fuel pump OPEL FRONTERA 1998 Workshop Manual

6C–10
ENGINE FUEL
Reuse of Quick–Connector
(Delivery Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.
NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks.
141RW018
(Return Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud or dust from the pipe and make sure
that the end including spool is free from defects, such
as scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
141RW017
Assembling Advice
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check
pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.
3. Make sure of no fuel leakage by conducting the above
fuel leak check a few times.
4. Start the engine and make sure of stable idling speed
and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.

6E–3 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0351
Ignition 1 Control Circuit 6E–206. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0352
Ignition 2 Control Circuit 6E–209. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0353
Ignition 3 Control Circuit 6E–212. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0354
Ignition 4 Control Circuit 6E–215. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0355
Ignition 5 Control Circuit 6E–218. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0356
Ignition 6 Control Circuit 6E–221. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0402
EGR Pintle Crank Error 6E–224. . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0404
EGR Open Stuck 6E–226. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0405
EGR Low Voltage 6E–228. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0406
EGR High Voltage 6E–231. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0502
VSS Circuit Low Input 6E–234. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0562
System Voltage Low 6E–237. . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0563
System Voltage High 6E–239. . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0601
PCM Memory 6E–240. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1154
HO2S Circuit Transition Time Ratio Bank 2
Sensor 1 6E–241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1171
Fuel System Lean During Acceleration 6E–245. . . .
Diagnostic Trouble Code (DTC) P1380
ABS Rough Road ABS System Fault 6E–248. . . . . .
Diagnostic Trouble Code (DTC) P1404
EGR Closed Stuck 6E–249. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1508
IAC System Low RPM 6E–251. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1509
IAC System High RPM 6E–254. . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1618
Serial Peripheral Interface (SPI) PCM
Interprocessor Communication Error 6E–257. . . . . .
Diagnostic Trouble Code (DTC) P1625
PCM Unexpected Reset 6E–258. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1640
Driver-1-Input High Voltage 6E–259. . . . . . . . . . . . . .
Symptom Diagnosis 6E–262. . . . . . . . . . . . . . . . . . . . .
Default Matrix Table 6E–288. . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor 6E–291. . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–292. . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–292.
Heated Oxygen Sensor (HO2S) 6E–293. . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E–295. . . . . . .
Knock Sensor (KS) 6E–296. . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor 6E–297. . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–297.
Malfunction Indicator Lamp (MIL) 6E–298. . . . . . . . . .
Powertrain Control Module (PCM) 6E–298. . . . . . . . .
EEPROM 6E–300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pressure (PSP) Switch 6E–300
. . . .
Throttle Position (TP) Sensor 6E–301. . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E–302. . . . . . . . . . . . .
Air Cleaner/Air Filter 6E–303. . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve 6E–304. . . . . . . . . . . . . . .
Common Chamber 6E–305. . . . . . . . . . . . . . . . . . . . . .
Accelerator Cable Assembly 6E–305. . . . . . . . . . . . . .
Accelerator Pedal Replacement 6E–308. . . . . . . . . . .
Fuel Filter Cap 6E–310. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6E–310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6E–313. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injectors 6E–314. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E–315. . . . . . . . . . . . . . . . .
Fuel Metering System 6E–317. . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly 6E–318. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6E–319. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Assembly 6E–319. . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6E–321. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) 6E–323. . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System 6E–324. . . . . . . . . . . . . . . .
Catalytic Converter 6E–325. . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Relay 6E–325. . . . . . . . . . . . . . . . . . .
EVAP Canister Hoses 6E–326. . . . . . . . . . . . . . . . . . . .
EVAP Canister 6E–326. . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Purge Solenoid 6E–327. . . . . . . . . . . .
Fuel Tank Vent Valve 6E–328. . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas Recirculation
(EGR) Valve 6E–328. . . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase Ventilation (PCV) Valve 6E–329.
Wiring and Connectors 6E–330. . . . . . . . . . . . . . . . . . .
PCM Connectors and Terminals 6E–330. . . . . . . . . . .
Wire Harness Repair: Twisted Shielded
Cable 6E–330. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twisted Leads 6E–331. . . . . . . . . . . . . . . . . . . . . . . . . .
Weather-Pack Connector 6E–332. . . . . . . . . . . . . . . . .
Com-Pack III 6E–333. . . . . . . . . . . . . . . . . . . . . . . . . . .
Metri-Pack 6E–333. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E–335. . . . . . . . . . . . . . . . . . . . .
General Description (PCM and Sensors) 6E–335. . .
58X Reference PCM Input 6E–335. . . . . . . . . . . . . .
A/C Request Signal 6E–335. . . . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–335. . . . . . .
Camshaft Position (CMP) Sensor and
Signal 6E–335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–335
Electrically Erasable Programmable Read
Only Memory (EEPROM) 6E–336. . . . . . . . . . . . . .
Fuel Control Heated Oxygen Sensors 6E–336. . . .
Intake Air Temperature (IAT) Sensor 6E–336. . . . .

