most efficiently.
With these ideas in mind, the customer should be informed and offered the
choice. Complete sets of injectors such as those in can be purchased at a
reasonable cost.
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IDLE AIR SPEED CONTROL DIAGNOSIS

Onanengineequippedwithfuelinjection
(TBIorportinjection),theidlespeedis
controlledbyincreasingordecreasingthe
amountofairbypassingthethrottleplate.
Again,anelectronicsteppermotoror
pulsewidthmodulatedsolenoidisused
tomaintainthecorrectidlespeed
Thiscontrolisoftencalledtheidleair
control(IAC).
SeeFigures6022and6023.
Figure 6021 An IAC controls idle speed by controlling the
amount of air that passes around the throttle plate. More
airflow results in a higher idle speed.
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Whentheenginestops,mostIACunitswillretractoutwardtoget
readyforthenextenginestart.Whentheenginestarts,theengine
speedishightoprovideforproperoperationwhentheengineiscold.
Astheenginegetswarmer,thecomputerreducesidlespeed
graduallybyreducingthecountsorstepscommandedbytheIAC.
Figure 6022 A typical IAC.
Figure 6023 Some IAC units are

purchased with the housing as shown.
Carbon buildup in these passages can
cause a rough or unstable idling or
stalling.
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There is No Substitute for a Thorough

Visual Inspection
An intermittent check engine light and a random-misfire diagnostic trouble
code (DTC) P0300 was being diagnosed. A scan tool did not provide any
help because all systems seemed to be functioning normally. Finally, the
technician removed the engine cover and discovered a mouse nest.
(a)
(b)
Figure 6024 (a) Nothing looks unusual when the hood is first opened. (b) When the cover is
removed from the top of the engine, a mouse or some other animal nest is visible. The animal had
already eaten through a couple of injector wires. At least the cause of the intermittent misfire was
discovered.

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FUEL INJECTION SERVICE

Sometechsstillmisunderstandtheprocessofproperfuelsystem
handling.Somemanufacturershavesuggestedmethods,while
othershaveissuedbulletinstoprohibitanycleaningatall.
Allenginesusingfuelinjectiondorequiresometypeoffuel
systemmaintenance.Normalwearandtearwithtodays
underhoodtemperaturesandchangesingasolinequality
contributetothebuildupofolefinwax,dirt,water,andmany
otheradditives.
Uniquetoeachengineisanaircontroldesignthatalsomay
contributedifferentlevelsofcarbondeposits,suchasoilcontrol.
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Fuelinjectionsystemserviceshouldincludethefollowing:
1. CheckfuelpumpoperatingpressureandvolumeMost
workingtechniciansassumethatifthepressureiscorrect,the
volumeisalsoOK.
Useafuelpressuretesterto
thefuelrailinlettoquickly
testthefuelpressurewiththe
enginerunning.
Atthesametime,testthe
volumeofthepumpby
sendingfuelintotheholding
tank.(Oneouncepersecond
istheusualspecification.)
Figure 6025 Checking fuel-pump volume using a hose from the
outlet of the fuel pressure regulator into a calibrated container.
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2. Testthefuelpressureregulatorforoperationand
leakageThisworkswellastheoperatorhastotalcontrol
ofrailpressurewithaunitcontrolvalve.Belowaresome
pointstoconsider:
Goodpressuredoesnotmeanpropervolume.Aclogged
filtermaytestokayonpressurebuttherestrictionmaynot
allowpropervolumeunderload.SeeFigure6026.
Itisagoodideatousethevehiclesowngasolineto
servicethesystemversusacanofshopgasolinethathas
beensittingaroundforsometime.
Pressureregulatorsdofailandalotmoredonotproperly
shutofffuel,causinghigherthannormalpumpwearand
shorterservicelife.
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Figure 6026 Testing fuel-pump volume using a fuel-pressure gauge with a bleed hose inserted
into a suitable container. The engine is running during this test.

