Ameer Randolph
Diesel fuel systems are a critical component of any diesel engine, and their optimal operation is essential for peak performance. Filtering diesel fuel is a crucial step before using it, as it often contains water, which can cause significant damage to the injection system. To pump and filter diesel fuel, you will need equipment such as a pump, filters, hoses, and clamps. The process involves connecting the pump to the filter outlet to ensure the fuel is filtered before reaching the injection pump. It is common to have multiple filters, such as a water/fuel separator and a primary and secondary fuel filter, to ensure the fuel is free of contaminants.
| Characteristics | Values |
|---|---|
| Type of fuel lines | Heavyweight, medium weight, and lightweight |
| Number of times diesel fuel must be filtered | Several times, typically three stages of progressive filters |
| Types of filters | Series filters, parallel filters |
| Simple fuel systems | Use gravity or air pressure to get fuel from the tank to the injection pump |
| Modern high-speed diesel engines | Use a fuel transfer pump |
| Four primary systems for injecting fuel | 1. Individual pump and injector for each cylinder. 2. Combined pump and injector for each cylinder (unit injector type). 3. One pump serving injectors for several cylinders (distributor type). 4. Pumps in a common housing with injectors for each cylinder (common rail system). |
| Common enemy of diesel fuel systems | Water |
| Ways to prevent premature failure of fuel pumps and injectors | Use E-ZOIL additives to increase fuel system lubricity |
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What You'll Learn
Types of fuel pump
Fuel pumps are a vital component of diesel engines, responsible for powering the vehicle by utilising an internal combustion system. The injection pump acts as the engine's heartbeat, powering the entire system.
There are several types of fuel pumps for diesel engines, each with unique characteristics. Here are some of the most common types:
Common Rail Fuel Injection Pump
The common rail fuel injection pump is an electronically controlled diesel fuel supply system. It consists of a supply pump, a common rail, electronically controlled injectors, various sensors, and a computer that manages the system. The engine drives the supply pump, which produces high-pressure fuel. The common rail then distributes the fuel to the injectors, which are mounted on each cylinder of the engine. This type of pump was developed to meet strict exhaust gas regulations and improve fuel efficiency.
Distributor (Rotary) Fuel Injection Pump
The distributor injection pump is a compact and lightweight design, making it ideal for small engines. It is controlled electronically by sensors, an electronic control unit, and an actuator. Unlike inline pumps, each cylinder on a rotary pump operates independently, allowing them to fail separately. The distributor injection pump has a single fuel pressure mechanism, regardless of the number of engine cylinders. It distributes pressurised fuel to each cylinder following a specific injection order.
Inline Fuel Injection Pump
The inline fuel injection pump is mechanically controlled and is commonly used for medium to large trucks and construction machinery. It has a plunger for each injector and cylinder, with the number of plungers and injectors matching the number of cylinders. The plungers are operated by a camshaft, which derives its power from the engine crankshaft. Inline pumps can generate extremely high pressure, making them suitable for heavy-duty applications.
High-Pressure Common Rail Pump
The high-pressure common rail pump has a unique design compared to rotary and inline pumps. It features revolving pistons, one inlet, and one or two outlets. The outlets are connected to a rail that supplies pressure to the system, while the ECU controls fuel distribution.
These are just a few examples of the types of fuel pumps used in diesel engines. Each pump is designed to meet specific requirements and applications, ensuring the efficient and reliable operation of diesel-powered vehicles and machinery.
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Types of fuel filter
Diesel fuel filters are designed to protect the fuel system components of the engine by removing extremely small particles to prevent engine failure. Modern diesel engines are more powerful and energy efficient, but they require very clean fuel.
There are several types of fuel filters, including primary and secondary fuel filters. The primary filter cleans out larger particles, such as dirt, rust flakes, waxes, and water, using a relatively coarse medium. It is usually rated to remove particles ranging from 10 to 15 microns in size. The secondary filter, on the other hand, is responsible for finer filtration, removing particles ranging from 3 to 5 microns in size. It is mounted directly onto the engine and operates at a much higher pressure than the primary filter. This ultra-fine filtering ensures that only the cleanest fuel reaches the sensitive injection components.
In addition to the primary and secondary filters, some diesel fuel systems may also include a fuel screen located at the fuel tank or transfer pump. This acts as a pre-filter to protect the fuel pump and prevent larger debris from clogging the post-pump filter. These pre-filters are often called "sock filters" or "fuel strainers".
The type of filter used also depends on the material. Paper filters, also known as cellulose filters, are disposable but should not be used with methanol or fuels containing more than 20% ethanol. Stainless steel filters are compatible with all fuels and can be cleaned and reused. Micro Glass filters, on the other hand, are for post-pump use only and are also disposable.