6E–4
ENGINE DRIVEABILITY AND EMISSIONS
Knock Sensor 6E–337. . . . . . . . . . . . . . . . . . . . . . . . .
Linear Exhaust Gas Recirculation (EGR)
Control 6E–337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mass Air Flow (MAF) Sensor 6E–337. . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–338
Powertrain Control Module (PCM) 6E–338. . . . . . .
PCM Function 6E–338. . . . . . . . . . . . . . . . . . . . . . . . .
PCM Components 6E–339. . . . . . . . . . . . . . . . . . . . .
PCM Voltage Description 6E–339. . . . . . . . . . . . . . .
PCM Input/Outputs 6E–339. . . . . . . . . . . . . . . . . . . .
PCM Service Precautions 6E–339. . . . . . . . . . . . . .
Reprogramming The PCM 6E–339. . . . . . . . . . . . . .
Throttle Position (TP) Sensor 6E–339. . . . . . . . . . .
Transmission Fluid Temperature (TFT)
Sensor 6E–340. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Range Switch 6E–340. . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E–340. . . . . . . . . . . .
Use of Circuit Testing Tools 6E–340. . . . . . . . . . . . .
Aftermarket Electrical and Vacuum
Equipment 6E–340. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Damage 6E–341. . . . . . . . .
Upshift Lamp 6E–341. . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Air Induction) 6E–341. . . . . . . .
Air Induction System 6E–341. . . . . . . . . . . . . . . . . . .
General Description (Fuel Metering) 6E–341. . . . . . .
Acceleration Mode 6E–341. . . . . . . . . . . . . . . . . . . . .
Accelerator Controls 6E–341. . . . . . . . . . . . . . . . . . .
Battery Voltage Correction Mode 6E–341. . . . . . . .
CMP Signal 6E–341. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Flood Mode 6E–342. . . . . . . . . . . . . . . . . . . . .
Deceleration Mode 6E–342. . . . . . . . . . . . . . . . . . . .
Engine Speed/Vehicle Speed/Fuel
Disable Mode 6E–342. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Mode 6E–342. . . . . . . . . . . . . . . . . . . . . .
Fuel Injector 6E–342. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Metering System Components 6E–342. . . . . . Fuel Metering System Purpose 6E–342. . . . . . . . . .
Fuel Pressure Regulator 6E–343. . . . . . . . . . . . . . . .
Fuel Pump Electrical Circuit 6E–343. . . . . . . . . . . . .
Fuel Rail 6E–343. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Valve 6E–343. . . . . . . . . . . . .
Run Mode 6E–344. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mode 6E–344. . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body Unit 6E–344. . . . . . . . . . . . . . . . . . . . .
General Description (Electronic Ignition
System) 6E–344. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position (CMP) Sensor 6E–344. . . . . . . .
Crankshaft Position (CKP) Sensor 6E–345. . . . . . .
Electronic Ignition 6E–345. . . . . . . . . . . . . . . . . . . . .
Ignition Coils 6E–345. . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control 6E–345. . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control PCM Output 6E–347. . . . . . . . . . . .
Knock Sensor (KS) PCM Input 6E–347
. . . . . . . . . .
Powertrain Control Module (PCM) 6E–347. . . . . . .
Spark Plug 6E–347. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Clutch Diagnosis 6E–349. . . . . . . . . . . . . . . . . . . .
A/C Clutch Circuit Operation 6E–349. . . . . . . . . . . .
A/C Clutch Circuit Purpose 6E–349. . . . . . . . . . . . .
A/C Request Signal 6E–349. . . . . . . . . . . . . . . . . . . .
General Description (Exhaust Gas
Recirculation (EGR) System) 6E–349. . . . . . . . . . . . .
EGR Purpose 6E–349. . . . . . . . . . . . . . . . . . . . . . . . .
Linear EGR Valve 6E–349. . . . . . . . . . . . . . . . . . . . .
Linear EGR Control 6E–349. . . . . . . . . . . . . . . . . . . .
Linear EGR Valve Operation and Results
of Incorrect Operation 6E–349. . . . . . . . . . . . . . . . .
EGR Pintle Position Sensor 6E–350. . . . . . . . . . . . .
General Description (Positive Crankcase
Ventilation (PCV) System) 6E–350. . . . . . . . . . . . . . .
Crankcase Ventilation System Purpose 6E–350. . .
Crankcase Ventilation System Operation 6E–350.

