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.

Thanks,

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'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

Make sure there is no little bur on the barb that may be damaging the new bypass hose as you put it on. Give enough "loop" to the hose so it's not stressed. Bypass hose will be under fuel pump pressure only, even with a totally clogged injector and the hose is made to take that and more.

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The Golden Rule

1984 300SD (bought new, sold it in 1988, bought it back 13 yrs. later)