MID 128-SID 4

January 2009 Page 227

MID 128-SID 4

MID 128 SID 4 — FUEL INJECTOR UNIT #4229

Figure 229 — Fuel Injector Unit #4 Circuit

Failure Mode Identifier (FMI): 3 (Voltage High/Open), 5 (Current Low/Open), 7 (Mechanical System Not Responding),12 (Failed Device)

Parameter Identification (PID): S4

Message Identification (MID): 128

Circuit Description: Fuel Injector Unit #4 operation is controlled by the Engine Management System (EMS) Module. This module provides supply voltage and output transistor drivers to control the ground circuits. There are two solenoid circuits within the injector; a Needle Control Valve (NCV) and a Spill Valve (SV).

Location: The Fuel Injector Units are located under the valve cover.

Code Setting Conditions: If the Engine Management System (EMS) Module detects a fault in the electrical circuit while attempting to operate the Fuel Injector Unit, the Electronic Malfunction Lamp (EML) will turn ON and code SID 4 will set.

Additional Symptoms: Poor performance, low power or no start.

Test 1 — Checking for Code SID 4

1. Check that code SID 4 is set.

If code SID 4 is set, go to “Test 2 — Checking for an Open Fuel Injector Unit #4 (Needle Control Valve)” on page 228.

If code SID 4 is NOT set, wiggle the harness connectors to try to set the code. Visually inspect Fuel Injector Unit #4 wires and pins for frayed, loose or corroded connections.

Page 228 January 2009

MID 128-SID 4

Test 2 — Checking for an Open Fuel

Injector Unit #4 (Needle Control

Valve)

230

Figure 230

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connector from Fuel Injector Unit #4.

3. Check for continuity between the pins 1 and 2 of the Fuel Injector Unit #4 (see Figure 230).

If the resistance is between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), go to “Test 3 — Checking for a Short to Ground in the Fuel Injector Unit #4 (Needle Control Valve)” on page 228.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #4 is faulty and must be replaced.

Test 3 — Checking for a Short to

Ground in the Fuel Injector Unit #4

(Needle Control Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #4.

3. Check for continuity from pins 1 and 2 on Fuel Injector Unit #4 to a good ground.

If there is NO continuity to ground at Fuel Injector Unit #4, go to “Test 4 — Checking for a Short to Ground at the Fuel Injector Unit #4 (Needle Control Valve) Harness Connector” on page 228.

If continuity exists, the Fuel Injector Unit #4 is shorted to ground and must be replaced.

Test 4 — Checking for a Short to

Ground at the Fuel Injector Unit #4

(Needle Control Valve) Harness

Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between the Fuel Injector Unit #4 harness connector pin 1 and 2 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 5 — Checking for an Open Circuit in the Fuel Injector Unit #4 (Needle Control Valve) Voltage Line” on page 229.

MID 128-SID 4

January 2009 Page 229

Test 5 — Checking for an Open

Circuit in the Fuel Injector Unit #4

(Needle Control Valve) Voltage Line

231

Figure 231

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between EMS Module harness connector A pin 61 and pin 1 of the Fuel Injector Unit #4 (see Figure 231).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 6 — Checking for an Open Circuit in the Fuel Injector Unit #4 (Needle Control Valve) Control Line” on page 229.

Test 6 — Checking for an Open

Circuit in the Fuel Injector Unit #4

(Needle Control Valve) Control Line

232

Figure 232

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between pin 2 of the the Fuel Injector Unit #4 and EMS Module harness connector A pin 52 (see Figure 232).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 7 — Checking for a Short to Voltage in the Fuel Injector Unit #4 (Needle Control Valve) Voltage Line” on page 230.

Page 230 January 2009

MID 128-SID 4

Test 7 — Checking for a Short to

Voltage in the Fuel Injector Unit #4

(Needle Control Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 61 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 8 — Checking for a Short to Voltage in the Fuel Injector Unit #4 (Needle Control Valve) Control Line” on page 230.

Test 8 — Checking for a Short to

Voltage in the Fuel Injector Unit #4

(Needle Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 20 and a good ground.