6E–24
ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way Blue Connector – Row “E”
(For except EXPORT and SOUTH AFRICA)
TS23346
PINPIN FunctionWire ColorIGN ONENG RUNRefer To
E1Transmission Output Shaft
Sensor (TOSS) HighRED0.0 V0.1 VAutomatic Transmission
(4L30E)
E2Transmission Output Shaft
Sensor (TOSS) LowWHT0.0 V0.0 VAutomatic Transmission
(4L30E)
E3Pressure Control Solenoid
LowPPL/RED0.0 V1.1 VAutomatic Transmission
(4L30E)
E4Pressure Control Solenoid
HighPPL/WHT0.0 V4.9 VAutomatic Transmission
(4L30E)
E5Exhaust Gas Recirculation
(EGR) Control HighBLK/YELB+B+General Description and
Operation, EGR Control
E6Exhaust Gas Recirculation
(EGR) Control LowYELB+B+General Description and
Operation, EGR Control
E7Transmission Range
Signal “B”BLU/YEL0.0 V0.0 VAutomatic Transmission
(4L30E)
E8Throttle Position (TP)
SensorBLU0.5-0.8 V0.5-0.8 V
(at idle)General Description and
Operation, Throttle Position
Sensor
E9Engine Coolant
Temperature (ECT)
SensorBLU/RED0.5-4.9 V
(depends on
temperature)0.5-4.9 V
(depends on
temperature)General Description and
Operation, Engine Coolant
Temperature (ECT) Sensor
E10Not Used————
E11Crankshaft Position (CKP)
Sensor +5 Volt ReferenceYEL/RED5.0 V or less
than 1.0 V5.0 VGeneral Description and
Operation, Crankshaft
Position Sensor
E12Transmission Range
Signal “A”BLU/WHTB+B+Automatic Transmission
(4L30E)
E13Fuel Pump (FP) RelayRED/WHT0.0 VB+On-Vehicle Service, Fuel
Pump Relay
E14Shift High (BAND APPLY)BRN/WHTB+B+Automatic Transmission
(4L30E)

