Component Tests and General Diagnostics

Fuel Injector Testing
















1. Turn manual shutoff valve (Figure 3) of test stand panel to OFF (closed) position.
2. Filter (use paint-type filter) and pour clean gasoline into the tester fuel tank, and fill to lower fill line for 8 cylinder vehicles, use less for 4 and 6 cylinder vehicles.

DO NOT ADD ANY CLEANER SOLVENT IN TANK FOR TESTING.






3. Connect power supply line (Figure 2) to vehicle battery (red terminal, positive; black terminal, negative). Red light (on cleaner side) will flash indicating power connection has been made and the unit is off.






4. Activate the 10 minute timer switch, check pressure gauge. The gauge should read 38-40 psi. If adjustment is necessary, turn shutoff valve to ON (open) position, for resetting of regulator (refer to Figure 3). Remove black cap, back-off locknut, turn screw to obtain proper setting and retighten lock nut. Replace cap. Turn unit off.
5. Connect fuel supply hose to outlet (Figure 3) and place other end of hose back into tank. Actuate the 10 minute timer switch and turn flowmeter selection valve to flowmeter No. 1 and then to flowmeter No.2. Repeat this procedure several times to eliminate all air bubbles from the system. Turn unit off. Flowmeter selection valve must be in position No. 1 or No. 2 for unit to function properly. Reinstall fuel tank cap snugly and back-off one turn.






6. Disconnect engine fuel inlet connection at the fuel manifold (rail). Connect the supply hose from testing equipment to the fuel inlet connection (Figure 1).
7. Disconnect engine fuel return connection at the fuel manifold (rail) from fuel return. Plug the return line as shown in Figure 1. Install the U-Tube (supplied) between the chassis supply line and the chassis return line (Figure 1).






8. Install the tunbuckle (Figure 6) loosely between throttle control rod and suitable hook-up point on vehicle fender wall. Activate the 10 minute timer switch.

CAUTION Be sure vehicle is in PARK or NEUTRAL position, parking brake on and/or wheels blocked front and rear.

Start engine and check for leaks.

9. Run the engine just long enough to eliminate all the air in fuel supply hose and fuel rail
10. Select the proper flow range. Turn the flowmeter selection valve to
Flowmeter No.1 for Blue, Grey or Yellow injectors, or
Flowmeter No.2 for White, Black, Green or Brown injectors.
The flow band colors correspond to the injector top color (Color may vary slightly between manufacturers.)






Refer to EFI Application Chart.






11. Install the tester injector harness (Figure 7) on the vehicle injectors. Match the injector number on the harness to that of the cylinder (or use 10 pin connector FA-41 2, Figure 8) for 5.OL engine (or 8 pin adaptor harness No.6222 for 3.8L).
12. Position injector selector switch to each injector number while pressing fuel injector test button.
13. Observe the position of the flowmeter float at eye level when the ball stops rising. A float level within the color code range on the scale indicates a good injector.
14. To confirm initial test readings, a maximum of three testings on the set of the injectors can be performed restarting the engine.
15. Any injectors removed from an engine should be bench tested to confirm diagnostic conclusions. A continuity checker FA~407 (Figure 6) is provided to check continuity of injector harness leads between the injector and the ECM unit. Disconnect injector and insert continuity checker FR-407 into injector plug. Start engine. Observe. Continuity checker will blink showing completed circuit for that injector being tested.

NOTE:

a. If the flowmeter readings are high or low on the color code scale, the fuel injectors should be cleaned.
b. If all the readings are high, there may be leaky injectors (one or more). To check for leaky injectors, observe pressure gauge. It should hold pressure with the fuel pump off. If there is a pressure drop, detect the leaky injector by observing flowmeter (the leaky injector shows less flow). If this is not possible, remove all injectors and test individually. Refer to Bench Testing procedure.
c. If fuel injector cleaner is required, turn manual shutoff valve to the ON position. Refer to fuel Injector Cleaning Procedure.
d. Testing may be performed before or after cleaning process.

Fuel Injector Bench Testing Procedure






Individual Injector Performance and Leakage Testing.
1. Check that the manual shutoff valve (Figure 3) at the back of test stand is in ON (open) position.
2. Fill the Tester/Cleaner fuel tank with several ounces of clean, fresh gasoline.
















3. Connect the fuel supply hose FA-402 (Figure 4) to the fuel supply outlet (Figure 3) and to the Bench Fixture (Figure 9).
4. Insert injector to be tested in Bench Fixture as shown in Figure 9.











5. Connect the No. 1 tester harness connector (Figure 7) to the fuel injector. Turn the injector selector switch (Figure 3) to No. 1 position.
6. Direct the injector nozzle into the tester fuel tank.






7. Connect the power supply leads (Fig. 2) to the battery, observing correct polarity.
8. Activate the 10 minute timer switch and check for leaks.






9. Press the injector test switch (Figure 3) and the purge switch together for about 30 seconds to eliminate air from the supply hose and injector.
10. No leakage from the fuel injector nozzle tip should be visible. Replace any leaking injector.






11. Press injector test switch (Figure 3) to test injector, observe float in flowmeter
12. Check the flowmeter readings and record all test results.

Factors That Cause False Flow Readings
^ Air bubbles in the system fuel lines.
^ Excessive amount of cleaner solution in the system.
^ Fuel pressure other than recommended 39-40 psi for all high-pressure EFI vehicles.
^ Low voltage from a weak power source.
^ Heat from prolonged engine running. Cool engine before retesting. Use the following approved solvents: D9AZ-1 9579-B or E6AZ-1 9579-C only.

Service Maintenance

Periodically the flowmeters need cleaning. Follow the Matheson Instrument instructions enclosed or flush unit with denatured alcohol, allow the fluid to recirculate several minutes, switching flowmeter selection valve from No. 1 to No.2 several times while unit is operating. Discard fluid. Reflush again using above procedure, discard fluid. Change filter.











To gain access to filter located under the front cover, refer to Figures 2 and 3, unscrew and remove the cover access bolts, each side and slide the cover off. Replace filter with in-line type filter. Change filter frequently.

When new injector applications are released, new calibrated flow tubes are available from

Triangle Special Products Group. This unit is suitable for conversion for K-Jetronic fuel systems. If K-Jetronic fuel system cleaning is desired, a modification kit is available from

NOTE:Triangle Special Products Group.
Triangle Special Products Group (Miller Special Tools) is a division of The Triangle Corporation.