If voltage is present, the Fuel Injector Unit #4 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 9 — Isolating a Short in the Fuel Injector Unit #4 (Needle Control Valve) Voltage Line” on page 230.

Test 9 — Isolating a Short in the

Fuel Injector Unit #4 (Needle Control

Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #4.

4. Check for continuity between EMS Module harness connector A pin 61 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 10 — Isolating a Short Circuit in the Fuel Injector Unit #4 (Needle Control Valve) Control Line” on page 230.

If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 10 — Isolating a Short Circuit

in the Fuel Injector Unit #4 (Needle

Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #4.

4. Check for continuity between the EMS Module harness connector A pin 52 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 11 — Checking for an Open Fuel Injector Unit #4 (Spill Valve)” on page 231.

If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

MID 128-SID 4

January 2009 Page 231

Test 11 — Checking for an Open

Fuel Injector Unit #4 (Spill Valve)

233

Figure 233

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #4.

3. Check for continuity between the pins 3 and 4 on Fuel Injector Unit #4 (see Figure 233).

If the resistance is between 1.1-5.8 Ohms at 68°F (20°C) or 1.9-6.2 Ohms at 218°F (103°C), go to “Test 12 — Checking for a Short to Ground in the Fuel Injector Unit #4 (Spill Valve)” on page 231.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #4 is faulty and must be replaced.

Test 12 — Checking for a Short to

Ground in the Fuel Injector Unit #4

(Spill Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #4.

3. Check for continuity from either pin on Fuel Injector Unit #4 to a good ground.

If there is NO continuity at Fuel Injector Unit #4, go to “Test 13 — Checking for a Short to Ground at the Fuel Injector Unit #4 (Spill Valve) Harness Connector” on page 231.

If continuity exists, the Fuel Injector Unit #4 is shorted to ground and must be replaced.

Test 13 — Checking for a Short to

Ground at the Fuel Injector Unit #4

(Spill Valve) Harness Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between the Fuel Injector Unit #4 harness connector pin 3 and pin 4 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 14 — Checking for an Open Circuit in the Fuel Injector Unit #4 (Spill Valve) Voltage Line” on page 232.

Page 232 January 2009

MID 128-SID 4

Test 14 — Checking for an Open

Circuit in the Fuel Injector Unit #4

(Spill Valve) Voltage Line

234

Figure 234

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between EMS Module harness connector A pin 60 and pin 3 of the Fuel Injector Unit #4 (see Figure 234).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 15 — Checking for an Open Circuit in the Fuel Injector Unit #4 (Spill Valve) Control Line” on page 232.

Test 15 — Checking for an Open

Circuit in the Fuel Injector Unit #4

(Spill Valve) Control Line

235

Figure 235

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Check for continuity between pin 4 of the the Fuel Injector Unit #4 and EMS Module harness connector A pin 56 (see Figure 235).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 16 — Checking for a Short to Voltage in the Fuel Injector Unit #4 (Spill Valve) Voltage Line” on page 233.

MID 128-SID 4

January 2009 Page 233

Test 16 — Checking for a Short to

Voltage in the Fuel Injector Unit #4

(Spill Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 60 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 17 — Checking for a Short to Voltage in the Fuel Injector Unit #4 (Spill Valve) Control Line” on page 233.

Test 17 — Checking for a Short to

Voltage in the Fuel Injector Unit #4

(Spill Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #4.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 56 and a good ground.

If voltage is present, the Fuel Injector Unit #4 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 18 — Isolating a Short in the Fuel Injector Unit #4 (Spill Valve) Voltage Line” on page 233.

Test 18 — Isolating a Short in the

Fuel Injector Unit #4 (Spill Valve)

Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #4.

4. Check for continuity between EMS Module harness connector A pin 60 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 19 — Isolating a Short Circuit in the Fuel Injector Unit #4 (Spill Valve) Control Line” on page 233.

If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 19 — Isolating a Short Circuit

in the Fuel Injector Unit #4 (Spill

Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #4.

