Non-OEM Approved Remanufactured Product Testing

Not all remanufactured injectors are the same. The quality of any remanufactured injector depends on the remanufacturing process and components.

Bosch recently tested and evaluated numerous remanufactured or rebuilt common rail fuel injectors available in the market. The Bosch team used a state-of-the-art Bosch EPS-815 test bench with Bosch patented Shot-to-Shot (SST) functionality and on vehicle testing using the EPA testing protocol. (See emissions testing overview).

More than 50 percent failed, and presented a significant hazard to the engine if installed in a diesel common rail system.

Following the testing Bosch also performed an injector tear-down for inspection and found that many of the components removed from non-authorized injectors were outside of the original design specifications including corrosion, pitting and re-machining. 

Valve Body

Sealing of the 1mm steel ball is critical for proper performance. Poor fuel quality over time damages the sealing surface and prevents the steel ball from sealing which changes the response time of the injection event as well as injected fuel quantity. During our review process Bosch found for many non-authorized injectors the valve body was re-used or resurfaced with both cases being outside the original design specifications. Impact on the vehicle could be smoke, erratic idle or full load, higher emissions and / or fuel consumption. For severe duty applications Bosch remanufactured injectors include a new patented hard chrome valve body for maximum service life.

Armature

The armature is a magnetic assembly that transfers the electrical energy into linear motion to control movement of the steel ball for the valve group. Poor fuel quality over time causes corrosion and fuel stains which directly impact overall reaction time and magnet force preventing the steel ball from moving while seated. Proper sealing is critical for proper injector performance. During our review process Bosch found components with excessive fuel staining and / or significant corrosion and pitting. Clearly, such components should always be replaced with new and never be re-used. Impact on the vehicle could be smoke, erratic idle or full load, higher emissions and / or fuel consumption.

Emissions Testing Overview

HC: Hydrocarbons

What it is: Unburned fuel

Effect: The higher the %, the more fuel is going out the tail pipe that does not produce any power and lowers fuel economy.

NoX: Nitrogen Oxides

What it is: Product of combustion Nitrogen Oxides are the source of Smog and Acid Rain. NOx formation control is a complicated process which requires exact control of temperature and pressure within the combustion chamber to minimize the time within the band that causes Nitrogen and Oxygen to combine into one of the Nitrogen Oxide gases.

Effect: Increased impact on the environment.

Particulates: Soot/Visible Smoke

What it is: Particulates are Hydrocarbons which started to burn but did not complete combustion. Unlike HC, these are either solids or liquids and not gases. This is what makes them visible.

Effect: Like HC, this is fuel which did not add to the formation of power and the higher the particulate levels, the lower the fuel economy and wasted fuel.

Valve Body

Smooth movement of the valve body plunger is critical for proper performance. Poor fuel quality over time causes corrosion and fuel stains which directly impacts smooth plunger movement required for proper injector performance. During our review process Bosch found components with significant corrosion and pitting. Clearly, such components should always be replaced with new and never be re-used. Impact on the vehicle could be smoke, erratic idle or full load, higher emissions and / or fuel consumption. For severe duty applications Bosch remanufactured injectors include a new patented hard chrome valve body for maximum service life.

Nozzle

The nozzle injects fuel at extreme high pressures (up to 36,000 psi) directly into the combustion chamber. Nozzle design, including location and configuration of the spray holes is critical for proper fuel atomization and complete combustion. The competitor’s nozzle we found during our review clearly shows incorrect spray hole location and configuration impacting engine performance and emissions.

CO: Carbon Monoxide

What it is: Incomplete burning, due to the fuel not having enough oxygen to complete the burning.

Effect: Just as in high HC, this is fuel which does not release all of the energy contained within it. The result is lower power and fuel economy.

NMHC: Non-Methane Hydrocarbons

What it is: Non-Methane Hydrocarbons are the portion of the measured Hydrocarbons which contribute to the formation of Ozone.

Effect: Increased impact on the environment.

Calculation Basis:

  • 50 K miles
  • $2.70/gallon diesel

Benefits using Bosch Injectors:

  • On average provides 3.6 % better fuel economy than non-authorized injectors
  • Average annual fuel savings of $300 (Can be as high as $565)

The diesel process involves a combination of fuel, air, heat and pressure. By controlling all of those, you get known repeatable power, fuel economy and emissions which can be guaranteed by using Bosch remanufactured injectors.