Common Rail Injector Failures PDF

If you are purchasing your own injectors, Bosch is the world’s leading supplier
you should purchase from a reputable, OE of diesel fuel injection systems and is A Bosch Guide to Potential Causes of
manufacturer. If considering injectors from a standard equipment on many diesel
Common Rail Injector Failures
non-OE endorsed manufacturer, be sure to ask the engines today. You can be confident
following questions to determine if the cost savings when you install Bosch OE injectors,
is worth the risk: Bosch remanufactured injectors, or
Bosch-authorized rebuilt injectors.
Do these injectors use new or reconditioned
components?
It is preferred that the remanufactured injector To find a local Bosch Diesel Service
use all new high-wear components vs. salvaged Center, visit www.boschcarservice.us
components. and click on “Find a Service Center“.
How are the remanufactured injectors tested?

You want injectors that are tested to exact OE
test specifications and not reverse engineered
specifications.
What type of testing equipment is used?

ffIt is preferable that their testing equipment is
certified by the OEM.
ffIt should be traceable back to the OE
manufacturers testing.
Is there a warranty?
Many reputable manufacturers offer at least a
one-year warranty.
Are the remanufactured/rebuilt injectors

upgraded to meet new OE specs?
Are component improvements added to match
Robert Bosch LLC
changes made by the engine manufacturers? 2800 South 25th Avenue
Broadview, IL 60155-4594
www.boschautoparts.com
BOSCH is a trademark licensed by Robert Bosch GmbH

and/or its affiliated entities.
© 2014 Robert Bosch LLC, USA. All rights reserved.
14040154 F00E381749 4GU

The common rail system is a major Poor Fuel Filtration Non-OEM Approved Remanufactured Products
advancement in diesel technology. However,
Not all remanufactured injectors are the same. The
common rail engines are less forgiving of poor 1 2
quality of any remanufactured injector depends on
quality than older fuel injection technologies. the remanufacturing process and components. Some
What used to be acceptable in the past can manufacturers sell refurbished/used injectors and market
cause the engine to malfunction and often them as rebuilt. However, instead of being rebuilt, they
are merely cleaned and polished, and the tips are not
result in a costly repair.
replaced. You might get a great deal on these non-OEM
1 Sealing surface for a new Bosch valve body.
approved products, but you are taking a huge risk that
The key causes of injector failures are: 2 Sealing surface of a competitor valve body these injectors may not be better than the one you are
ff Fuel Contamination showing ball seat erosion. trying to replace.
ff Poor Fuel Filtration

A common problem with diesel injectors is erosion of What Can I Do?
ff Incorrect Installation Solution: Make sure your car is being serviced by a
the control valve. The heart of the common rail injector
ff Non-OEM approved remanufactured products is the valve through which fuel passes at extremely reputable shop and ask about the parts they use on
high pressure. The passage opening is sealed using your diesel engine to ensure they are from the OEM or
a pressurized ball that is only 1mm in size. A proper from an authorized Bosch supplier.
Fuel Contamination
seal is critical for exact injector performance. Abrasive
contaminants, released by inadequate filtration, can erode Incorrect Installation
1 2
and damage the control valve and not allowing the ball to
seal. This can lead to excessive smoke, starting or idling Missing sealing rings, incorrect tightening torque,
problems and potential engine failure. incorrect cleaning of the nozzle can cause poor
performance, misfiring , black smoke and check engine
What Can I Do? light (MIL) to come on.
Solution: To ensure exact performance within the
1 New Bosch valve body. designed service life of the injector, use only OE filters or What Can I Do?
filters having the same OE micron rating and follow the Solution: Always follow the engine manufacturer’s
2 Image of corroded valve body
recommended OE filter change interval. Using anything maintenance procedures and have repair work done by a
less can cost you more in the long run. reputable shop.
The majority of diesel engine problems stem from
contaminated fuel. Common problems include corrosion
from excessive water in the fuel, micro fine particles in the
fuel and improper fuel storage, which is caused by water in
the fuel.
There are two ways in which water can get into the fuel:
Bosch’s remanufactured injectors follow the same
through the delivery system and through the tank vent. fit, form, and function as OE injectors. Bosch
remanufactured injectors include all OE updates, so
What Can I Do?
they can often be superior to the OE injectors that
Solution: Always purchase fuel from a reputable service
they replace.
provider and use a proper fuel/water separator. Periodic
inspection of the vehicle’s tank vent is also recommended.

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If you are purchasing your own injectors, Bosch is the world’s leading supplier

How are the remanufactured injectors tested?

What type of testing equipment is used?

Are the remanufactured/rebuilt injectors

BOSCH is a trademark licensed by Robert Bosch GmbH

14040154 F00E381749 4GU

ff Poor Fuel Filtration

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