4. Check for continuity between the EMS Module harness connector A pin 56 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 20 — Checking for a Short at the EMS Module Connector” on page 233.

If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 20 — Checking for a Short at

the EMS Module Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the EMS Module.

3. Visually inspect EMS Module connectors A and B for dirt, loose pins or deformed contacts.

4. If a pin feels loose or appears damaged, repair the connector.

If all the pins appear to make good contact and feel tight, go to “Test 21 — Verifying if the Fault Code is Still Active” on page 234.

Page 234 January 2009

MID 128-SID 4

Test 21 — Verifying if the Fault Code

is Still Active

1. Turn the ignition key OFF.

2. Connect all harness electrical connectors to the Fuel Injector Unit #4 solenoids.

3. Connect Engine Management System (EMS) Module connectors A and B.

4. Turn the ignition key ON.

If the blink code is still active, check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 7 or 12, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident, switch the location of Fuel Injector Unit #4 with that of a fault-free Fuel Injector Unit #4. Reconnect all harness connectors and retest the system. If the PID has changed to the new location of the suspect Fuel Injector Unit #4, replace the Fuel Injector Unit #4, install all Fuel Injector Unit #4s in their original location, and retest the system.

If only the Fuel Injector Unit #4 blink code is still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, replace the EMS Module and retest the system.

If multiple Fuel Injector Unit #4 blink codes are still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, go to “Test 22 — Inspecting the Mechanical Fuel System Components” on page 234.

If the blink code is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections.

Test 22 — Inspecting the

Mechanical Fuel System

Components

1. Ensure that there is fuel in the fuel tank.

2. Inspect the fuel lines between the tank and the transfer pump for sharp bends or kinks, and repair as needed.

3. Check for air in the fuel system, and repair as needed.

4. Check the fuel pressure at the secondary fuel filter outlet.

If the fuel pressure is NOT within specifications, perform any required fuel system repairs.

5. Remove Fuel Injector Unit #4 from the engine and inspect for surface rust between the O-rings.

If rust is present, locate the source of the fuel contamination and replace any damaged components.

If all of the mechanical fuel system components are in good working order, replace the EMS Module and retest the system.

MID 128-SID 5

January 2009 Page 235

MID 128-SID 5

MID 128 SID 5 — FUEL INJECTOR UNIT #5236

Figure 236 — Fuel Injector Unit #5 Circuit

Failure Mode Identifier (FMI): 3 (Voltage High/Open), 5 (Current Low/Open), 7 (Mechanical System Not Responding),12 (Failed Device)

Parameter Identification (PID): S5

Message Identification (MID): 128

Circuit Description: Fuel Injector Unit #5 operation is controlled by the Engine Management System (EMS) Module. This module provides supply voltage and output transistor drivers to control the ground circuits. There are two solenoid circuits within the injector; a Needle Control Valve (NCV) and a Spill Valve (SV).

Location: The Fuel Injector Units are located under the valve cover.

Code Setting Conditions: If the Engine Management System (EMS) Module detects a fault in the electrical circuit while attempting to operate the Fuel Injector Unit, the Electronic Malfunction Lamp (EML) will turn ON and code SID 5 will set.

Additional Symptoms: Poor performance, low power or no start.

Test 1 — Checking for Code SID 5

1. Check that code SID 5 is set.

If code SID 5 is set, go to “Test 2 — Checking for an Open Fuel Injector Unit #5 (Needle Control Valve)” on page 236.

If code SID 5 is NOT set, wiggle the harness connectors to try to set the code. Visually inspect Fuel Injector Unit #5 wires and pins for frayed, loose or corroded connections.

Page 236 January 2009

MID 128-SID 5

Test 2 — Checking for an Open Fuel

Injector Unit #5 (Needle Control

Valve)

237

Figure 237

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connector from Fuel Injector Unit #5.

3. Check for continuity between the pins 1 and 2 of the Fuel Injector Unit #5 (see Figure 237).

If the resistance is between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), go to “Test 3 — Checking for a Short to Ground in the Fuel Injector Unit #5 (Needle Control Valve)” on page 236.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #5 is faulty and must be replaced.

