PSA/Ford 2.2 HDi and TDCi (DW12)Injectors
Piezo injector wear and failure on the 2.2 HDi
Why this rating?
High severity: Risk of a serious engine, turbo or gearbox failure.
Frequency occasional: Fiches-auto records 15 injector cases among 277 reviews (5.4%) in the 128-138 hp version and 4 among 172 (2.3%) in the 204 hp one; these figures are well below those for the DPF in the 128-138 hp version, so we classify it as occasional.[2][4]
Symptoms
- Harder or rougher cold starts.[2]Hard to start: other faults that cause it · Garage soon
- Jerking or an unstable idle.[2]Jerking: other faults that cause it · Garage soon
- Black smoke from incomplete combustion.[2]Black smoke: other faults that cause it · Garage soon
- Increased diesel consumption.[2]Uses more fuel: other faults that cause it · Monitor
Why it happens
Piezo injectors work at very high pressure (up to 1,800-2,000 bar depending on the version) with several holes and up to six injections per cycle; normal wear, diesel quality or carbon deposits can alter the spray pattern over time.[1]
If it is not repaired: A worn or faulty injector can cause hard starting, jerking, an unstable idle or higher consumption; in advanced cases it can affect the cylinder itself if it delivers too much fuel.[2]
Affected cars and years
It potentially affects all versions, which share the same third-generation common-rail system with piezo injectors.[1][3]
| Version | Years | Codes |
|---|---|---|
| 2.2 HDi 128-138 (DW12 TED4, single turbo, 2000-2006) | 2000–2006 | DW12DW12TED4 |
| 2.2 HDi 150-156 (single variable-geometry turbo, 2006-2012) | 2006–2012 | DW12 |
| 2.2 HDi 170-175 twin-turbo (DW12 BTED4, 2005-2010) | 2005–2010 | DW12DW12BTED4ZSD-422 |
| 2.2 HDi 190-204 twin-turbo (DW12 C, 2010-2015) | 2010–2015 | DW12DW12CZSD-422 |
Models fitted with the affected versions
Citroën
- Citroën C5 I2001–2007
- Citroën C5 II2011–2015
- Citroën C62006–2010
- Citroën C82002–2010
- Citroën C-Crosser2006–2012
Ford
- Ford Mondeo IV2007–2014
Land Rover
- Land Rover Freelander 22007–2014
- Land Rover Range Rover Evoque I2011–2015
Peugeot
- Peugeot 4072004–2009
- Peugeot 6071999–2010
- Peugeot 8072002–2010
- Peugeot 40072006–2012
- Peugeot 4062001–2005
How much it costs to repair
Includes: Depending on the diagnosis: cleaning the injectors or replacing one or more units.[2]
We have not found a verified price in Spain for the injectors on this engine.
Prices in Spain, including VAT. A workshop hour costs on average €38–66 at independent garages and €77–134 at dealerships in Spain, depending on the region and the brand. How we calculate costs
How to check for it before buying a used car
- Start the engine from cold and check that it does not take too long or sound uneven.
- Ask for invoices for injector cleaning or replacement.
- A diagnostic scan with a code reader can detect imbalances between cylinders that point to an injector.
Parts needed
The part or kit that fixes this fault, according to the sources.
Piezo injector for 2.2 HDi
Replaces a worn or faulty injector; it is usually recommended to check the others if one fails.
Affiliate links: if you buy from these shops, MotorFiable may receive a commission at no cost to you. Check compatibility against the registration plate or VIN before ordering. Affiliate links
How to prevent it
- Refuel at reputable filling stations and avoid driving with an almost empty tank to protect the pump and the injectors.
Recalls, campaigns and claims
As of 27 September 2026, we have no record of recalls, campaigns or extended manufacturer warranties for this fault. Check with an official dealer using the chassis (VIN) number: they will tell you whether the car has any outstanding campaign.
What owners say
Frequently asked questions
Are piezo injectors more fragile than others?
We have not found a reliable direct comparison; what fiches-auto does document are isolated injector cases across several power outputs of the 2.2 HDi, without it being the most repeated fault.[2]
What injection pressure does this engine use?