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3. Flushtheentirefuelrailandupperfuelinjectorscreens
includingthefuelpressureregulator.Raisetheinput
pressuretoapointaboveregulatorsettingtoallowaconstant
flowoffuelthroughtheinletpressuresideofthesystem,
throughthefuelrail,andouttheopenfuelpressureregulator.
Inmostcasestheappliedpressureis75to90psi,(517to
620kPa)butwillbemaintainedbythepresenceofa
regulator.Atthispoint,cleaningchemicalisaddedtothefuel
ata5:1mixtureandallowedtoflowthroughthesystemfor
15to30minutes.
Resultsarebestonahotenginewiththefuelsupplylooped
andtheenginenotrunning.
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Figure 6027 A typical two-line cleaning machine hookup, showing an extension hose that can
be used to squirt a cleaning solution into the throttle body while the engine is running on the
cleaning solution and gasoline mixture.

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Moreitemstoconsider:
Thisflushisthefixmostvehiclesneedfirst.Thedifference
isthatthedepositsareremovedtoaremotetankandfilter
versusattemptingtosoftenthedepositsandblowthem
throughtheupperscreens.
Mostinjectorsusea10micronfinalfilterscreen.A25%
restrictionintheupperscreenwouldincreasetheinjector
ontimeapproximately25%.
CleanthefuelinjectorsAdjustoutputpressurecloserto
regulatorpressureorlowerthaninprevioussteps.Lower
pressurewillcausethepulsewidthtoopenuplongerand
allowtheinjectorstobecleaned.Cleaninjectorsarethe
objective,butthechemicalshouldalsodecarbontheengine
valves,pistons,andoxygensensor.
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4. Decarbontheengineassembly.Onmostvehicles,the
injectorspraywillhelpthedecarboningprocess.
Onothers,youmayneedtoenhancetheoperationwith
externaladditionofamixturethroughthePCVhose,
throttleplates,oridleaircontrols.
Check the Injectors at the Bends and Ends
Injectors that are most likely to become restricted due to clogging of the
filter basket screen are the injectors at the ends of the rail especially on
returnless systems where dirt can accumulate. Also the injectors that are
located at the bends of the fuel rail are also subject to possible clogging
due to the dirt being deposited where the fuel makes a turn in the rail.
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5. Cleanthethrottleplateandidleaircontrolpassages.
Doingthisservicealoneonmostlatemodelengineswillshow
amanifoldvacuumincreaseofupto2in.Hg.
Cleantheareasasneeded,thenuseahandheldfuelinjector
connectedinparallelwiththepressurehose,alongwitha
pulsertoallowcleaningofthethrottleplateswiththesame
chemicalasinjectorsarerunningon.
Thisworkswellasairis
drawnintoIACpassages
onarunningengineand
willcleanthepassages
withoutIACremoval.
Figure 6028 To thoroughly clean a
throttle body, it is sometimes best to
remove it from the vehicle.
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6. Relearntheonboardcomputer.Somevehiclesmayhave
beenrunninginsuchapoorstateofoperationtheonboard
computermayneedtoberelearned.Consultservice
informationforthesuggestedrelearnprocedures.
Thisserviceusuallytakesapproximatelyonehourforthevehicle
torunoutoffuelandtheentireservicetobeperformed.Thegood
thingisthatthetechnicianmaydootherserviceswhilethisis
beingperformed.
Sometechniciansmayinstallasetofplugsorchangethefuel
filterwhiletheengineisflushing.Thisserviceshouldrestorethe
fuelsystemtooriginaloperations.
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Be Sure To Clean the Fuel Rail

Whenever you service the fuel injectors, or if you suspect that there may be a fuelinjector problem, remove the entire fuel rail assembly and check the passages for
contamination. Always thoroughly clean the rail when replacing fuel injectors.