6E–26
ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way Blue Connector – Row “E”
(For EXPORT and SOUTH AFRICA)
TS23346
PINPIN FunctionWire ColorIGN ONENG RUNRefer To
E1Transmission Output Shaft
Sensor (TOSS) HighRED0.0 V0.1 VAutomatic Transmission
(4L30E)
E2Transmission Output Shaft
Sensor (TOSS) LowWHT0.0 V0.0 VAutomatic Transmission
(4L30E)
E3Pressure Control Solenoid
LowPPL/RED0.0 V1.1 VAutomatic Transmission
(4L30E)
E4Pressure Control Solenoid
HighPPL/WHT0.0 V4.9 VAutomatic Transmission
(4L30E)
E5Not Used————
E6Not Used————
E7Transmission Range
Signal “B”BLU/YEL0.0 V0.0 VAutomatic Transmission
(4L30E)
E8Throttle Position (TP)
SensorBLU0.5-0.8 V0.5-0.8 V
(at idle)General Description and
Operation, Throttle Position
Sensor
E9Engine Coolant
Temperature (ECT)
SensorBLU/RED0.5-4.9 V
(depends on
temperature)0.5-4.9 V
(depends on
temperature)General Description and
Operation, Engine Coolant
Temperature (ECT) Sensor
E10Not Used————
E11Crankshaft Position (CKP)
Sensor +5 Volt ReferenceYEL/RED5.0 V or less
than 1.0 V5.0 VGeneral Description and
Operation, Crankshaft
Position Sensor
E12Transmission Range
Signal “A”BLU/WHTB+B+Automatic Transmission
(4L30E)
E13Fuel Pump (FP) RelayRED/WHT0.0 VB+On-Vehicle Service, Fuel
Pump Relay
E14Shift High (BAND APPLY)BRN/WHTB+B+Automatic Transmission
(4L30E)
E15A/C RequestGRN/ORN0.0 V0.0 VElectric Cooling Fans
E16Ignition Feed (1 of 2 F16)RED/BLUB+B+—

6E–32
ENGINE DRIVEABILITY AND EMISSIONS
Undercarriage Component Locator
F00RW040
Undercarriage Component Locator Table (Automatic Transmission)
Number
NameLocation
1Fuel Pump AssemblyInstalled in the top of the fuel tank
2Fuel Gauge UnitInstalled in the front edge of the fuel tank, on
the right side
3Fuel FilterLocated along the inside of the right frame rail,
ahead of the rear axle
4Vehicle Speed Sensor (VSS)2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5Heated Oxygen Sensor (Bank 1, HO2S 1)Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6Heated Oxygen Sensor (Bank 2, HO2S 1)Threaded into the exhaust pipe ahead the
left-hand catalytic converter

6E–33 ENGINE DRIVEABILITY AND EMISSIONS
Undercarriage Component Locator Table (Manual Transmission)
Number
NameLocation
1Fuel Pump AssemblyInstalled in the top of the fuel tank
2Fuel Gauge UnitInstalled in the front edge of the right frame
rail, ahead of the rear axle
3Fuel FilterLocated along the inside of the right frame rail,
ahead of the rear axle
4Vehicle Speed Sensor (VSS)2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5Heated Oxygen Sensor (Bank 1, HO2S 1)Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6Heated Oxygen Sensor (Bank 2, HO2S 1)Threaded into the exhaust pipe ahead of the
left-hand catalytic converter
Fuse and Relay Panel (Underhood Electrical Center)
TS23336