Test 3 — Checking for a Short to

Ground in the Fuel Injector Unit #5

(Needle Control Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #5.

3. Check for continuity from pins 1 and 2 on Fuel Injector Unit #5 to a good ground.

If there is NO continuity to ground at Fuel Injector Unit #5, go to “Test 4 — Checking for a Short to Ground at the Fuel Injector Unit #5 (Needle Control Valve) Harness Connector” on page 236.

If continuity exists, the Fuel Injector Unit #5 is shorted to ground and must be replaced.

Test 4 — Checking for a Short to

Ground at the Fuel Injector Unit #5

(Needle Control Valve) Harness

Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between the Fuel Injector Unit #5 harness connector pin 1 and 2 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 5 — Checking for an Open Circuit in the Fuel Injector Unit #5 (Needle Control Valve) Voltage Line” on page 237.

MID 128-SID 5

January 2009 Page 237

Test 5 — Checking for an Open

Circuit in the Fuel Injector Unit #5

(Needle Control Valve) Voltage Line

238

Figure 238

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between EMS Module harness connector A pin 61 and pin 1 of the Fuel Injector Unit #5 (see Figure 238).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 6 — Checking for an Open Circuit in the Fuel Injector Unit #5 (Needle Control Valve) Control Line” on page 237.

Test 6 — Checking for an Open

Circuit in the Fuel Injector Unit #5

(Needle Control Valve) Control Line

239

Figure 239

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between pin 2 of the the Fuel Injector Unit #5 and EMS Module harness connector A pin 44 (see Figure 239).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 7 — Checking for a Short to Voltage in the Fuel Injector Unit #5 (Needle Control Valve) Voltage Line” on page 238.

Page 238 January 2009

MID 128-SID 5

Test 7 — Checking for a Short to

Voltage in the Fuel Injector Unit #5

(Needle Control Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 61 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 8 — Checking for a Short to Voltage in the Fuel Injector Unit #5 (Needle Control Valve) Control Line” on page 238.

Test 8 — Checking for a Short to

Voltage in the Fuel Injector Unit #5

(Needle Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 20 and a good ground.

If voltage is present, the Fuel Injector Unit #5 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 9 — Isolating a Short in the Fuel Injector Unit #5 (Needle Control Valve) Voltage Line” on page 238.

Test 9 — Isolating a Short in the

Fuel Injector Unit #5 (Needle Control

Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #5.

4. Check for continuity between EMS Module harness connector A pin 61 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 10 — Isolating a Short Circuit in the Fuel Injector Unit #5 (Needle Control Valve) Control Line” on page 238.

If continuity exists, the Fuel Injector Unit #5 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 10 — Isolating a Short Circuit

in the Fuel Injector Unit #5 (Needle

Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #5.

4. Check for continuity between the EMS Module harness connector A pin 44 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 11 — Checking for an Open Fuel Injector Unit #5 (Spill Valve)” on page 239.

If continuity exists, the Fuel Injector Unit #5 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

MID 128-SID 5

January 2009 Page 239

Test 11 — Checking for an Open

Fuel Injector Unit #5 (Spill Valve)

240

Figure 240

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #5.

3. Check for continuity between the pins 3 and 4 on Fuel Injector Unit #5 (see Figure 240).

If the resistance is between 1.1-5.8 Ohms at 68°F (20°C) or 1.9-6.2 Ohms at 218°F (103°C), go to “Test 12 — Checking for a Short to Ground in the Fuel Injector Unit #5 (Spill Valve)” on page 239.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #5 is faulty and must be replaced.

Test 12 — Checking for a Short to

Ground in the Fuel Injector Unit #5

(Spill Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #5.

3. Check for continuity from either pin on Fuel Injector Unit #5 to a good ground.

If there is NO continuity at Fuel Injector Unit #5, go to “Test 13 — Checking for a Short to Ground at the Fuel Injector Unit #5 (Spill Valve) Harness Connector” on page 239.

If continuity exists, the Fuel Injector Unit #5 is shorted to ground and must be replaced.

