Katerina Swanson
Running out of diesel fuel can have several consequences, from engine stalling to potential fuel system damage. This can be caused by the introduction of air into the fuel system, clogging of the fuel filter, or damage to the fuel pump, injectors, and other vital parts. Restarting a diesel engine that has run out of fuel may be challenging and time-consuming, and repairs or replacements can be costly. Therefore, it is essential to understand the risks associated with running out of diesel fuel and to prioritize timely refueling and diligent maintenance of diesel engines.
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What You'll Learn
Restarting a diesel engine
Running out of fuel in a diesel engine can be a big deal. Fuel-injected diesel engines operate under extremely high pressure and require lubrication. Running out of fuel can cause air to get sucked into the system, which can damage injectors and other parts due to a lack of lubrication.
If your diesel engine runs out of fuel, the first step is to add more fuel. If your engine is older, you may need to manually prime the fuel system. This can be done by turning the ignition on for 30 seconds without starting the engine, then turning the ignition off and cranking it for 15 seconds. Repeat this process until the engine starts. If your engine is newer (from around 2000 onwards), it may be able to prime the fuel system itself.
If your engine still won't start, you may need to bleed the fuel system. This involves venting the air out of the system through a Schrader or banjo bolt valve. This can be a messy process and may require a wrench, a bottle or receptacle to collect fuel, and rags to clean up.
It's important to keep an eye on your fuel gauge and not let your diesel engine run out of fuel. Running low on fuel can introduce contamination into the fuel system, as contaminants often settle at the bottom of the fuel tank. This can damage the fuel pump, filter, rail, and injectors, leading to costly repairs.
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Bleeding the fuel system
Running a diesel engine out of fuel can cause air to enter the fuel supply parts, which can cause the engine to experience difficulties operating at full capacity. This can lead to reduced engine power or, in severe cases, the inability to start the engine. This presence of air bubbles within a diesel fuel system is known as an "airlock".
- Familiarize yourself with the engine and identify the key components of its fuel system, including the fuel tank, fuel lines, fuel filter, and fuel injectors.
- Turn off the engine and remove the ignition key from the cylinder.
- Locate the fuel filter and determine whether it has a built-in bleeder screw.
- If the fuel filter has a bleeder screw, position a clean rag or towel beneath it to catch any fuel spills, then use a wrench or bleeder screw key to slowly loosen the screw in a counterclockwise direction.
- Once the screw is loosened, grab some rags as the next step can be messy.
- Find the fuel pump lever or plunger. Your fuel lift pump will be mounted on the engine and connected to the primary fuel filter.
- Cover all venting units to prevent spills.
- Locate and open the bleed plug on your secondary filter.
- Open the fuel supply valve.
- Use the manual pump to prime your diesel engine by pushing fuel through your system. Pump multiple times until you see a steady flow of fuel.
- Tighten the bleed plug.
- Attempt to start your engine and evaluate its condition.
- If the engine does not start or there are indications that air remains in the system, repeat the bleeding process at the fuel filter or fuel injectors.
- If the problem is resolved, properly dispose of any spilled fuel and clean up any messes.
It is important to note that newer diesel engines, especially those from 2000 onwards, are more self-serving when it comes to the priming process. After adding fresh diesel, the fuel can be brought to the front in just a few minutes without leaving the driver's seat.
Additionally, consider replacing your current primary fuel filter with an AirDog® fuel system to reduce the likelihood of having to bleed the fuel system in the future and to benefit from improved fuel economy and performance.
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Fuel system damage
Running a diesel engine out of fuel can cause fuel system damage. Fuel injection systems on diesel engines are high-pressure systems. They require lubrication due to the very tight tolerances in the high-pressure pump, which they get from the diesel fuel. If you run out of fuel, you risk damaging the high-pressure side of the fuel system, which can be costly to repair.
