Electronic Unit Injector – Test

This procedure assists in the cause for an injector misfiring. This procedure is done after performing the
“Cylinder Cutout test”

Injection actuation pressure test

The test for injection actuation pressure is used in order to check for the following conditions:

 The unit injector hydraulic pump is producing maximum pressure

 The pump pressure regulator is working properly
 Then unit injector pump is worn
 System leaks

The Caterpillar Electronic Technician (Cat ET) is used to perform this test

Cylinder Cutout Test

The test is useful for troubleshooting

1. Low Power
2. Rough operation
3. Misfiring
4. Excessive fuel consumption

The test is designed to provide satisfactory results without extremely loading the engine. The test
provides a fast method and an effective method in order to diagnose cylinders without the use of
dynamometer. This makes the test well suited for use in the field. Proper use of the tests will reduce
troubleshooting time and repair costs. The test will also improve troubleshooting accuracy.

The cylinder cutout test is used on an engine in order to determine the individual cylinder performance
while the engine is running. As one or more cylinders are cut out during the test, the cylinder cutout test
uses the fuel position of each injector in order to evaluate the performance of the remaining cylinders
that are firing. As the different cylinders are cut out, a comparison of the change in fuel position is used
to identify cylinders that are weak or misfiring. One reason for a cylinder that is weak or to misfire, is an
injector that is malfunctioning mechanically.

During the test, when a good injector is cut out, the fuel position of the remaining injectors will show a
consistent change. This consistent change in the fuel position is caused by the remaining injectors that
are compensating for the cut out injector. If a malfunctioning injector is cut out, the fuel position will not
show a proportional change.

This unbalanced change is the result of the smaller quantity of fuel that is needed to compensate for the
power loss from the malfunctioning injector. The cylinder cutout test is used to isolate a malfunctioning
injector in order to avoid replacement of injectors that are in good repairs

Fuel System Pressure

Low Fuel Pressure

Low fuel pressure can cause low power and cavitation. Cavitation damages the fuel injectors.

Causes of low fuel pressure are as follow;

1. Plugged fuel filters

2. Debris in the check valves for the fuel priming pump
3. Sticking or worn fuel pressure regulating valve in the fuel transfer pump
4. Severe wear on the return fuel pressure regulating valve at the rear of the cylinder head
5. Worn gears in the fuel transfer pump
6. Pinched fuel lines or undersized fuel lines
7. Pinched or undersized fuel line fittings
8. Debris in the fuel tank, fuel lines, or fuel system components that create restriction

High Fuel Pressure

Excessive fuel pressure can cause rupture of fuel filter gaskets.

Causes of high fuel pressure:

1. Plugged orifice in the pressure regulating valve

2. Stuck fuel pressure regulating valve in the fuel transfer pump
3. Pinched fuel return line