Test 13 — Checking for a Short to

Ground at the Fuel Injector Unit #5

(Spill Valve) Harness Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between the Fuel Injector Unit #5 harness connector pin 3 and pin 4 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 14 — Checking for an Open Circuit in the Fuel Injector Unit #5 (Spill Valve) Voltage Line” on page 240.

Page 240 January 2009

MID 128-SID 5

Test 14 — Checking for an Open

Circuit in the Fuel Injector Unit #5

(Spill Valve) Voltage Line

241

Figure 241

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between EMS Module harness connector A pin 60 and pin 3 of the Fuel Injector Unit #5 (see Figure 241).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 15 — Checking for an Open Circuit in the Fuel Injector Unit #5 (Spill Valve) Control Line” on page 240.

Test 15 — Checking for an Open

Circuit in the Fuel Injector Unit #5

(Spill Valve) Control Line

242

Figure 242

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Check for continuity between pin 4 of the the Fuel Injector Unit #5 and EMS Module harness connector A pin 48 (see Figure 242).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 16 — Checking for a Short to Voltage in the Fuel Injector Unit #5 (Spill Valve) Voltage Line” on page 241.

MID 128-SID 5

January 2009 Page 241

Test 16 — Checking for a Short to

Voltage in the Fuel Injector Unit #5

(Spill Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 60 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 17 — Checking for a Short to Voltage in the Fuel Injector Unit #5 (Spill Valve) Control Line” on page 241.

Test 17 — Checking for a Short to

Voltage in the Fuel Injector Unit #5

(Spill Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #5.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 48 and a good ground.

If voltage is present, the Fuel Injector Unit #5 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 18 — Isolating a Short in the Fuel Injector Unit #5 (Spill Valve) Voltage Line” on page 241.

Test 18 — Isolating a Short in the

Fuel Injector Unit #5 (Spill Valve)

Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #5.

4. Check for continuity between EMS Module harness connector A pin 60 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 19 — Isolating a Short Circuit in the Fuel Injector Unit #5 (Spill Valve) Control Line” on page 241.

If continuity exists, the Fuel Injector Unit #5 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 19 — Isolating a Short Circuit

in the Fuel Injector Unit #5 (Spill

Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #5.

4. Check for continuity between the EMS Module harness connector A pin 48 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 20 — Checking for a Short at the EMS Module Connector” on page 241.

If continuity exists, the Fuel Injector Unit #5 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 20 — Checking for a Short at

the EMS Module Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the EMS Module.

3. Visually inspect EMS Module connectors A and B for dirt, loose pins or deformed contacts.

4. If a pin feels loose or appears damaged, repair the connector.

If all the pins appear to make good contact and feel tight, go to “Test 21 — Verifying if the Fault Code is Still Active” on page 242.

Page 242 January 2009

MID 128-SID 5

Test 21 — Verifying if the Fault Code

is Still Active

1. Turn the ignition key OFF.

2. Connect all harness electrical connectors to the Fuel Injector Unit #5 solenoids.

3. Connect Engine Management System (EMS) Module connectors A and B.

4. Turn the ignition key ON.

If the blink code is still active, check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 7 or 12 check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident, switch the location of Fuel Injector Unit #5 with that of a fault-free Fuel Injector Unit #5. Reconnect all harness connectors and retest the system. If the PID has changed to the new location of the suspect Fuel Injector Unit #5, replace the Fuel Injector Unit #5, install all Fuel Injector Unit #5s in their original location, and retest the system.

If only the Fuel Injector Unit #5 blink code is still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, replace the EMS Module and retest the system.

If multiple Fuel Injector Unit #5 blink codes are still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, go to “Test 22 — Inspecting the Mechanical Fuel System Components” on page 242.

If the blink code is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections.

Test 22 — Inspecting the

Mechanical Fuel System

Components

1. Ensure that there is fuel in the fuel tank.

2. Inspect the fuel lines between the tank and the transfer pump for sharp bends or kinks, and repair as needed.

3. Check for air in the fuel system, and repair as needed.

4. Check the fuel pressure at the secondary fuel filter outlet.

If the fuel pressure is NOT within specifications, perform any required fuel system repairs.

