TESTING AND DIAGNOSING

FUEL INJECTOR PROBLEMS

GROUP 6

V-MA
PIMENTEL, LUCKY BOY
GALAY, RODEL
MARQUEZ, PETER DAREY

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TESTING AND DIAGNOSING FUEL INJECTOR PROBLEMS

Common tests for Diesel and Gasoline Injectors

Listening for Bad Fuel Injectors

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

Figure 6.1. Listening for Injectors

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.

Another helpful diagnostic tool is an engine stethoscope. This tool

enables a car owner to listen for any problems with the fuel injectors by
placing the tip of the stethoscope on each injector.

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.

Spray Pattern Verification

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.

Figure 6.2. Spray Pattern

Gasoline Injector Testing

Ensuring the Injectors Are Receiving Power

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.

 The vehicle’s battery is powering everything during this test, so you

should turn off things like the headlights and stereo to converse power
and ensure it has enough to start the vehicle again later.

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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

Figure 6.3. Ohm Testing

Dead fuel injectors cannot be repaired and should be replaced with a similar
unit.

Flow Rate Verification

This test is done by pumping liquid in the injectors simultaneously at a given

time. This is to check the flow rate of each injector. Even if the spray pattern
isn’t affected by deposits, it is still possible for internal deposits and/or
corrosion to cause variations in flow rate. If your injectors do not flow the
correct amount, a cleaning will typically correct the imbalance.

Diesel Injector Testing

Common Rail Flow testing

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.

Figure 6.4. Common Rail Testing

Common Problems for Gasoline Injectors.

Dirty Fuel Injectors

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.

Clogged Fuel 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.

 Solution: add an injector cleaner additive to the fuel or have it

unclogged by a professional mechanic or send it to the repair shop
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Fuel Injector Does Not Open

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.

 Solution: Seek professional assistance or go to Fuel Injector clinics

Fuel Injector Does Not Close

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.

 Solution: Seek professional assistance or go to Fuel Injector clinics

Fuel Injector Leaks

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

Common Problems for Diesel Engine

High Internal Leakage or Return Flow

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:

 Replace worn and high-mileage injectors; do not use these injectors as a

foundation for building a high-output injector set
 Replace worn nozzles
 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

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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

Incorrect Injection Timing and Duration

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

Symptoms That Can Signify a Problem

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

Inconsistent An inconsistent fuel supply can Dirty fuel injector

Engine Power cause the engine to rev high and

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 Associated
Symptom Description
Problems

low, with the RPM gauge

fluctuating.

Dirty fuel injector

When the fuel supply is inadequate
upon ignition, the engine might Clogged fuel
Misfiring Engine misfire. An 8 to 10 percent injector
reduction in one fuel injector can
Fuel injector does
cause this to occur.
not open

An engine should idle smoothly, but

Uneven Engine
an uneven fuel supply will cause Dirty fuel injector
Idling
idling disturbances.

Leaking fuel from a faulty fuel Fuel injector does

Fuel Scent injector will create a strong gasoline not close
smell. Fuel injector leaks

A fuel injector that delivers drops of Fuel injector does

Diminished Gas gasoline instead of a mist will make not close
Mileage for inefficient use of the gas,
reducing the car's gas mileage. Fuel injector leaks

For Diesel

Associated
Symptom Description
Problems

The first areas to check are the

Engine Is Slow to ones directly connected to the Faulty
Crank starter . This includes the connections
batteries, cables and terminals ,

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 Associated
Symptom Description
Problems

and the actual starter itself. Look

for corrosion or loose connections
with the cables and terminals. The
easy way to check the starter is to
connect a voltmeter to the terminals
to see if the difference between the
terminal ends is indeed 12 volts.

This usually has to do with an issue

with the fuel transfer, which can
lead to the possibility that there
might not be any fuel in the
Clogged Fuel
Engine Cranks but cylinders. Start by checking the fuel
Filters
Does Not Start filter to see if there are any clogs;
then check the fuel pump and fuel Clogged Fuel
injector. This, too, can be tested by pump
checking the voltage differential on
the solenoid.

Most of the new cars with diesel

engines have electronic computer
systems that control the idle
settings and even the fuel injector
Engine Starts but settings. Both of these could lead to
Runs at High RPM having too much fuel in the Dirty fuel injector
chamber, therefore, idling too high.
A code reader is needed in order to
hook up to the car's computer
system.

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 Associated
Symptom Description
Problems

This usually has to do with an issue

of fuel delivery or air intake or a
combination of both. The first place
to always start is with all of the
Engine Seems to
filters. Clogged or plugged filters are Clogged Fuel
Lack Power
often the culprit. When this Filters
happens, the fix is to just remove
the old filter and replace it with a
new one.

This usually has to do with the

Fuel injector leaks
pump to engine time or the fuel
Black Smoke or injection nozzle. The simple Faulty injector
Low Power solution here is to just change out Nozzle
the fuel injection nozzle with a new
one to see if that corrects the
problem. The pump can be checked
with a code reader.

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