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Old 10-08-2001, 10:55 AM
Gray Market Survivor Gray Market Survivor is offline
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Join Date: Oct 2000
Location: Columbus, Ohio, USA
Posts: 72
Failure Method for Diesel Fuel Injector

I've done a search, but haven't found an answer to this one...

Can anyone tell me the common causes for how and why diesel fuel injectors fail?

The reason I am asking is because I replaced my injector bypass hose and plug after 266k. I figured it was time because I was leaking between #1 and #2 cylinder, so I replaced all the lines. Now, 10k miles later, I again had a leak in the new bypass hose between #1 and #2 cylinders. (I removed the line and found a 1 cm slit under the braiding abount a half inch from the hose barb.

Is it possible that high pressure is leaking from the inlet to the bypass and rupturing the hose?

or is it just a fantastic coincidence that either I installed that length of hose the wrong way or the hose had a defect?

Any opinions would be apreciated. I am more than prepared to admit I may have installed it wrong.

'06 E320 CDI 51K miles
'02 VW Jetta GLS TDi 120k miles
'99 Ford E350 7.3L Powerstroke 200k miles -sold
'84 Euro 300D 5 spd manual 317k miles - sold
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