Main Technics Repair Repair of a car Common Rail Bosch Injectors Cleaning

Common Rail Bosch Injectors Cleaning

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There is a problem with the modern diesel engines (and with the other engines) that feed units which inject fuel to combustion chamber are become dirty with the time. This can influence negatively on the engine running and on its start. In this article there will be description of how to deal with injectors Common Rail Bosch (as well you can read article about Common Rail DENSO injectors cleaning). In my case the engine running has not changed significantly but the engine’s start has become to experience difficulties. I could not understand what was going on. In case I pushed my car the engine started very well. But this was almost impossible with starter unless liquid «Start fluid» on the base of ester could help anyhow. The start was when revolves was increasing within 5-7 sec and its were close to 800 rpm. The car’s operational kilometers was 100K. This was high time I began to change injectors.

As far as I did not know what was wrong I decided to go to diagnostics at service station. The servicemen told me that «the pressure in fuel Common Rail grew very slowly». And there are two reasons are possible: diesel high pressure fuel pump has been frayed and it flushed weakly or back-pressure valves in injectors did not hold fuel and fuel leaked through this one. Which is to say that injectors pour off fuel to by-pass channel. After deep thinking it was decided to start with injectors' cleaning, as far as in any case there was time to change its by the book. If its break I will buy new ones. If injectors resume working I will know for the future that their resource is more that 100K operational kilometers. For this time being the price for 1 injector was approximately 400 USD. This was the cheapest one which I had found. There are 3 types of this injector «X», «Y» and «Z». As manufacturer claims that it is impossible to insert in engine all 3 cheap pieces, its must be in combination with others. Not the cheapest injector’s cost was 1K USD. I have not any distinct idea why prices differs a lot however I think that the ecology is the main point.

Prior to starting

I overhauled injectors without preparation as far as I had done this operation not for the first or the second time. Before the first time of injectors' overhaul I prepared very well theoretically, I studied its working actions, operation principles and control system of injectors. This was difficult process to understand how all this works and I spent two days studying theory. Eventually I cottoned on. Briefly I will tell how its work.

Initial conditions: the injector is closed, the fuel’s working pressure in input approximately 300 bars or more. Injector’s opening: voltage applies to the solenoid coil, back-electromagnetic valve is being opened. The ball which closes the output orifice is going up and fuel starts discharging to back channel. The fuel pressure in control chamber is going down. Before this the same pressure influenced on the all details of injector meaning that on the needle from bottom and on increaser from the top as well. Therefore the fuel pressure difference from below and in control chamber begins moving needle and increaser to the top and injector’s atomizing holes open. When control voltage removes the back-valve closes and pressure in control chamber increases. After this due to internal pressure the needle of nozzle is pressed to the support saddle. And in conditions of working pressure absence the needle is pressed to the support saddle with the spring.

The principle of Common Rail injector operating

Demonstrative Movie «How does Common Rail Injector Work»

Getting to the work

First of all injectors must be picked-off.

Common rail injectors

Dismantling of injectors Common Rail

We twist off solenoid and see inside spring and ring. We hold to injector’s body with wrench (12) but you may use instrument the most comfortable for you. The most thing is that you must hold injector strongly, pliers or something else are not the right choice. But with pliers we twist off metal screw which holds the solenoid (as indicated on the photo below). Please note that I could not twist off screw with pliers, just only gas wrench helped me to do this. However when I dismantled injectors for the first time everything was twisted off with the help of pliers.

Way to unscrewing the solenoid of injectors
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24.04.2014 at 23:11 Samuel said:

You are a great man! Marvelous!

I never have seen more detailed report!

I spend all my afternoon to read your reports. And they are exelent.

Thank you very much for the good information and the good time I passed with!

13.12.2014 at 23:05 Mr. Magiroos said:

Perfect!!!! Super!!! This is just for my kind men. I just have to do things my self. One question.

Is there any rubber seals to change? Can you send me the factory code to order them. My problem starts from leaking upper line. I have chrysler voyager 2,4 crd. 2002 diisel. Many thanks!!!

14.10.2016 at 02:16 Scottie said:

Thank you for the detailed write up. Diesel injector rebuilding seems to be a dark art, with very little published on the internet. Your article is the most comprehensive I've seen. I purchased my valve balls from

Kit13315 1.3mm Loose Ceramic Balls G5 Si3N4 Bearing Balls $1.49 each

14.10.2016 at 11:03 George said:

Dear Scottie,

Thanks! Yes, it's some kind of dark art. Did you successful repair your injectors? As I know ball diameter is 1.34mm.

10.10.2017 at 03:10 Axallindo said:

Hi guest

I have clean all injector part and change a new seal and new nozzle but why after i use at my engine is always knocking in acceleration?

10.10.2017 at 03:10 Axallindo said:

Hi guest

I have clean all injector part and change a new seal and new nozzle but why after i use at my engine is always knocking in acceleration?

19.07.2018 at 21:15 Henry said:


Need your permission to translate this article in bahasa indonesia and upload it to my blog.



24.07.2018 at 19:28 George said:

Dear Henry,

I do not mind if you will translete the article and upload to your blog with link to the source.

REgards, George.

16.07.2019 at 16:34 Zox said:


Like Axallindo, I have cleaned injectors and put new seal and ball. Now I have knocking injectors on acceleration...

It looks like that injector must be adjusted with shims and take care about torque settings.

Pre-ignition paremeter is not good...