5A - Fuel Injector Tip Leakage Test
TOOLS REQUIRED^ J 37088A Fuel Line Disconnect Set
CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANYTIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
1. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief" procedure.) Service and Repair
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING WHILE CONNECTING GAUGE, TO COLLECT FUEL. PLACE THE CLOTH IN AN APPROVED CONTAINER.
2. Connect pressure test adapter to fuel pressure test port.
CAUTION:
^ LAY SHOP TOWELS ON INTAKE MANIFOLD AND CAM COVER TO COLLECT ANY FUEL.
^ MAKE SURE THE INJECTORS ARE POSITIONED TO PREVENT FUEL FROM BEING SPRAYED ONTO THE ENGINE. MAKE SURE THAT THE INJECTOR RETAINING CLIPS ARE PROPERLY INSTALLED.
3. Disconnect fuel feed line from underhood. Remove fuel line clip and using Fuel Line Disconnect Set J 37088A, disconnect fuel feed line from fuel rail assembly.
4. Loosen clamp at air cleaner and throttle body assembly.
5. Remove attachment bolts from outlet resonator/duct assembly.
6. Remove outlet resonator duct assembly.
7. Remove outlet duct assembly to manifold nuts.
8. Remove outlet duct assembly bracket.
9. Disconnect brake booster hose at brake booster.
10. Disconnect intake plenum solenoid.
11. Remove intake port cover (if equipped).
12. Remove 5 upper manifold bolts (1/4 in. drive T-30 with a 6 in. extension can be used to gain access to bolts).
13. Remove lower intake bolt under throttle body assembly (throttle body assembly removal is not required).
14. Disconnect purge line from stud (note position of black clip).
15. Remove rear electrical harness bolts to manifold.
16. Disconnect coolant pump connector and throttle body electrical connector.
17. Disconnect small PCV hose at throttle body.
18. Position harness away from manifold.
NOTE:
^ To gain access to all components under the intake manifold, the manifold can be loosened and tilted upward.
^ Care must be taken while lifting and supporting intake manifold assembly.
19. Lift intake manifold from cylinder head. (Manifold will not be completely removed.)
20. Tie or support intake manifold when desired position is achieved.
21. Reconnect fuel line to fuel rail assembly using extension line from fuel pressure adapter lines.
22. Wipe tips of fuel injectors free of any fuel or debris.
22.1 Place a clean white towel directly under fuel injectors.
22.2 Ensure towel lightly contacts with fuel injector tip.
23. Connect Scan tool and turn ignition on.
IMPORTANT: Battery must be a minimum of 12 volts when performing any fuel system test. Charge battery before proceeding if below 12 volts.
24. Energize fuel pump. (Refer to "Energizing the Fuel Pump" procedure.) Procedures
25. Observe fuel injector tips for leakage of fuel. If one or more of the white towels becomes wet with fuel after five minutes, replace faulty fuel injector. (Refer to "Fuel Rail and Injector(s) Replacement - 4-Cyl" procedure in the Fuel System.)
26. Pressure gauge reading should be approximately 400 kPa (58 psi).
27. Test assembly a minimum of two times.
28. Install bleed hose from pressure test adapter into an approved container and relieve fuel system pressure.
29. Remove fuel pressure adapter from fuel pressure port.
30. Remove tie up or support from intake manifold assembly.
31. Lubricate injector O-ring with clean engine oil and lower intake manifold assembly onto cylinder heads.
32. Connect coolant pump connector and throttle body electrical connector.
33. Connect small PCV hope at throttle body.
34. Re-position electrical harness onto intake manifold assembly.
35. Install rear electrical harness bolts to manifold.
Rear Electrical Harness Bolts: 8 N.m (71 in-lbs)
36. Install purge line onto stud.
37. Connect purge valve onto manifold.
38. Install 5 upper manifold bolts (1/4 in. drive T-30 with a 6 in. extension can be used to gain access to bolts).
39. Install lower intake manifold bolt under throttle body assembly.
Lower Intake Manifold Bolt: 7.5 N.m (66 in-lbs)
40. Install intake port cover (if equipped).
41. Connect intake plenum solenoid.
42. Connect brake booster hose to brake booster.
43. Disconnect fuel line extension.
44. Install fuel transfer line onto fuel rail assembly.
45. Install outlet duct assembly bracket.
46. Install outlet duct bracket to manifold nuts.
Outlet Duct Assembly Bracket-to-Manifold Nuts: 5 N.m (44 in-lbs)
47. Install outlet resonator duct assembly.
48. Install attachment bolts from outlet resonator/duct assembly to support bracket.
Outlet Resonator Duct Assembly-to-Support Bracket Bolts: 10 N.m (89 in-lbs)
49. Start engine and check for leaks.