Fuel Injector Inspection

FUEL INJECTOR INSPECTION
On-vehicle
1. Warm up the engine and let it idle.
2. Listen for operation sound of each fuel injector with a screwdriver or a sound scope.
- If no sound is heard, carry out the fuel leakage test.

Note: The best way to judge the performance of a fuel injector is to compare its sound with the sound of other fuel injectors.

KL

Fuel Injector Resistance Inspection [FS]
1. Disconnect the fuel injector connectors.

2. Measure the resistance of the fuel injector.
- If not as specified, replace the fuel injector.
Resistance 12 - 16 ohms (at 20 degrees C (68 degrees F))

Fuel Injector Resistance Inspection [KL]
1. Turn off the ignition switch and disconnect the fuel injector connectors.

2. Measure resistance of the fuel injector with an ohmmeter at the following conditions.
- If not as specified, inspect continuity of the harness and inspect for poor connection.
- If the harness is okay, replace the fuel injector.
Resistance 12-16 ohms 120 degrees C (68 degrees F)]

Fuel Leakage Test [FS]

Warning: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

1. Complete the "BEFORE REPAIR PROCEDURE".
2. Disconnect the negative battery cable.
3. Remove the fuel injectors together with the fuel distributor.

4. Fasten the fuel injectors firmly to the fuel distributor with wire.

5. Remove the fuel pump relay.

Caution: Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminal only.

6. Short the fuel pump relay socket terminals 30 to the body GND using a jumper wire.

Caution: Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.

7. Connect the negative battery cable to operate the fuel pump.

8. Tilt the fuel injectors approximately 60 degrees and verify that no fuel leaks from the fuel injector nozzles.
- If not as specified, carry out the "Volume Test [IFS].
Fuel leakage Less than 1 drop/2 minutes
9. Disconnect the negative battery cable and remove the jumper wire.
10. Complete the "AFTER REPAIR PROCEDURE".

Fuel Leakage Test [KL]

Warning: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

1. Complete the "BEFORE REPAIR PROCEDURE".
2. Disconnect the negative battery cable.
3. Remove the fuel distributor component from the intake manifold.

4. Connect the fuel hoses.

5. Remove the fuel pump relay.

Caution: Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminal only.

6. Short the fuel pump relay socket terminals 30 to the body GND using a jumper cable.

Caution: Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.

7. Connect the negative battery cable to operate the fuel pump and inspect for fuel leaks from the fuel injectors.
Fuel leakage Less than 1 drop/2 min.

8. Disconnect the negative battery cable and remove the jumper wire.
- If not as specified, remove the leaking fuel injector and inspect the O-rings and fuel distributor for damage. Replace as necessary.
9. Install the fuel injector.

Caution: Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminal only.

10. Short the fuel pump relay socket terminals 30 to the body GND using a lumber wire.

Caution: Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.

11. Connect the negative battery cable to operate the fuel pump and inspect for fuel leaks from fuel injector.
12. Disconnect the negative battery cable and remove the jumper wire.
- If not as specified, carry out the "Volume Test [AL].
13. Complete the "AFTER REPAIR PROCEDURE".

Injection Volume Inspection [FS]

Warning: Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

Note:
- Perform the following inspection only when directed.
- If there is an after market fuel injector tester or the SST (49 L018 901), perform this inspection.
- If there is no after market fuel injector tester or the SST, perform "Simulation Test", "Resistance Inspection" and "Fuel Leakage Inspection" to verify whether the fuel injector is okay or not.

1. Complete the "BEFORE REPAIR PROCEDURE".
2. Disconnect the negative battery cable.

Using the SST
1. Remove the fuel injector together with the fuel distributor.
2. Fasten the fuel injectors firmly to the fuel distributor with wire.

3. Connect the SST as shown in the figure.

4. Remove the fuel pump relay.

Caution: Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminal only.

5. Short the pump relay socket terminal 30 to the body GND using a jumper wire.

Caution: Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.

6. Connect the negative battery cable to operate the fuel pump.
7. Measure the injection volume of each fuel injector by using a graduated container.
Injection volume 47 - 58 ml (47 - 58 cc, 1.4 - 2.0 fl oz)/15 sec.
8. Disconnect the negative battery cable and remove the jumper wire.
- If not as specified, replace the fuel injector.
9. Complete the "AFTER REPAIR PROCEDURE".

Using a Fuel Injector Tester
1. Remove the fuel injectors.
2. Connect the fuel injector to a fuel injector tester.
3. Measure the injection volume of each fuel injector.
- If not as specified, replace the fuel injector.
Injection volume 47 - 58 ml
4. Complete the "AFTER REPAIR PROCEDURE".

Injection Volume Inspection [KL]

Warning: Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

Note:
- Perform the following inspection only when directed.
- If there is an after market fuel injector tester or the SST (49 E018 9A0), perform this inspection.
- If there is no after market fuel injector tester or the SST, perform "Simulation Test", "Resistance Inspection" and "Fuel Leakage Inspection" to verify whether the fuel injector is okay or not.

1. Complete the "BEFORE REPAIR PROCEDURE".
2. Disconnect the negative battery cable.

Using the SST
1. Remove the fuel injector together with the fuel distributor. )
2. Fasten the fuel injectors firmly to the fuel distributor with wire.

3. Connect the SST as shown in the figure.

4. Remove the fuel pump relay.

Caution: Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminal only.