Regan Brown
Running out of fuel in a diesel engine can be a costly mistake. The high-pressure fuel injection system in diesel engines requires lubrication, which it gets from the diesel fuel. When the fuel runs out, air gets sucked into the system, and the engine shuts down. This air must be bled or purged from the system before the engine can be restarted. The process of restarting a diesel engine after it has run out of fuel depends on the age of the engine. Older mechanical engines require manual priming of the fuel system, while newer engines from around the year 2000 are self-priming.
| Characteristics | Values |
|---|---|
| What not to do | Do not start the engine without fuel as injectors and other parts could be damaged due to lack of lubrication. |
| What to do | Add fuel, bleed the lines and injectors. |
| Older setups | Require physical input to get their engines re-fired. |
| Newer setups | Self-priming |
| How to prime the fuel system | Turn the ignition on (Run position) for 30 seconds, but do not start the engine. Turn the ignition off, and then crank it for 15 seconds. If it does not start, repeat the process. |
| If the engine starts but immediately stalls | Wait for one minute before making another attempt. |
| Once the engine starts | Allow it to idle for several minutes and check for any leaks before driving. |
| If the engine doesn't start after several attempts | Take a break and then repeat the process. |
| If the engine runs rough or produces white smoke | Have your vehicle checked as soon as possible. |
| If the engine fails to start | Do not crank the engine for more than 10 seconds as starter damage may occur. Switch the ignition off and wait 30 seconds before cranking the engine again. |
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What You'll Learn
Restarting a diesel engine after running out of fuel
Running out of fuel in a diesel engine can be harmful and potentially ruin the entire fuel system. This is because diesel fuel acts as a lubricant for the high-pressure fuel injection system. When the tank is empty, air gets sucked into the system and must be vented, or "bled", out.
If you have run out of diesel and refuelled your vehicle, but it still won't start, there are a few things you can try. Firstly, check that the electrical parts of the engine are functioning properly. If they are, you may need to loosen the injector fuel lines and then crank the engine until fuel starts to flow. After this, retighten the lines and attempt to start the engine.
If your engine still won't start, you may need to prime the fuel system. To do this, turn the ignition on (to the "Run" position) for 30 seconds, but do not start the engine. Then, turn the ignition off and crank it for 15 seconds. Repeat these steps until the engine fires up. If the engine starts but immediately stalls, wait for one minute before attempting to start it again. Once the engine starts, let it idle for several minutes and check for any leaks before driving.
If your vehicle is out of fuel and on a steep grade, you may need to add more than 4-5 gallons (15-19 litres) of fuel to restart the engine. You must also purge any trapped air from the system by repeating the process of switching the ignition on for 30 seconds and then off six times in a row.
It's important to note that newer diesel engines, roughly from the year 2000 onwards, are more self-serving when it comes to the priming process. They may also have self-bleeding systems. However, older diesel engines may require physical input to get their engines restarted, such as bleeding the lines and injectors.
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Bleeding the fuel system
Before attempting to bleed the air from the fuel system, it is important to determine how air entered the system in the first place so that it does not re-enter after the bleeding process. Air can enter the system in several ways, including running out of fuel, leaks in the fuel line, or following a fuel filter change.
- Familiarize yourself with the engine and identify the key components of its diesel 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.
- Use a wrench or bleeder screw key to slowly loosen the screw in a counterclockwise direction.
- Cover all venting units to prevent spills.
- Force fuel through the system and push the trapped air out, following the specific order outlined in your vehicle's manual.
- Tighten the bleed plug and attempt to start the engine.
- If the engine does not start or runs poorly, repeat the steps for the primary filter, fuel pump, and injection lines.
It is important to note that modern vehicles are often equipped with self-bleeding capabilities, but a manual bleed is sometimes necessary. Additionally, consider replacing your fuel filter if it is old or at the end of its life.
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Priming the fuel system
When a diesel engine runs out of fuel, air gets sucked into the system, which must be vented (bled) out. This is necessary to ensure that the system is properly filled and there is no remaining air inside, which would interfere with fuel delivery and engine operation. Modern vehicles have systems that allow for easy air extraction without using too many tools.