When you run out of diesel, air gets sucked into the system, and it must be vented out. This is called "bleeding" the fuel system. Depending on the machine, this can take several hours to complete. Some machines have self-bleeding systems, but most require a service call.
Running low on diesel can also introduce contamination into the fuel system because the contaminants are often at the bottom of the fuel tank. Fuel contamination can damage the fuel system. The poorest-quality fuel settles at the bottom of the tank, and it is often full of sediment. When this sediment is sent through the fuel system, it can clog or break your fuel pump, filter, rail, and injectors, and you might need to replace one or all of these parts.
Additionally, some newer diesel engines have CP4 injection pumps, which are fuel-lubricated. If these pumps fail due to a lack of lubrication, you may need to replace the entire fuel system.
Therefore, it is essential to keep your diesel tank fuelled and to pay attention to your vehicle's "low fuel" light to prevent potential fuel system damage.
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Fuel contamination
Running a diesel engine out of fuel can cause air to get sucked into the system, which then needs to be vented out. This process is known as "bleeding" the fuel system, and it can be time-consuming and messy. However, it is important to note that newer diesel engines from around the year 2000 onwards are more self-serving and may not require manual priming.
Now, let's focus on fuel contamination:
The fuel injection system in diesel engines operates under extremely high pressure, and it relies on lubrication from the diesel fuel. When the fuel runs dry, the lack of lubrication can damage the high-pressure components of the fuel system. Additionally, contaminants can cause wear and tear on the internal pump components, leading to corrosion, blockages, and reduced fuel atomization.
One of the critical components vulnerable to diesel fuel contamination is the fuel injector valve. When contaminated fuel flows through the injectors, the valve begins to deteriorate, leading to a decrease in fuel pressure and volume. This, in turn, can initiate a cascade of internal engine damage that may ultimately result in complete engine failure.
To manage fuel contamination, fuel filtration plays a vital role. Modern diesel engines often use primary and secondary filters to trap contaminants before they reach sensitive components. Routine filter changes are essential, and a sudden increase in filter clogging can be a red flag indicating fuel contamination. Detecting contamination early is crucial to prevent extensive damage and costly repairs.
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Priming the fuel system
Running out of fuel in a diesel engine can be harmful and costly. Fuel injection systems in diesel engines are high-pressure systems that require lubrication. Running out of fuel can damage the high-pressure side of the fuel system. When the fuel runs dry, air gets sucked into the system and must be vented out. This process is called "bleeding" the fuel system.
To prime the fuel system, first ensure there is a reasonable amount of fuel in the tank. Then, open the bleed screw to allow air to escape. The bleed screw is a small valve with a hexagonal head and a small hole on top, typically requiring a wrench or screwdriver to open. Have a container and a rag ready to catch any fuel that escapes along with the air.
After bleeding the system, the next step is to add fresh diesel fuel. Then, turn the ignition to the "Run" position for 30 seconds, but do not start the engine. This allows the pump to prime the system. Turn the ignition off, then crank it for 15 seconds. If the engine does not start, repeat the previous steps until it does. If the engine starts but stalls, wait a minute before attempting to start it again.
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Frequently asked questions
The engine will shut down and will need to be refuelled. However, running out of diesel can cause air to enter the fuel system, which can lead to engine stalling and fuel system damage.
Air enters the fuel system when a diesel engine runs out of fuel, disrupting the normal fuel flow and combustion process. This can cause the engine to sputter, misfire, or fail to restart.
First, add fresh diesel fuel. Then, prime the fuel system by turning the ignition on for 30 seconds without starting the engine. Turn the ignition off, and then crank it for 15 seconds. Repeat these steps until the engine starts.
Running out of diesel fuel can lead to a chain reaction of problems, including engine stalling, fuel system damage, clogged fuel filters, and contaminated fuel.
Regularly monitor fuel levels and refuel before the tank is completely empty. Address warning lights promptly and follow maintenance schedules to avoid potential issues.
