Fuel Injector Diagnosis w/J39021 or w/Tech 2

The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases.

When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump relay. The fuel injector tester or scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel. This causes a drop in system fuel pressure that can be recorded and used to compare each injector.

Schematic Reference

Engine Controls Schematics

Connector End View Reference

Component Connector End Views

Electrical Information Reference

Scan Tool Reference

Special Tools

Fuel Injector Coil Test

Verify that the resistance of each fuel injector with one of the following methods:

Note: 

Fuel Injector Balance Test - Fuel Pressure Test

1. Install the fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal.
2. Turn the ignition ON with the engine OFF.

Note: 

•	The fuel pump relay may need to be commanded ON a few times, in order to obtain the highest possible fuel pressure.

•	DO NOT start the engine.

3. Command the fuel pump relay ON with a scan tool.
4. Observe the fuel pressure gage, with the fuel pump commanded ON. The fuel pressure should be within 380-414 kPa (55-60 psi). Refer to Fuel System Diagnosis.
5. Monitor the fuel pressure gage for 1 minute. The fuel pressure should not decrease more than 34 kPa (5 psi).

⇒	If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis.

6. Perform Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2.

Fuel Injector Balance Test with Special Tool

1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amps position.
2. Connect J 39021 and J 44602 together to the injector.
3. Command the fuel pump relay ON and OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. This is the starting pressure at which you will pulse each injector.
4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing the Push to Start test button on the J 39021 at the previously selected pressure.
5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure.

Note: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested

6. Clear the Min/Max results.
7. Select normal from Display Mode.
8. Repeat steps 2, 4 to 7 for each fuel injector.
9. Perform the Pressure Decrease Calculation.

Perform Fuel Injector Balance Test with Tech2

1. Command the fuel pump relay ON and OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select the maximum pump pressure within 34 kPa (5 psi). Record this fuel pressure. This is the starting pressure at which you will pulse each injector.
2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions menu.
3. Select an injector to be tested.
4. Press Enter to start the fuel system.
5. Energize the injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure.
6. After the injector stops pulsing, select Min from the CH-48027 Display Mode and record the Min pressure.

Note: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested.

7. Clear the Min/Max results on the CH-48027 .
8. Select Normal from on the CH-48027 Display Mode.
9. Press Enter on the scan tool to bring you back to the Select Injector screen.
10. Repeat steps 3 to 9 for each fuel injector.
11. Perform the Pressure Decrease Calculation.

Pressure Drop Calculation

1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the pressure drop value.
2. Obtain a pressure drop value for each fuel injector.
3. Add all of the individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop.
4. Divide the total pressure drop by the number of injectors that were added together. This is the average pressure drop. The difference between the individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi).

⇒	If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Fuel Injector and Fuel Rail Replacement

Fuel Injector Diagnosis w/CH47976

The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases.

The Active Fuel Injector Tester (AFIT), CH-47976 , is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be downloaded from storage and printed.

Schematic Reference

Engine Controls Schematics

Connector End View Reference

Component Connector End Views

Electrical Information Reference

Special Tools

CH-47976 Active Fuel Injector Tester (AFIT)

Fuel Injector Coil Test

Verify that the resistance of each fuel injector with one of the following methods:

Note: Do not perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result from hot soak fuel boiling.

Note: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.

AFIT Test Procedure

1. Turn OFF all of the accessories.
2. Turn the ignition OFF.
3. Install the AFIT. Refer to the AFIT User Guide.
4. Turn ON the AFIT and select the vehicle.
5. Turn the ignition ON and perform the Injector Test.

⇒	If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis.

6. View the test results.

⇒	If any injector exceeds the suggested tolerance, replace the injector(s).

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Fuel Injector and Fuel Rail Replacement