It is important to choose the right type of fuel filter for your diesel engine and to replace them regularly to ensure optimal performance and protect your engine from contamination.
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How to prime a diesel fuel filter
To prime a diesel fuel filter, you must ensure that your engine starts up because the fuel filter has diesel available and that all air is removed from the fuel system. This step is necessary if you are changing the fuel filter or if your diesel engine runs out of fuel.
Most diesel engines have a manual primer pump and an air-bleed screw that can be used to bleed the air and prime the pump. To operate these manual features, pump the primer handle (this can take anywhere from 50 to 500 pumps) while turning the screw until the hissing noise of escaping air stops. Once the noise stops, tighten the screw and try to turn the engine.
In some diesel engines, priming the fuel pump is as simple as turning the ignition key to "run" for several seconds, turning it off, and then repeating up to four times. After the fourth or fifth turn, crank the engine, which should start. Ensure that you let the engine run for 30 seconds before turning it off and inspecting the fuel filter for any leaks.
It is important to note that if your engine still won't crank, it may be a sign of a more serious problem that should be examined by a certified diesel mechanic.
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How to prevent water in the fuel system
Water in a fuel tank can cause serious damage to a vehicle, including rust and corrosion, which can spread to other important parts of the fuel system. Water can enter the fuel supply in several ways, including condensation, rain, and bacterial growth. Therefore, it is important to regularly inspect your vehicle's fuel system and take preventive measures to stop water from entering the fuel supply.
Firstly, it is important to keep the fuel tank as full as possible to minimise air space and avoid condensation. Refuelling during cooler periods can also prevent temperature changes that contribute to condensation. Additionally, the fill pipe must be properly capped and sealed to prevent rainwater from entering the tank. A well-maintained gas cap offers an appropriate seal, and if the gas cap is faulty or worn, it should be replaced.
Underground tanks should have a suitable gasket around the plug to prevent water from seeping in after a rainstorm. The gasket must be tight and in good condition to provide a dependable seal. Large bulk storage tanks should be checked for condensation accumulation and bled periodically to prevent water from being drawn out with the oil.
Water-absorbing treatments can be used to remove water from the tank and preserve the maximum volume of fuel. Fuel additives can also be used to disperse water by breaking down water particles into smaller sizes and preventing the formation of larger droplets. Water removal products are essential treatments as they combat rust and corrosion, prevent fuel line freeze, and remove water, slime, and contaminants.
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How to prevent fuel system failure
Diesel fuel systems require fuel to be injected at high pressure into each engine cylinder at the right time. The fuel pump is responsible for delivering fuel from the tank to the engine at the correct pressure.
- Maintain fuel quality: Use high-quality, clean diesel fuel from a reliable source to prevent contaminated fuel, which is a leading cause of fuel pump failure. Contaminants such as dirt, water, and other impurities can damage the fuel pump and injectors. Regularly test and clean fuel tanks, especially if they have been sitting idle for extended periods.
- Regularly replace fuel filters: Fuel filters help trap contaminants and prevent them from reaching critical engine components. Follow the manufacturer's recommendations for fuel filter replacement intervals, typically every 40,000 miles or annually.
- Ensure adequate lubrication: Diesel fuel pumps require lubrication to operate smoothly. Use appropriate lubricants and maintain the engine's oil and fuel system to prevent excessive friction and wear on pump components.
- Maintain fuel levels: Avoid letting your fuel tank get too low. Keeping a quarter tank of fuel or more helps prevent injection pump problems and ensures adequate fuel pressure. Running the tank low can push air through the system instead of fuel, wearing out pump bearings and affecting fuel injection.
- Prevent overheating: Ensure your engine's cooling system is functioning correctly, and install proper ventilation and heat shields to protect the fuel pump from excessive heat, which can lead to leaks and reduced efficiency.
- Store vehicles properly: If a vehicle is left unused for an extended period, store it with a full tank of fresh diesel fuel and add a fuel stabilizer to prevent fuel degradation, clogs, and corrosion in the fuel system.
By following these preventative measures, you can help maintain the performance and longevity of your diesel engine and reduce the risk of fuel system failure.
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Frequently asked questions
If you notice a black sediment in your diesel tanks, it may be time to filter your fuel. This sediment could indicate the presence of biological growth or water in your fuel, which can cause damage to your engine.
A fuel transfer pump is typically used to supply fuel to the diesel injection system. A HEP-02A pump is one example of a pump that can be used for this purpose.
It is recommended to use multiple filters to ensure the diesel is free of contaminants. A combination of a water separator and a WK 820/1 filter can be effective.
It is recommended to place the filters before the lift pump to ensure optimal flow and accessibility.
Yes, there are three types of diesel fuel lines: heavyweight, medium weight, and lightweight. The type of line used depends on the pressure of the fuel system.