5. Remove Fuel Injector Unit #5 from the engine and inspect for surface rust between the O-rings.

If rust is present, locate the source of the fuel contamination and replace any damaged components.

If all of the mechanical fuel system components are in good working order, replace the EMS Module and retest the system.

MID 128-SID 6

January 2009 Page 243

MID 128-SID 6

MID 128 SID 6 — FUEL INJECTOR UNIT #6243

Figure 243 — Fuel Injector Unit #6 Circuit

Failure Mode Identifier (FMI): 3 (Voltage High/Open), 5 (Current Low/Open), 7 (Mechanical System Not Responding),12 (Failed Device)

Parameter Identification (PID): S6

Message Identification (MID): 128

Circuit Description: Fuel Injector Unit #6 operation is controlled by the Engine Management System (EMS) Module. This module provides supply voltage and output transistor drivers to control the ground circuits.There are two solenoid circuits within the injector; a Needle Control Valve (NCV) and a Spill Valve (SV).

Location: The Fuel Injector Units are located under the valve cover.

Code Setting Conditions: If the Engine Management System (EMS) Module detects a fault in the electrical circuit while attempting to operate the Fuel Injector Unit, the Electronic Malfunction Lamp (EML) will turn ON and code SID 6 will set.

Additional Symptoms: Poor performance, low power or no start.

Test 1 — Checking for Code SID 6

1. Check that code SID 6 is set.

If code SID 6 is set, go to “Test 2 — Checking for an Open Fuel Injector Unit #6 (Needle Control Valve)” on page 244.

If code SID 6 is NOT set, wiggle the harness connectors to try to set the code. Visually inspect Fuel Injector Unit #6 wires and pins for frayed, loose or corroded connections.

Page 244 January 2009

MID 128-SID 6

Test 2 — Checking for an Open Fuel

Injector Unit #6 (Needle Control

Valve)

244

Figure 244

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connector from Fuel Injector Unit #6.

3. Check for continuity between the pins 1 and 2 of the Fuel Injector Unit #6 (see Figure 244).

If the resistance is between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), go to “Test 3 — Checking for a Short to Ground in the Fuel Injector Unit #6 (Needle Control Valve)” on page 244.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #6 is faulty and must be replaced.

Test 3 — Checking for a Short to

Ground in the Fuel Injector Unit #6

(Needle Control Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #6.

3. Check for continuity from pins 1 and 2 on Fuel Injector Unit #6 to a good ground.

If there is NO continuity to ground at Fuel Injector Unit #6, go to “Test 4 — Checking for a Short to Ground at the Fuel Injector Unit #6 (Needle Control Valve) Harness Connector” on page 244.

If continuity exists, the Fuel Injector Unit #6 is shorted to ground and must be replaced.

Test 4 — Checking for a Short to

Ground at the Fuel Injector Unit #6

(Needle Control Valve) Harness

Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between the Fuel Injector Unit #6 harness connector pin 1 and 2 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 5 — Checking for an Open Circuit in the Fuel Injector Unit #6 (Needle Control Valve) Voltage Line” on page 245.

MID 128-SID 6

January 2009 Page 245

Test 5 — Checking for an Open

Circuit in the Fuel Injector Unit #6

(Needle Control Valve) Voltage Line

245

Figure 245

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between EMS Module harness connector A pin 61 and pin 1 of the Fuel Injector Unit #6 (see Figure 245).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 6 — Checking for an Open Circuit in the Fuel Injector Unit #6 (Needle Control Valve) Control Line” on page 245.

Test 6 — Checking for an Open

Circuit in the Fuel Injector Unit #6

(Needle Control Valve) Control Line

246

Figure 246

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between pin 2 of the the Fuel Injector Unit #6 and EMS Module harness connector A pin 36 (see Figure 246).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 7 — Checking for a Short to Voltage in the Fuel Injector Unit #6 (Needle Control Valve) Voltage Line” on page 246.

