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GROUP 6
V-MA
PIMENTEL, LUCKY BOY
GALAY, RODEL
MARQUEZ, PETER DAREY
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TESTING AND DIAGNOSING FUEL INJECTOR PROBLEMS
1. Find a long metal rod or screwdriver. Locate a thin piece of metal that’s at
least a foot or so long. It should be made mostly of metal, but you could opt to
use a screwdriver despite it having a plastic or rubber handle.
2. Place the tip of the rod on a fuel injector. You will be using the metal rod
to transmit sound from the fuel injector to your ear without having to bring
your face too close to a running engine. Set one end of the rod or screwdriver
on the injector itself while holding it up with one hand.
3. Bring your ear close to the rod and listen for clicking. Lean your ear
close to the end of the metal rod or screwdriver that is opposite the injector. As
the engine runs, listen for an audible clicking sound given off by the injector.
This sound indicates the injector being activated
4. Repeat these steps for each injector. Use the same method to check each
fuel injector in your vehicle. If you find one that is not clicking, there is an
issue with the injector or the electronic control that is transmitting to the
injector. Replacing this injector may solve the problem, but you may also need
to have a diagnostic done of your vehicle’s electronic control unit and fuel
system by a professional mechanic.
Pop Testing
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Pop testing fuel injectors is the process of testing fuel injectors to see at what
pressure they spray fuel. Fuel injectors are responsible for injecting fuel into
your cylinder to be ignited. The injectors should pop at the manufacturers
recommended pressure so it creates a proper atomized spray pattern. Atomized
pattern means the fuel is a fine mist so it combusts better.
For smaller cars, 1200-1800 psi is needed to pop the fuel injector. While for
large vehicles, 2000 psi or greater is required.
A test done at Fuel injector clinic which simulates the actual spray pattern of
the fuel injectors. If there are deposits on the nozzle, the spray pattern can be
adversely affected – this can be corrected by cleaning the injectors.
1. Turn the key to the “on” position without starting the engine. To
conduct this test, the vehicle's electrical system must be active without the
engine actually running. Insert the key and turn it until the electrical system
activates, but stop before you engage the engine's starter. This should activate
all of the vehicle’s electronics like interior lighting and the radio.
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2. Connect a test light to the negative terminal on the battery. A test light
looks like a screwdriver with a finely pointed end and a wire hanging out of the
handle. When the wire from the handle and the pointed end come into contact
with a completed and powered circuit, a light bulb lights up inside the handle
of the test light. The wire extending from the handle will have an alligator clip
at the end. Attach that alligator clip to the negative terminal of the vehicle’s
battery.
3. Locate the two wires going into each injector. Each fuel injector will have
a metal clip plugged into it with two wires coming out of it. One of those two
wires is a 12-volt constant that should be continuously receiving power from
your vehicle’s electrical system. There should be a small portion of each wire
exposed coming out of the plastic clip that connects to the injector.
These wires are often grey and black, but can come in any number of
colors.
They will be the only wires coming from each injector.
4. Test each wire for voltage. Take the sharp end of the test light and press it
firmly into the rubber coating around each wire until it penetrates into the
metal wiring itself. One of the two wires should make the test light turn on
when it comes into contact with the wire inside the protective coating. If the
test light turns on with one wire, then the injector is receiving the necessary
constant voltage.
If neither wire makes the light turn on, then there is an issue with the
power reaching the fuel injector, which will result in in failing to fire.
If the all of the wires that light up are a certain color, make note of which
wires are the constants.
5 . Repeat the process for each injector. Test each wire coming out of the
fuel injectors in your vehicle. If you locate one injector with a power issue, that
doesn’t mean others may not have the same problem. Once you identify an
injector with a power issue, make a note of which one it was and continue to
test the rest.
Follow the wires on the injectors that fail to engage the test light to make
sure there are no breaks in the wire that may prevent the electricity from
reaching it.
Let your mechanic know that you were able to identify the injector with a
power issue. It may require replacing the vehicle’s electronic control unit.
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Ohm testing
A simple test to verify the condition of the injector coil, we test the resistance
(measured in Ohms) across the terminals of the injector connector. An
Ohmmeter or a Multi-tester can be used to measure resistance. A dead fuel
injector is an injector that does not
have resistance and does not respond to electrical input.
Injector impedance describes the electrical resistance of the solenoid windings.
These are usually grouped in two categories: Low- 1.7 to 3.0 ohms and High-
10 to 16 ohms
Dead fuel injectors cannot be repaired and should be replaced with a similar
unit.
This simple test is to be carried out on the low-pressure fuel side only and
tampering with the potentially hazardous, highly-pressurized fuel is not
required or recommended.
