2001 S60 Fuel Injector Circuit Open and Cylinder 4 Misfire

midimykeys · Post by **midimykeys** » 09 Jun 2013, 13:28

This is my first post in the S60 forum. It's been primarily all 850 threads. So I'm having a problem with a new S60, well new to me anyway. The car is a 2.4 T automatic with 177k.

I pulled 3 codes yesterday.
P0204 - Fuel Injector Circuit / Open - Cylinder 4.
P0304 - Cylinder 4 Misfire Detecter
P0422 - Main Catalyst Efficiency Below Threshold (bank 1)

The 2 codes are most likely from the open fuel injector problem I'm guessing. The car runs fine for about 30 minutes, longer if the a/c isn't running. Then it will misfire, and acts like one cylinder isn't working. The problem is intermittent after it happens once. It will go away, and come back again on a day with heavy errands and multiple starts and stops. I think I need to replace the #4 fuel injector. I'm wondering if there's anything else to look for, a way to test, or anything helpful. Any thoughts before I attempt this repair would be greatly appreciated.

Post by **DGM** » 09 Jun 2013, 16:54

midimykeys wrote: Any thoughts before I attempt this repair would be greatly appreciated.

One thing you can do is to look at the electrical connector on the injector #4 to see if it is well seated. Look for signs of corrosion on the injector/connector contacts. Spray the contacts with WD-40 and plug-unplug a few times the connector. Inspect the wiring from the connector to the main harness for signs of chaffing.

On the green wire you should read battery voltage. On the other side it is switched by the ECM.

Here is a general procedure on how to test fuel injectors;

http://troubleshootmyvehicle.com/nissan ... njectors-1

If you have a fuel pressure meter you can take the pressure at the end of fuel rail. You should have a reading of about 55psi at 1200rpm. This will confirm that the injectors have sufficient fuel for their normal operation.

Finally the injector pintle can be sticky on its course. Before to change anything you could use some injector cleaner.

Personally I had good results with MMO. You can buy it by the quart at your local hardware store or at Walmart. Use one ounce per 10 liters of fuel for two or three tanks in a row. Your engine should run much smoother after.

midimykeys · Post by **midimykeys** » 10 Jun 2013, 06:47

Thanks for the tips, I'll certainly give those a try. That would be great if it was something simple! Will post back

midimykeys · Post by **midimykeys** » 10 Jun 2013, 17:02

I added seafoam per the service advisor at Volvo, and had the ignition coil on cylinder 4 replaced, along with wires and spark plugs. No help. I did notice that the outside temperature affects the time the car misfires. All week up until yesterday, it has been in the low 70's. It would take about 30 minutes of driving before the misfiring and check engine light flashing. Today, it was 85, and it only took 10 minutes. Both the service manager at Volvo and the mechanic that replaced the ignition coil said that it was unusual that a fuel injector goes bad on those cars. Anything else I can look for before I replace it? This is starting to cost a lot of $. Thanks for any help!

bw77 · Post by **bw77** » 11 Jun 2013, 04:34

You could swap the injector in #4 with the injector in another cylinder and
see if the misfire moves with the injector. If it moves, that would indicate
a bad injector, if it stays on #4 it would indicate a different problem.

Post by **DGM** » 12 Jun 2013, 05:45

midimykeys wrote:Anything else I can look for before I replace it? This is starting to cost a lot of $. Thanks for any help!

In addition to the proposed swap you can take the ohms reading on the injector as mentioned in the given link. Take it cold and compare with the others. Also take it hot to see if you have degradation.

Also what codes have been registered by the ECM since your last reset ?

P0204 - Fuel Injector Circuit / Open - Cylinder 4, has it come back?

http://www.obd-codes.com/p0204

If this code is recurring it indicates a problem with the circuit. It can be the injector, the wiring or the ECM.

Coil packs are definitely a weak point at high mileage but injectors can fail too. Usually they get sticky and need to be cleaned.

Squarewheels · Post by **Squarewheels** » 15 Jun 2013, 01:46

Midimykeys, any word on this? Did you replace the injector?

Im throwing p0202 and p0302 (xc70, 2001) Similar situation to you with the mechanics. I called around and they all said "Injectors? That's weird. Never heard those fail. We dont even stock them. You should replace the coils and plugs." Pretty much exact statement from three places.

I'm waiting on my code reader to arrive, had to go to Autozone for the codes. As soon as i get it ill be swapping coil packs and injectors. I'll let you know what comes of it.

Ariewhr · Post by **Ariewhr** » 25 Jul 2017, 15:20

Hello,

Recently I bought a S60 2.4T with exactly the same issue. The only difference is that my car gives the code on cylinder 1.
Have you found a solution yet. I know it's 4 years later now, but I am really curious about the outcome. I did not buy a 5 cylinder car to drive on 4 cylinders.

If you know what it can be, please let me know so I can fix it myself. I would really like it to have it fixed.

Salute from the Netherlands
Arie,

Post by **abscate** » 25 Jul 2017, 19:08

Move the coils, injectors, and spark plug, one at time , you see if you can move the misfire.

The injectors work with a constant 12V and are grounded by the ECU. The coils work the same way. If you find the wiring diagram will show Which terminals to test for power

Ariewhr · Post by **Ariewhr** » 25 Jul 2017, 23:24

The problem is that it only occurs one in a while. It never happens when the engine is cold. Ben when I start the car after I've been driving for I while the change is about 90%.
I replaced all the spark plugs and I've been moving the coils and injectors multiple times, without any results.

I really don't know where to look anymore, so that's why I'm really curious what helped with Midimykeys his car.