Page 246 January 2009

MID 128-SID 6

Test 7 — Checking for a Short to

Voltage in the Fuel Injector Unit #6

(Needle Control Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 61 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 8 — Checking for a Short to Voltage in the Fuel Injector Unit #6 (Needle Control Valve) Control Line” on page 246.

Test 8 — Checking for a Short to

Voltage in the Fuel Injector Unit #6

(Needle Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 20 and a good ground.

If voltage is present, the Fuel Injector Unit #6 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 9 — Isolating a Short in the Fuel Injector Unit #6 (Needle Control Valve) Voltage Line” on page 246.

Test 9 — Isolating a Short in the

Fuel Injector Unit #6 (Needle Control

Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #6.

4. Check for continuity between EMS Module harness connector A pin 61 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 10 — Isolating a Short Circuit in the Fuel Injector Unit #6 (Needle Control Valve) Control Line” on page 246.

If continuity exists, the Fuel Injector Unit #6 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 10 — Isolating a Short Circuit

in the Fuel Injector Unit #6 (Needle

Control Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #6.

4. Check for continuity between the EMS Module harness connector A pin 36 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 11 — Checking for an Open Fuel Injector Unit #6 (Spill Valve)” on page 247.

If continuity exists, the Fuel Injector Unit #6 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

MID 128-SID 6

January 2009 Page 247

Test 11 — Checking for an Open

Fuel Injector Unit #6 (Spill Valve)

247

Figure 247

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #6.

3. Check for continuity between the pins 3 and 4 on Fuel Injector Unit #6 (see Figure 247).

If the resistance is between 1.1-5.8 Ohms at 68°F (20°C) or 1.9-6.2 Ohms at 218°F (103°C), go to “Test 12 — Checking for a Short to Ground in the Fuel Injector Unit #6 (Spill Valve)” on page 247.

If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #6 is faulty and must be replaced.

Test 12 — Checking for a Short to

Ground in the Fuel Injector Unit #6

(Spill Valve)

1. Turn the ignition key OFF.

2. Disconnect the harness electrical connectors from Fuel Injector Unit #6.

3. Check for continuity from either pin on Fuel Injector Unit #6 to a good ground.

If there is NO continuity at Fuel Injector Unit #6, go to “Test 13 — Checking for a Short to Ground at the Fuel Injector Unit #6 (Spill Valve) Harness Connector” on page 247.

If continuity exists, the Fuel Injector Unit #6 is shorted to ground and must be replaced.

Test 13 — Checking for a Short to

Ground at the Fuel Injector Unit #6

(Spill Valve) Harness Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between the Fuel Injector Unit #6 harness connector pin 3 and pin 4 and a good ground.

If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.

If there is NO continuity, go to “Test 14 — Checking for an Open Circuit in the Fuel Injector Unit #6 (Spill Valve) Voltage Line” on page 248.

Page 248 January 2009

MID 128-SID 6

Test 14 — Checking for an Open

Circuit in the Fuel Injector Unit #6

(Spill Valve) Voltage Line

248

Figure 248

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between EMS Module harness connector A pin 60 and pin 3 of the Fuel Injector Unit #6 (see Figure 248).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 15 — Checking for an Open Circuit in the Fuel Injector Unit #6 (Spill Valve) Control Line” on page 248.

Test 15 — Checking for an Open

Circuit in the Fuel Injector Unit #6

(Spill Valve) Control Line

249

Figure 249

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Check for continuity between pin 4 of the the Fuel Injector Unit #6 and EMS Module harness connector A pin 40 (see Figure 249).

If there is NO continuity, repair the open in the circuit.

If continuity exists, go to “Test 16 — Checking for a Short to Voltage in the Fuel Injector Unit #6 (Spill Valve) Voltage Line” on page 249.

MID 128-SID 6

January 2009 Page 249

Test 16 — Checking for a Short to

Voltage in the Fuel Injector Unit #6

(Spill Valve) Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Turn the ignition key ON.

4. Measure the voltage between EMS Module connector A pin 60 and a good ground.

If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.

