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 Although Common Rail injectors are designed to last, advances in injection technology mean that they are more     prone to wear from issues including:

1.Particle contamination: With tolerances a fraction the width of a human hair, even the smallest of particles can cause significant damage. Often the consequence of ineffective filtration, these minute particles can erode the control valve and ball, resulting in a poor seal between the two. Over time this can alter the fuel spray pattern, and in turn, the quantity, timing and distribution of fuel injected.

2.   Water contamination: Another common cause of Common Rail injector failure is contamination from excess water in the fuel. If not stored or handled correctly, water can enter the fuel and will react with the chemicals in it to
corrode metal surfaces and reduce lubrication between the moving parts. Combined this can cause premature wear of both the injectors and high-pressure fuel pump.

3.    Deposit build-up: Any fuel that is left in the injector after engine shut down, will effectively be ‘cooked’ by the residual heat, creating carbon deposits, also known as coking. If left unchecked, these deposits will build-up around the nozzle tip and the injector’s internal parts, causing the needle to stick. Again this can disrupt both the quantity and timing of injection.

4.    Incorrect installation: Poor installation practices can also contribute to premature failure. For example, a missing nozzle washer, or one that has not been properly seated, will allow combustion residue to leak past the nozzle washer. Similarly seal rings can easily roll out of their grooves. Whilst these may seem like simple issues, they can result in much bigger problems including poor injector performance, starting and fuel efficiency.