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FUEL SYSTEM SCAN TOOL DIAGNOSTICS

Diagnosingafaultyfuelsystemcanbeadifficulttaskthatcanbe
madeeasierbyutilizingtheinformationavailableviatheserial
datastream.
Observingthelongtermfueltrimandtheshorttermfueltrimcan
helpdeterminehowthefuelsystemisperforming.
Shorttermfueltrimandlongtermfueltrimcanhelpustozeroin
onspecificareasoftrouble.Readingsshouldbetakenatidleandat
3000rpm.
Usethechartfollowing.
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PHOTO SEQUENCE Fuel Pump Relay Circuit Diagnosis
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PHOTO SEQUENCE Relay Circuit Diagnosis
(cont.)
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PHOTO SEQUENCE Relay Circuit Diagnosis

(cont.)
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PHOTO SEQUENCE Fuel Injector Cleaning
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PHOTO SEQUENCE Fuel Injector Cleaning

(cont.)
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SUMMARY
1. Atypicalthrottlebodyfuelinjectorusesacomputercontrolled
injectorsolenoidtosprayfuelintothethrottlebodyunitabove
thethrottleplates.
2. Atypicalportfuelinjectionsystemusesanindividualfuel
injectorforeachcylinderandsquirtsfueldirectlyintotheintake
manifoldabout3inches(80millimeters)fromtheintakevalve.
3. Atypicalfuelinjectionsystemfuelpressureshouldnotdrop
morethan20psiin20minutes.
4. Anoidlightcanbeusedtocheckforthepresenceofaninjector
pulse.
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SUMMARY
(cont.)
5. Injectorscanbetestedforresistanceandshouldbewithin0.3to
0.4ohmsofeachother.
6. Differentdesignsofinjectorshaveadifferentscopewaveform
dependingonhowthecomputerpulsestheinjectoronandoff.
7. Anidleaircontrolunitcontrolsidlespeedandcanbetestedfor
properoperationusingascantoolorscope.

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end
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start

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Prepare for ASE Engine Performance (A8)

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Describe how to test fuel injectors.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

PORT FUEL-INJECTION PRESSURE

Pressure Transducer Fuel Pressure Test

DIAGNOSING ELECTRONIC FUEL-INJECTION

Stethoscope Fuel Injection Test - Part 1

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Stethoscope Fuel Injection Test - Part 2

Figure 605 Fuel should be heard returning to the

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Quick and Easy Leaking Injector Test

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

SCAN TOOL VACUUM LEAK DIAGNOSIS

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

PORT FUEL INJECTION SYSTEM DIAGNOSIS

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 608 Shutoff valves must be used on vehicles

TESTING FOR AN INJECTOR PULSE

Figure 6010 Use a DMM set to read DC volts to check

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

CHECKING FUEL INJECTOR RESISTANCE

MEASURING RESISTANCE OF GROUPED

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

MEASURING RESISTANCE OF INDIVIDUAL

Equal Resistance test

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

PRESSURE DROP BALANCE TEST

Figure 6015 Connect a fuel pressure gauge

INJECTOR VOLTAGE DROP TESTS

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

SCOPE TESTING FUEL INJECTORS

Figure 6018 The injector on-time is called the pulse width.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

If Three of Six Injectors Are Defective, Should I Also

IDLE AIR SPEED CONTROL DIAGNOSIS

Figure 6023 Some IAC units are

There is No Substitute for a Thorough

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

FUEL INJECTION SERVICE

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Be Sure To Clean the Fuel Rail

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

FUEL SYSTEM SCAN TOOL DIAGNOSTICS

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

PHOTO SEQUENCE Fuel Pump Relay Circuit Diagnosis

PHOTO SEQUENCE Relay Circuit Diagnosis

PHOTO SEQUENCE Relay Circuit Diagnosis

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

PHOTO SEQUENCE Fuel Injector Cleaning

PHOTO SEQUENCE Fuel Injector Cleaning

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

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