Injector Leak Quantity

WARNING: REVIEW THE HIGH PRESSURE FUEL SYSTEM WARNING BEFORE BEGINNING SERVICE . Refer to WARNING .

NOTE: If an injector is found to be out of specification, repeat this test procedure after the injector replacement. Hydraulic flow will take the path of least resistance and multiple failures may be identified.

Perform this test with the engine at operating temperature. This test will assist in determining a defective or internally leaking injector(s) is present by measuring the amount of fuel return.

Fig 1: FUEL VIALS 9545

Courtesy of DAIMLERCHRYSLER CORP.

Turn the ignition off.
Remove the engine cover. On 1.6L, (Refer to ENGINE - REMOVAL) or on 2.4L, (Refer to ENGINE - REMOVAL) .
Disconnect the fuel return hoses at the top of the injectors.
Disconnect and block off the oil return line at the banjo bolt fitting of the fuel rail.
Disconnect the fuel rail solenoid.
Install the test vials onto the injectors and secure with the return hose clips. See Fig 1.
Crank the engine for ten seconds while monitoring each inner test vial.
After ten seconds, a maximum of two graduation lines may be reached. If the level has exceeded the two graduation line, replace that effected cylinder's injector, clear the memory using the scan tool, empty the test vials, and retest. If the level did not pass the two graduation line limit, continue to the next step.
Turn the ignition off. Leave the emptied test vials in place. Reconnect the fuel pressure solenoid. Disconnect the cam position sensor, crank the engine for ten seconds.

After ten seconds, a maximum of four graduation lines of the inner test vial may be reached. If the level has exceeded the four graduation line, replace that effected cylinder's injector, clear the memory using the scan tool, empty the test vials, and retest. If the level did not pass the four graduation line limit, continue with the diagnostic service information.