Note: Before starting the test, check the following: idle speed, fuel injection and CO2 at idle.
If the engine is running:
1. With the engine idling, disconnect each injector connector individually and observe the change in idle speed.
If the idle drop is almost the same in each cylinder, the injectors are fine. If the RPM or idle quality remains the same when you disconnect an individual injector, replace the injector and check again.
2. With the engine idling, using a stethoscope, check the clicking sound of each injector.
If any of the injectors do not produce the typical clicking sound, check the sound again after replacing the injector.
If there is still no clicking sound, check the following:
Is there a short circuit, broken wire or poor connection in the YEL/BLK wire between the main injection relay and the injector.» There is no rupture or corrosion in the connection connector. Is there a short circuit, broken wire or poor connection in the RED/BLK wire between the connection connector and the injector. Is there a short circuit, broken wire or poor connection in the wire between the injector and the engine/automatic transmission electronic control unit? (EU M/R SM). If everything is ok, check the electronic engine control unit/automatic transmission (ECM/RSM) and the main injection system relay.
If the engine cannot be started:
1. Remove the injector connector and measure the resistance between the two injector contacts.
- Resistance should be: 10-13 Ohm
If resistance is not within specification, replace the injector. If resistance is within specification, check fuel pressure.
If the fuel pressure is within specification, check the following:
Is there a short circuit, broken wire or poor connection in the YEL/BLK wire between the main injection relay and the injector.
Is there any rupture or corrosion in the connection connector?
Is there any short circuit, broken wire or poor connection in the RED/BLK wire between the connection connector and the injector,
Is there a short circuit, broken wire or poor connection in the wire between the injector and the engine/automatic transmission electronic control unit? (ECM/RSM).
If everything is in order, check the electronic engine control unit/automatic transmission (ECM/RSM)
Replacement
Attention: Do not smoke when working on the fuel system. Keep open flames away from your work area.
1. Reduce (release) fuel pressure.
2. Disconnect the connectors from the fuel injectors (D16Y7 engine: Remove the air filter).
3. Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator (D16Y5, 016Y8 engine: Disconnect the vacuum hoses and 2P, the connector from the cleaning system for removing fuel vapor from the intake manifold is controlled by the solenoid valve).
Caution: Place a rag or rag over the hoses before disconnecting them.
4. Loosen the holder nuts on the fuel manifold.
5. Disconnect the fuel manifold.
6. Remove the fuel injectors from the intake manifold.
7. Move new cushion rings onto the fuel injectors.
8. Coat the new O-rings with a coat of clean engine oil and place them on the injectors.
9. First insert the injectors into the fuel manifold.
10. Coat the new O-rings with clean engine oil and press them into the intake manifold.
11. Install the injectors and torus assembly in the intake manifold.
Caution: To prevent damage to the O-ring, install the fuel injectors in the fuel manifold first, then install them in the intake manifold.
12. Install and tighten the holder nuts (retainer).
13. Connect the vacuum hoses and the fuel return hose to the fuel pressure regulator (D16Y5, D16Y8 engine: Connect the vacuum hoses and 2P connector to the cleaning system for removing fuel vapor from the intake manifold controlled by the solenoid valve).
14. Install the connectors on the fuel injectors (D16Y7 engine: Install the air filter).
15. Turn on the ignition (11), but do not use a starter. After the fuel pump runs for about two seconds, fuel pressure in the fuel line rises. Repeat these two or three times, then check if there is any fuel leakage.