If there is NO voltage present, go to “Test 17 — Checking for a Short to Voltage in the Fuel Injector Unit #6 (Spill Valve) Control Line” on page 249.

Test 17 — Checking for a Short to

Voltage in the Fuel Injector Unit #6

(Spill Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect Engine Management System (EMS) Module connectors A and B.

3. Disconnect the harness connector from Fuel Injector Unit #6.

4. Turn the ignition key ON.

5. Measure the voltage between the EMS Module connector A pin 40 and a good ground.

If voltage is present, the Fuel Injector Unit #6 control line is shorted to voltage. Locate and repair the short.

If voltage is NOT present, go to “Test 18 — Isolating a Short in the Fuel Injector Unit #6 (Spill Valve) Voltage Line” on page 249.

Test 18 — Isolating a Short in the

Fuel Injector Unit #6 (Spill Valve)

Voltage Line

1. Turn the ignition key OFF.

2. Disconnect connector A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from the Fuel Injector Unit #6.

4. Check for continuity between EMS Module harness connector A pin 60 and all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 19 — Isolating a Short Circuit in the Fuel Injector Unit #6 (Spill Valve) Control Line” on page 249.

If continuity exists, the Fuel Injector Unit #6 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Test 19 — Isolating a Short Circuit

in the Fuel Injector Unit #6 (Spill

Valve) Control Line

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the Engine Management System (EMS) Module.

3. Disconnect the harness electrical connector from Fuel Injector Unit #6.

4. Check for continuity between the EMS Module harness connector A pin 40 all other pins on EMS Module connectors A and B.

If there is NO continuity, go to “Test 20 — Checking for a Short at the EMS Module Connector” on page 250.

If continuity exists, the Fuel Injector Unit #6 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.

Page 250 January 2009

MID 128-SID 6

Test 20 — Checking for a Short at

the EMS Module Connector

1. Turn the ignition key OFF.

2. Disconnect connectors A and B from the EMS Module.

3. Visually inspect EMS Module connectors A and B for dirt, loose pins or deformed contacts.

4. If a pin feels loose or appears damaged, repair the connector.

If all the pins appear to make good contact and feel tight, go to “Test 21 — Verifying if the Fault Code is Still Active” on page 250.

Test 21 — Verifying if the Fault Code

is Still Active

1. Turn the ignition key OFF.

2. Connect all harness electrical connectors to the Fuel Injector Unit #6 solenoids.

3. Connect Engine Management System (EMS) Module connectors A and B.

4. Turn the ignition key ON.

If the blink code is still active, check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 7 or 12, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident, switch the location of Fuel Injector Unit #6 with that of a fault-free Fuel Injector Unit #6. Reconnect all harness connectors and retest the system. If the PID has changed to the new location of the suspect Fuel Injector Unit #6, replace the Fuel Injector Unit #6, install all Fuel Injector Unit #6s in their original location, and retest the system.

If only the Fuel Injector Unit #6 blink code is still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, replace the EMS Module and retest the system.

If multiple Fuel Injector Unit #6 blink codes are still active and the FMI is 3 or 5, check the EMS Module and connectors for dirt, loose or shorted pins, or any other repairable damage. If no damage is evident or is not repairable, go to “Test 22 — Inspecting the Mechanical Fuel System Components” on page 250.

If the blink code is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections.

Test 22 — Inspecting the

Mechanical Fuel System

Components

1. Ensure that there is fuel in the fuel tank.

2. Inspect the fuel lines between the tank and the transfer pump for sharp bends or kinks, and repair as needed.

3. Check for air in the fuel system, and repair as needed.

4. Check the fuel pressure at the secondary fuel filter outlet.

If the fuel pressure is NOT within specifications, perform any required fuel system repairs.

5. Remove Fuel Injector Unit #6 from the engine and inspect for surface rust between the O-rings.

If rust is present, locate the source of the fuel contamination and replace any damaged components.

If all of the mechanical fuel system components are in good working order, replace the EMS Module and retest the system.