This Industry standard test requires the removal of the return flow pipes only
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and fitting the specific test lines with adaptors to the injectors requiring
testing. This can quickly determine if an injector is functioning correctly.
Fuel additives that do not spray into the intake manifold can leave a residue on
the fuel injectors. These can burn and form a crust because fuel injectors run
very hot due to the friction that is produced from rapid and repetitive
movement. The crust on the fuel injectors can result in a weak spray and an
uneven pattern.
Solution: clean the fuel injectors using a cleaning kit intended for
fuel injectors or visit a professional mechanic or repair shop for the
manual cleaning of your fuel injectors
Ultrasonic fuel injector cleaning and flow testing is the only
process that can guarantee reliable and complete fuel injector
cleaning. Even with the proper tools, professional fuel injector
cleaning equipment and specialized ultrasonic cleaning solutions it
still takes about 45 – 60 minutes to properly clean injectors.
Fuel injectors can also clog from the build-up of microscopic foreign objects,
which are usually in the form of rust. This is typically introduced from a source
upstream in the gasoline supply, such as the fuel supply line or the fuel rail,
and it can result from a car sitting idle without maintenance for a long time. A
clogged fuel injector will not be able to supply gasoline to the intake manifold.
The valve in the fuel injector might not open as the result of faulty windings or
as the result of a rusted fuel injector. The windings might overheat, short out,
or break, and rust can cause the valve to stick. In any of these instances, the
valve will not open and the fuel injector will be unable to deliver gasoline
through its nozzle.
The valve in the fuel injector might also be unable to close due to a faulty
spring or due to a build-up of rust or fuel additives. If the valve is unable to
close properly, the fuel injector will leak gasoline.
The fuel injector may also leak gasoline if other parts of the system fail, such as
the mechanism that cools the injector. The fuel injector can then overheat and
fail, resulting in a leak. It is also possible that the injector has a faulty part
that does not enable it to function properly.
Solution: clean the fuel injector. If this does not solve the problem,
seek professional assistance or go to Fuel Injector Clinic
This is caused by Worn injector ball seat, Leaking cross feed tubes ,Blown
internal high-pressure seal, Incorrect nozzle needle clearance, Cracked nozzle
body and Cracked injector body.
Prevention:
Keep fuel system clean, change fuel filters, purchase fuel from
reliable sources, avoid filling from portable construction fuel tanks
Avoid overly aggressive tuning that increases rail-pressure and
injector pulse widths and do not remove pressure-limiting devices
from the system
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Do not use remanufactured or aftermarket injection components that
are not properly designed or manufactured
Reject all fuel system replacement parts that have metallic burrs
Do not mix nozzle needles, because they are matched to the body and
moving one from another can result in excessive clearance or
improper needle lift
No Injection
The causes of this are Debris or rust in the injector plugging the nozzle,
Armature and/or nozzle needle stuck and Loss of cylinder compression or
other mechanical problem
Prevention:
Keep fuel system clean, change filters, purchase fuel from reliable
sources, and avoid filling from portable construction fuel tanks or
questionable sources
Do not use remanufactured or aftermarket components that are not
properly designed or manufactured
Reject all fuel system replacement parts that have metallic burrs
Excessive Injection
The causes of excessive injection are Worn ball seat in injector or poor end of
injection cut off, Nozzle needle seat worn or damaged, Debris in control system
of injector, which holds it open, Debris in nozzle needle seat holding it open
and Cracked nozzle from overpressure, or overheated nozzle from improper
installation of injector
Prevention:
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Incorrect Injection Rate
The causes of incorrect injection rate are Poor nozzle flow balance, Nozzle
needle lift incorrect (mixed or missing parts), Partially plugged nozzle and Wire-
brushed nozzles
Prevention:
Keep fuel system clean, change filters, purchase fuel from reliable
sources, and avoid filling from portable construction fuel tanks or
questionable sources
Reject all fuel system replacement parts that have metallic burrs
Do not use remanufactured or aftermarket components that are not
properly designed or manufactured
Ensure injectors are serviced or purchased from a reliable source
Do not clean nozzles with a wire brush
The causes of Incorrect Injection Timing and Duration are Ball seat wear
,Incorrect injector assembly, parts mixed, or parts missing, Injector needle lift
increased to increase output
Prevention:
Replace worn injectors
Ensure injectors are serviced, tested, and purchased from a reliable
source
The table below describes the various symptoms that can signify a possible
problem with fuel injectors. It also associates the problems detailed above with
these symptoms.
For Gasoline
Associated
Symptom Description
Problems
84
Associated
Symptom Description
Problems
For Diesel
Associated
Symptom Description
Problems
85
Associated
Symptom Description
Problems
86
Associated
Symptom Description
Problems
87