To prime the fuel system, first, ensure there is a reasonable amount of fuel in the tank. The system will start drawing fuel, and it may draw air again if there isn't enough. Then, locate the bleed screw, which is usually a small valve with a hexagonal head and a small hole on top to insert a tool for opening and closure. Depending on its head design, you will need either a wrench or a screwdriver to open it. Place a container and a rag beneath the bleed screw to collect any escaping fuel and to clean up any mess.
Now, turn the ignition on (Run position) for 30 seconds, but do not start the engine. Turn the ignition off, then crank it for 15 seconds. If it does not start, repeat the previous steps until it does. If the engine starts but immediately stalls, wait for a minute before attempting again.
Once the engine starts, let it idle for several minutes and check for any leaks before driving. Finally, dispose of any spilled fuel, perform general clean-up, and return your tools to their proper location.
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Potential damage to the fuel system
Running out of diesel fuel can lead to a series of issues, with engine stalling being the most immediate and obvious. However, the potential damage to the fuel system is a more severe and costly problem.
Firstly, diesel engines operate under extremely high fuel pressure, and the fuel injection systems require lubrication due to the very tight tolerances in the high-pressure pump. This lubrication is provided by the diesel fuel itself. Therefore, running out of fuel can cause damage to the high-pressure side of the fuel system due to a lack of lubrication.
Secondly, when a diesel engine runs out of fuel, air gets sucked into the system, and if the engine is cranked for too long with a dry pump, contaminants from the bottom of the fuel tank can be introduced into the fuel system. This can lead to fuel contamination and clog or damage the fuel pump, filter, rail, and injectors. The repair costs for such damage can be significant, potentially running into thousands of dollars, and the vehicle may be out of action for weeks.
Newer diesel engines from around the year 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 a matter of minutes without leaving the driver's seat. However, older diesel engines may require manual priming of the fuel system, which can be time-consuming and messy.
In conclusion, allowing a diesel engine to run out of fuel can cause serious damage to the fuel system, resulting in costly repairs and extended downtime. Therefore, it is essential to regularly monitor fuel levels and address warning lights promptly to prevent this risky scenario.
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How to avoid running out of fuel
Running out of diesel can have serious consequences for your vehicle, so it's important to take steps to avoid this preventable issue. Here are some detailed instructions on how to avoid running out of fuel:
Firstly, it is crucial to monitor your fuel levels regularly. Keep a close eye on your fuel gauge and don't ignore the "low fuel" light. This simple habit can help you avoid the hassle and potential damage caused by running out of diesel.
Additionally, be mindful of how much fuel is in your tank, especially if you're driving an older vehicle. When fuel levels get too low, the fuel pump may draw air through the fuel system, leading to an abrupt shutdown. This can be dangerous, especially when driving on busy roads.
To prevent this, always ensure you have sufficient fuel in your tank. Keep your tank filled and avoid letting the fuel level drop too low. This is especially important for older vehicles, which are more susceptible to pulling debris and sediment from the bottom of the fuel tank, leading to clogged fuel filters and engine problems.
For added peace of mind, consider using real-time maintenance alerts, such as those offered by T3's operating system, to be notified when your machine is running low on fuel. This extra layer of defense can help you stay on top of your fuel levels and avoid unexpected empty tanks.
By following these instructions and staying vigilant about your fuel levels, you can significantly reduce the chances of your diesel vehicle running out of fuel and potentially save yourself from costly repairs and inconveniences.
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Frequently asked questions
First, do not attempt to start the engine without fuel as injectors and other parts could be damaged due to a lack of lubrication. If you have extra diesel, add 4-5 gallons of fuel to your tank and restart the engine. If your vehicle is on a steep grade, you may need to add more than 5 gallons.
You will need to purge any trapped air from the system before restarting the engine. Turn the ignition on for 30 seconds, then turn it off. Repeat this process six times in a row. If the engine still won't start, it may be due to a vacuum leak on the fuel suction side.
Your fuel pump might send air through your fuel system instead of gas, causing your vehicle to shut down. To fix this, you will need to "bleed" the fuel system, which can take several hours and may require a service call.
Always keep an eye on your fuel gauge and be mindful of how much fuel is in your tank. Use real-time maintenance alerts to learn when your machine is running low on fuel.
Running out of diesel fuel can potentially damage your entire fuel system, including the pump, injector pump, and injectors. This can result in costly repairs and weeks of downtime.
