Rajan Wilcox
Diesel fuel lines are an essential component of any diesel-powered vehicle, but they can be prone to issues with air in the fuel system and fuel gelling in cold temperatures. While there is limited information on whether newer diesels have heated fuel lines, some solutions exist to prevent fuel lines from freezing, such as using fuel additives or installing electric in-line fuel heaters. These heaters are designed to be installed before the main fuel filter and can thaw frozen diesel fuel in just a few minutes. Additionally, some users have suggested using heating pads or heat tape to wrap around the fuel tank and lines, although this may not be as effective as the fuel continues to cool as it passes through the lines.
| Characteristics | Values |
|---|---|
| Fuel line issues in diesel engines | Air in the fuel system, inefficient fuel pump |
| Solutions to fuel line issues | Bleeding the fuel lines, using electric fuel pumps, adding anti-gelling fuel additives, using heating pads or heating wire |
| Fuel line materials | Stainless steel, steel high-pressure tubing |
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What You'll Learn
Electric fuel pumps in newer diesels
Newer diesel engines, whether common-rail or unit-injector systems, usually have at least one electric fuel pump, with some having two electric pumps and a mechanical high-pressure pump. These electric fuel pumps aid in transferring fuel from the tank to the engine's injection system.
Electric fuel pumps can be used as a fuel pre-pump for diesel engines, as a temporary solution for repairs, or as an additional pump that can be switched on depending on demand. They can also be used as a refilling or supply pump in refilling systems, additional tanks, or heating systems. In modern designs, the pumping stage is seated directly on the shaft of the electric motor, allowing the fuel to pass through the pump and simultaneously cool and lubricate it.
There are two main types of electric fuel pumps: flow pumps and positive displacement pumps. Flow pumps operate at lower pressures (0.2 to 3 bar) and do not require flaps or valves for the fuel to pass through. However, they are not self-priming, meaning they must always be placed below the liquid level within the fuel tank. On the other hand, positive displacement pumps are used for higher system pressures (up to approximately 6.5 bar) found in conventional injection systems.
When considering upgrading the fuel system in a diesel engine, it is important to choose a pump that is specifically designed for diesel engines. Companies like FASS Fuel Systems offer a range of options, from small electric replacement pumps to complete systems for high-end racing vehicles. Additionally, pump and filter combos offer better filtration, fuel-air separation, and higher-flowing filters that match the performance pump's capabilities.
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Bleeding diesel fuel lines
Bleeding air out of a diesel fuel system is an important process to ensure the engine works properly. Air in the fuel system can cause issues with starting the engine, reduce its power, or even cause an inability to start the engine. Air can enter the system in several ways, such as running out of fuel, leaks in the fuel lines, or after a fuel filter change.
Before attempting to bleed the air from the system, it is important to identify the key components of the diesel fuel system, including the fuel tank, fuel lines, fuel filter, and fuel injectors. It is also crucial to determine how air entered the system to prevent it from happening again.
If your fuel filter has a bleeder screw, the first step is to 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.
If your fuel filter does not have a bleeder screw, or if you believe air remains in the system, you may need to bleed the fuel system at the fuel injectors. Locate the engine's fuel injectors, which are typically connected to the fuel lines. Use a wrench or socket set to loosen the fuel line connection. Crank the engine for a few seconds to allow the air to escape, being cautious of any fuel spills. Tighten the fuel line connection once you observe a steady fuel flow without air bubbles.
Repeat this process for each cylinder and fuel injector, starting with the cylinder closest to the fuel pump and working your way to the farthest. After bleeding the fuel system, attempt to start the engine. If the engine starts, let it idle for a few minutes while checking for any issues.
Finally, properly dispose of any spilled fuel, clean up, and return your tools to their proper places. If you encounter any difficulties or persistent issues, consult a professional diesel mechanic or contact the manufacturer for assistance.
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Fuel line anti-gelling additives
One of the main disadvantages of diesel fuel is its poor performance in cold weather. When temperatures drop, the wax in diesel fuel can cause it to gel or crystallize, clogging fuel lines and filters. This can prevent engines from starting and even lead to costly repairs if the engine is damaged. To prevent this, fuel line anti-gelling additives can be used.
