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Fuel Injector Malfunction

DTC DETECTION CONDITION POSSIBLE COUSES CHART

DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P0277 FUEL INJECTOR MALFUNCTION
DETECTION CONDITION
  • P0201-P0206 indicates the fuel injector does not operate electrically even though the harness assembly and fuel injectors test satisfactorily.
  • P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, and P0277 indicate a concern is detected in the fuel injector interface module in the primary (forward) fuel injector circuit.
POSSIBLE CAUSES
  • Fuel injector(s)
  • Harness circuits: VPWR and INJ 1 - 6
  • PCM
HINT Fuel Injector Description 
  • Solenoid-operated valve that meters fuel flow to the engine.
    • Opens and closes a constant number of times per crankshaft revolution.
    • The amount of fuel is controlled by the length of time it is held open.
  • Normally closed and is operated by 12 V VPWR from the electronic engine control power relay with the ground controlled by the PCM.
G06157091Courtesy of MAZDA MOTORS CORP.
DTC DETECTION CONDITION POSSIBLE COUSES CHART

STEP INSPECTION ACTION
1 PCM QUICK TEST
  • Was PCM Quick Test carried out? 
 Yes GO to the next step.
No CARRY OUT the PCM Quick Test. See PCM QUICK TEST  .
2 DTCs P0201 THROUGH P0206 OR SYMPTOMS WITHOUT DTCs: CHECK THE VPWR CIRCUIT FOR AN OPEN IN THE HARNESS
NOTE:
  • Disconnect the suspect fuel injector harness connector. Only the suspect injector needs to be diagnosed.
NOTE:
  • On some vehicles, the injector voltage is only present when the fuel pump relay is energized. Measure the injector voltage within 2 seconds of the key ON.
  • Key OFF.
  • INJ connector disconnected.
  • Key ON, engine OFF (KOEO).
  • Measure the voltage between:
    • (+) INJ Connector VPWR, Harness Side and (-) Ground
  • Is the voltage greater than 10 V? 
 Yes GO to the next step.
No REPAIR the open circuit. CLEAR the DTCs.
REPEAT the self-test.
3 CHECK THE INJ CIRCUIT FOR AN OPEN IN THE HARNESS
  • Key in OFF position.
  • Measure the voltage between:
    • (+) PCM Connector Suspect INJ, Harness Side and (-) INJ Connector INJ, Harness Side.
  • Is the resistance less than 5 ohms? 
 Yes GO to the next step.
No REPAIR the open circuit. CLEAR the DTCs.
REPEAT the self-test.
4 CHECK THE INJ CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS
  • Key ON, engine OFF (KOEO).
  • Measure the voltage between:
    • (+) INJ Connector INJ, Harness Side and (-) Ground
  • Is any voltage present? 
 Yes REPAIR the short circuit. CLEAR the DTCs.
REPEAT the self-test.
No GO to the next step.
5 CHECK THE RESISTANCE OF THE FUEL INJECTOR
NOTE:
  • This erases continuous memory DTCs.
  • Key OFF.
  • Measure the voltage between:
    • (+) INJ Connector VPWR, Component Side and (-) INJ Connector INJ, Component Side
  • Is the resistance between 11 - 18 ohms? 
 Yes GO to the next step.
No INSTALL a new fuel injector. See FUEL RAIL REMOVAL/INSTALLATION - 2.5L or FUEL RAIL REMOVAL/INSTALLATION - 3.0L 01-14A-29.
6 CHECK THE FUNCTIONALITY OF THE INJ CIRCUIT
  • PCM connector connected.
  • Key ON, engine OFF (KOEO).
  • Connect a non-powered test lamp between:
    • (+) INJ Connector VPWR, Harness Side and (-) INJ Connector INJ, Harness Side
  • Key ON, engine running. (KOER).
  • Is the test lamp blinking? 
 Yes GO to next step.
No GO to step 8.
7 CARRY OUT A THOROUGH WIGGLE TEST ON THE FUEL INJECTOR HARNESS
  • Key OFF.
  • Connect the INJ connector.
  • Key ON, engine running (KOER).
  • Engine at normal operating temperature.
  • Access the PCM and monitor the INJ_F PID.
  • Wiggle, shake, and bend small areas of the wiring harness while working from the fuel injector to the PCM.
  • Are any injector values fluctuating in and out of range? 
 Yes ISOLATE the concern and REPAIR as necessary.
No See TEST 3: INTERMITTENT  .
8 CHECK FOR CORRECT PCM OPERATION
  • Disconnect all the PCM connectors.
  • Check for:
    • corrosion
    • damaged pins
    • pushed-out pins
  • Connect all connectors and make sure they seat correctly.
  • Clear DTCs from PCM memory using IDS or equivalent generic OBD II tester.
  • Carry out the PCM Quick Test. See PCM QUICK TEST  .
  • Is the same DTC present? 
 Yes INSTALL a new PCM.
See POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION - 2.5L or POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION - 3.0L .
REPEAT the PCM Quick Test. See PCM QUICK TEST  .
No If any other DTC is present, go to applicable DTC inspection.
If no DTC is present, troubleshooting complete.
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