6E–60
ENGINE DRIVEABILITY AND EMISSIONS
Electronic Ignition System Diagnosis
If the engine cranks but will not run or immediately stalls,
the Engine Cranks But Will Not Start chart must be used
to determine if the failure is the ignition system or the fuel
system. If DTC P0341, or P0336 is set, the appropriate
diagnostic trouble code chart must be used for diagnosis.
If a misfire is being experienced with no DTC set, refer to
the
Symptoms section for diagnosis.
Fuel Metering System Check
Some failures of the fuel metering system will result in an
“Engine Cranks But Will Not Run” symptom. If this
condition exists, refer to the
Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the PCM, or the fuel pump
electrical circuit.
Refer to
Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to
Fuel System
Diagnosis
, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump. If a malfunction
occurs in the fuel metering system, it usually results in
either a rich HO2S signal or a lean HO2S signal. This
condition is indicated by the HO2S voltage, which causes
the PCM to change the fuel calculation (fuel injector pulse
width) based on the HO2S reading. Changes made to the
fuel calculation will be indicated by a change in the long
term fuel trim values which can be monitored with a Tech
2. Ideal long term fuel trim values are around 0%; for a
lean HO2S signal, the PCM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the same.
If the fuel trim values are greater than +23%, refer to
DTC
P0131, DTC P0151, DTC P0171, and DTC 1171
f o r i t e m s
which can cause a lean HO2S signal.
Idle Air Control (IAC) Valve
The Tech 2 displays the IAC pintle position in counts. A
count of “0” indicates the PCM is commanding the IAC
pintle to be driven all the way into a fully-seated position.
This is usually caused by a large vacuum leak.
The higher the number of counts, the more air is being
commanded to bypass the throttle blade. Refer to IAC
System Check in order to diagnose the IAC system.
Refer to
Rough, Unstable, or Incorrect Idle, Stalling in
Symptoms for other possible causes of idle problems.
Fuel System Pressure Test
A fuel system pressure test is part of several of the
diagnostic charts and symptom checks. To perform this
test, refer to
Fuel Systems Diagnosis.
Fuel Injector Coil Test Procedure and
Fuel Injector Balance Test Procedure
T32003
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
2. Relieve the fuel pressure by connecting the
5-8840-0378-0 Fuel Pressure Gauge to the fuel
pressure connection on the fuel rail.
CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any fuel
leakage that occurs during the connection of the fuel
pressure gauge. Place the towel in an approved
container when the connection of the fuel pressure
gauge is complete.
Place the fuel pressure gauge bleed hose in an
approved gasoline container.
With the ignition switch “OFF,” open the valve on the
fuel pressure gauge.
3. Record the lowest voltage displayed by the DVM
after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
Resistance Ohms
Voltage Specification at
10
C-35C (50F-95F)
11.8 – 12.65.7 – 6.6
The voltage displayed by the DVM should be within
the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector windings
changes.

6E–63 ENGINE DRIVEABILITY AND EMISSIONS
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
StepNo Ye s Va l u e ( s ) Action
51. Set injector switch box injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
IMPORTANT:The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value?
9.5 VGo to Step 4Go to Step 6
61. Identify the highest voltage reading recorded (other
than those above 9.5 V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted Value in step 2
greater than the specified value?
0.6 VGo to Step 4Go to Step 7
7CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge is
complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the scan tool.
3. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading on
the fuel pressure gauge.
Is the fuel pressure within the specified values?
296-376 kPa
(43-55 psi)
Go to Step 8
Go to Fuel
System
Diagnosis
8Turn the fuel pump “OFF.”
Does the fuel pressure remain constant?
—Go to Step 9
Go to Fuel
System
Diagnosis

6E–64
ENGINE DRIVEABILITY AND EMISSIONS
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
StepNo Ye s Va l u e ( s ) Action
91. Connect the 5-8840-2638-0 Fuel Injector Tester
and 5-8840-2619-0 Injector Switch Box the fuel
injector harness connector.
2. Set the amperage supply selector switch on the fuel
injector tester to the “Balance Test” 0.5–2.5 amp
position.
3. Using the scan tool turn the fuel pump “ON” then
“OFF” in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push
to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first
pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10.Add all of the individual pressure drop values. This
is the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or lower
than the average pressure drop by the specified value?
10 kPa
(1.5 psi)
Go to Step 10
Go to OBD
System
Check
10Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value?
10 kPa
(1.5 psi)
Go to Step 11
Go to
Symptoms
11Replace the faulty fuel injector(s). Refer to Fuel
Injector.
Is the action complete?—Verify repair—