According to the technical tests consulted, up to 1,800-2,000 bar depending on the version, with multi-hole piezo injectors and up to six injections per cycle.[1][3]
Does poor-quality fuel affect the injectors?
Yes: poor-quality diesel or driving with an almost empty tank can accelerate wear on the high-pressure pump and injectors.[2]
What can you do now?
We will put you in touch with a partner only if you authorise it in the form.
Other 2.2 HDi faults
- High severityFrequency: CommonEmissions controlDPF clogging with additive, especially on the 128-138 hp versionThe particulate filter (DPF) with additive on the 2.2 HDi has a documented recurring problem in the 128-138 hp version (98 cases out of 277 reviews on fiches-auto); the more powerful twin-turbo versions show far fewer cases. The emissions fault warning light comes on and, if ignored, the car loses power.
- High severityFrequency: OccasionalTurboTurbo faults, somewhat more frequent on the sequential twin-turbo versionsThe 2.2 HDi comes in single-turbo versions (128-156 hp) and twin-turbo versions with two turbochargers in sequence (170 hp and up). Fiches-auto does not consider it a chronic problem, but it does record a significant number of turbo cases across all power outputs, somewhat higher on the twin-turbos.
- Medium severityFrequency: RareClutchDual-mass flywheel wear, less frequent than on other HDi enginesThe 2.2 HDi has a dual-mass flywheel but, unlike smaller HDi engines such as the 1.6 HDi, fiches-auto does not document a chronic problem: very few cases in the tables consulted. Even so, it is a wear part: vibration and knocking are the signs to watch for before buying.
More faults with the injectors on other engines and cars
- High severityFrequency: Very frequentOM651Delphi piezo injector failure (220/250 CDI)Yes: 220 and 250 CDI models built between 2008 and 2011 had Delphi piezo injectors that were prone to failing and seizing in the cylinder head. Mercedes-Benz replaced them under warranty in 2009 and switched the 220 CDI to solenoid injectors from 2010-2011, but the 250 CDI kept them.Repair (garage): €3,600–€5,900
- High severityFrequency: CommonBMW N52 / N53N53 piezoelectric injector failureThe N53's piezoelectric direct injectors fail frequently and cause misfires, rough idle and limp mode; replacing them is expensive and they must be coded.
- High severityFrequency: CommonMZR-CDOil dilution from leaking injector seals and DPF regenerationsOn the 2.0 and 2.2 MZR-CD, injector seals that age badly and incomplete particulate filter regenerations on short journeys can let unburnt diesel into the sump, diluting the oil and leaving the engine with less lubrication.
- High severityFrequency: CommonOM642Wear and failure of the Bosch piezo injectorsThe OM642's Bosch piezo injectors can fail from around 150,000-200,000 km, especially with poor-quality diesel; they cannot be repaired, only replaced. Because it is a V engine, those on the rear bank are harder to reach, which pushes up labour costs.Repair: €4,500–€6,500
- High severityFrequency: Common2.2 CDI (OM646)Injector seal leak with carbonisation around the seatYes: the copper washer that seals each injector can harden and let combustion gases through, forming a black crust of carbon around it. It is a known fault on Mercedes CDI diesels of this era, with injectors described as fragile on both the OM611 and the OM646.
- High severityFrequency: Common2.2/2.5 dCiInjection pump or injector failureThe 2.2 dCi's common rail injectors fail fairly often on the X-Trail and Almera, with cases of seizing and leaks; on the Almera with the older YD22DDT, the documented fault is in the injection pump electronics, not the injectors.
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Sources
Every fact on this page links to its source. If you find an error, let us know.
- Citroën C5 2.2 HDI 173 FAPAutopista.es · Motoring press · published 15 June 2006 · consulted 27 September 2026 · in Spanish
- Essai, avis et fiabilité des 2,2 HDI 136 chevauxFiches-Auto · Motoring press · consulted 27 September 2026 · in French
- Essai Citroën C5 Exclusive + 2.2 HDI 200 TourerActu Automobile · Motoring press · published 2011 · consulted 27 September 2026 · in French
- Essai, avis et fiabilité des 2,2 HDI 204 chevauxFiches-Auto · Motoring press · consulted 27 September 2026 · in French