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

Common Rail Bosch Injectors Cleaning

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We put in the injector body the rod and control chamber

Next we put together the details of atomizer, insert needle, put up small details, twist mouse pieces but not tighten its.

Assembled nozzle without nut

Further we put up valve accurately. The ball and its holder (ball’s saddle) in shape of cylinder with cave are magnetic and these ones draw together to the pivot with cap. The ball and its holder must adjoin to the pivot (however these ones draw weakly therefore be careful). This construction I put together out of valve and after assembly I insert all construction in valve and tighten with screw. The screw is not symmetric therefore don’t mix up the side. Now you can tighten all: the screw and the injector’s mouth piece.

Return valve

Further it is necessary to bolt on fuel supply fitting and to tighten it.

Let’s assembly the mechanism with tri-lobe device, put on spring on it, mount and fix with the available half-ring.

After this we insert plate and the ring into solenoid and twist it, not forgotten to lay plate-laying.

shim, spring and solenoid

The injector cleaned perfectly and put up together and it ready to run 100K km again. Other injectors must be cleaned with the same method. This helped me and with the cleaned injectors my car started well and drove 65K km almost.

However nothing last forever and therefore some details can fail, for example needle can stick in atomizer and I do not know how to get the needle without harm for it. The valve’s saddle can frayed and pair valve-multiplier can end working. And for this case you have an opportunity to order spare parts, please see their codes:

  • Multiplier with control chamber (valve’s saddle): F00VC01044.
  • Gaskets package (Its put on package of control chamber, i.e. on valve’s saddle): F00VC99002.
  • Ball valve’s saddle (ball guide-way, cylinder with cave): F00VC21002; F00VC21001.
  • Valve’s ball: F00VC05001.
  • Injector’s nozzle: 0433171755.

There are lot of variants of codes and I personally didn’t booked for the time being. I can’t confirm that this is ideal substitution (I select using the codes fof Bosch injector). Perhaps there are different codes and details differs not a lot and these ones are interchanged or don’t have any variations at all. Sometimes manufacturer substitute old details for the new ones identically.

I found information regarding balls:

  1. F00VC05001 — steel, diameter: 1,34 mm, but I booked this one two times with this code as far as balls arrived with two types: with diameter 1,5 mm, and another with diameter — 1,34 mm.
  2. F00VC05002 — ceramic, diameter: 1,34 mm (personally I didn’t book).
  3. F00VC05003 — some ball.
  4. F00VC05006 — steel, diameter: 1,5 mm, ball from high pressure fuel pump. I booked but ceramic arrived 1,45 mm.
  5. F00VC05008 — ball from high pressure fuel pump. I booked but ceramic arrived, 1,30 mm.
  6. F00VC05009 — ball from high pressure fuel pump. I booked but ceramic arrived, 1,45 mm.
  7. F00VC05010 — some valve’s ball.
  8. F00VC05027 — some valve’s ball.

Ladies and Gentlemen who dismantle the injectors,let me ask you to measure ball and to write it dimension and your injector’s code in commentaries. I will find balls knowing their codes and therefore we will know which ball is designated for which injector.

There is list of cars where this injector can be applied (33800-279002X, 33800-279002Y, 33800-279002Z):


The codes of detail of injector:

  1. 33800-279002X
  2. 33800-279002Y
  3. 33800-279002Z

The cars where the same engine (1.5 CRDI D3EA, 3 cylinders):

  1. HYUNDAI Accent
  2. HYUNDAI Getz
  3. HYUNDAI Matrix

The cars where the similar engine (2.0 CRDI D4EA, 4 cylinders):


The analogic injector of «33800-27900» is from Bosch: 0 445 110 290; 0 445 110 126.

One of visitors-Alexander, and he sent report about injector Bosch 0 445 110 250 tests on stand).

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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...