Fuel Injection System Cleaning and Inspection Checklist

This fuel injection system cleaning and inspection checklist provides systematic procedures for both port fuel injection and gasoline direct injection engines. GDI engines have no fuel washing of intake valves, causing carbon deposits that reduce airflow and power after 40,000-60,000 miles. Walnut blasting is the industry standard for GDI carbon removal. Aligned with SAE fuel system standards, OEM GDI recommendations, and ASE A8 engine performance certification.

Industry: Automotive Service
Frequency: Every 30,000-60,000 Miles GDI / Per Performance Complaint
Estimated Time: 45-120 minutes
Role: ASE A8-Certified Engine Performance Technician
Total Items: 26
Compliance: SAE J1297 Fuel System Service Standards, ASE A8 Engine Performance Certification, EPA Tier 3 Fuel System Standards, OEM GDI Service Recommendations, CARB GDI Maintenance Guidelines

Fuel Pressure and Delivery Testing

Verify fuel delivery before cleaning or part replacement.

Fuel rail pressure tested at idle and load within OEM spec - GDI 500-2200 PSI, PFI 30-65 PSI?
Fuel pressure holds after shutoff - no more than 5 PSI drop in 10 minutes?
Fuel pump volume output within OEM specification?
Serviceable fuel filter replaced if at or approaching mileage interval?
No fuel leaks at rail, injectors, lines, or connections?

Injector Cleaning and Balance Testing

Clean and verify injector performance.

Injector balance test - all cylinders within 10% contribution of each other?
Appropriate cleaning method selected for injection type - on-car chemical vs off-car ultrasonic?
GDI or PFI-specific cleaner used per injection system type?
Post-cleaning balance test confirms improved cylinder contribution balance?
Injector O-rings replaced if injectors were removed during service?

GDI Intake Valve Carbon Cleaning

GDI-specific carbon deposit removal from intake valves.

Vehicle confirmed as GDI requiring intake valve carbon cleaning?
Intake valve carbon level assessed via borescope through intake port or spark plug hole?
Walnut shell blasting performed - OEM-approved soft media carbon removal method?
All walnut shell media thoroughly vacuumed from intake ports before reassembly?
Next GDI cleaning interval established - typically every 30,000-50,000 miles?

Related Fuel System Component Service

Service related components that affect fuel system operation.

MAF sensor cleaned with MAF-specific spray if contaminated?
Throttle body bore and plate cleaned of carbon deposits?
PCV valve and hoses inspected - primary source of GDI intake carbon deposits?
Fuel trim within acceptable range after cleaning - STFT and LTFT within plus or minus 10%?
No misfire codes present after service and road test?

Post-Service Verification and Documentation

Confirm fuel system performance and document services.

Road test confirms improved idle quality, throttle response, and acceleration?
Customer advised on premium fuel requirement for GDI engines where OEM specifies?
Next GDI intake cleaning interval communicated to customer?
Fuel system service documented on RO with services performed and before/after results?
Customer advised that fuel economy improvement may be noticeable after GDI cleaning?
Related tune-up items (spark plugs, air filter) recommended during same service visit?

Related Automotive Checklists

Related Service Center Checklists

Why Use This Fuel Injection System Cleaning and Inspection Checklist?

This fuel injection system cleaning and inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for ase a8-certified engine performance technician professionals, this checklist covers 26 critical inspection points across 5 sections. Recommended frequency: every 30,000-60,000 miles gdi / per performance complaint.

Ensures compliance with SAE J1297 Fuel System Service Standards, ASE A8 Engine Performance Certification, EPA Tier 3 Fuel System Standards, OEM GDI Service Recommendations, CARB GDI Maintenance Guidelines, UK SMMT Fuel System Service Standards, India CMVR BS VI Fuel System Requirements. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Fuel Injection System Cleaning and Inspection Checklist cover?

This checklist covers 26 inspection items across 5 sections: Fuel Pressure and Delivery Testing, Injector Cleaning and Balance Testing, GDI Intake Valve Carbon Cleaning, Related Fuel System Component Service, Post-Service Verification and Documentation. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed every 30,000-60,000 miles gdi / per performance complaint. Each completion takes approximately 45-120 minutes.

Who should use this Fuel Injection System Cleaning and Inspection Checklist?

This checklist is designed for ASE A8-Certified Engine Performance Technician professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.