The amount of anti-gelling additive required depends on the temperature and the volume of fuel being treated. For example, a 16 oz. bottle of Hot Shot's Secret Diesel Winter Anti-Gel treats 125 gallons of diesel fuel, while a 1-quart bottle treats 250 gallons. It is recommended to use anti-gelling additives anytime temperatures drop below 32°F (0°C).
In addition to preventing clogged fuel lines and filters, anti-gelling additives can also improve the quality of standard diesel fuel. They can enhance detergency, stability, lubricity, and winter operability, as well as boost the fuel's cetane number. Anti-gelling additives are safe for use in all diesel engines, including semi-trucks, pick-up trucks, farm equipment, and standard-sized automotive vehicles.
For emergency situations where fuel or fuel filters have already frozen, there are specialized additives, such as Fuel Ox™ Heat Bomb, that can dethaw fuel and de-ice filters, restoring the flow of frozen fuel lines.
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Diesel heater fuel line maintenance
Diesel fuel lines are prone to air ingress, especially after major engine work. This can lead to fuel starvation and engine issues. To prevent this, diesel fuel lines should be "bled" to remove air from the system. This is done by starting from the tank and using either an electric or mechanical pump to push fuel through the lines to the injectors, ensuring no air is left in the lines. Some systems have multiple bleed valves that should be opened to allow air to escape and then closed when diesel begins to escape.
In cold environments, diesel fuel can freeze and block fuel lines. To prevent this, fuel line heaters are available that can thaw frozen diesel fuel in 3-4 minutes. These heaters are installed before the main fuel filter and adjust their heat output automatically based on fuel temperature. Additionally, a diesel blend with kerosene can help lower the cloud point of the fuel, improving performance in cold climates.
After using a diesel heater, it is important to store it away inside and cover it with a tarp or blanket to prevent blockages in the fuel lines. For long periods of non-use, the fuel tank should be drained or the fuel used up to prevent blockages. If wax forms in the diesel fuel, it will block fuel lines and filters, and the heater may not start due to fuel starvation. This can be identified by a white or yellow deposit or cloud in the fuel. The fuel lines, filters, and nozzle should be cleaned or soaked in diesel or kerosene regularly, especially in cold, dusty, or dirty environments.
It is important to note that any electrical work or servicing of a diesel heater must be completed by a qualified person. If the plug or lead is damaged, it should be replaced by a qualified individual, and the manufacturer or seller should be contacted if the heater is under warranty.
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Fuel line diameter and wall thickness
Fuel lines are used to transport fluids, gases, and solid particles, and are also used in industries such as construction, chemical, metallurgy, and more. The specification of a fuel line typically includes its outer diameter (OD), wall thickness (WT), length (L), and other factors. The outer diameter refers to the outside diameter of the fuel line, usually measured in inches. The inner diameter, on the other hand, is the diameter of the inside of the fuel line and is typically smaller than the outer diameter.
Wall thickness is usually expressed in nominal wall thickness (SCH), with larger SCH values indicating thicker walls. For example, a wall thickness of 0.109 inches is represented by SCH40, while SCH80 represents a wall thickness of 0.179 inches. It is important that the wall thickness meets the requirements of the application to prevent potential issues.
The size of fuel lines can vary depending on the specific application. For instance, Scheid Diesel offers fuel lines ranging from 0.062" inner diameter for smaller applications to 0.140" for larger fueling applications.
When determining the appropriate fuel line diameter, it is important to consider the recommendations of in-line fuel pump manufacturers to ensure optimal performance and prevent issues such as starving the pump. Additionally, the type of fuel used can impact the required fuel line size. For example, when using ethanol or methanol, it is recommended to increase the fuel line size compared to a gasoline requirement.
To maximize energy efficiency and prevent fuel contamination, some fuel lines are equipped with electric in-line fuel heaters. These heaters are designed to thaw frozen diesel fuel and automatically adjust their heat output based on the fuel temperature.
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