Mercedes Mullins
Running out of diesel in your car is a situation best avoided. If you do run out, your engine will cut out, and you will need to add more fuel to your tank. However, this is not always a simple process, and the fallout from an empty fuel tank can be complicated, time-consuming, and costly. When you run low on diesel, your fuel pump might send air through your fuel system instead of gas, which can damage the fuel lines, block the fuel filter, and even damage the engine itself. This is called bleeding the fuel system, and it can take several hours to complete. If you have a CP4 injection pump, you may need a brand new fuel system, which can cost thousands of dollars. To prevent your car from running out of fuel, it is important to always have a full gas tank and avoid driving on empty.
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What You'll Learn
Injectors may be damaged
Injectors are a component of diesel engines that help spray diesel fuel into the engine's cylinders. They are responsible for providing the right amount of fuel to the engine to help it run properly. When a diesel engine draws in air instead of fuel, the injectors can become damaged. This is because diesel fuel is used to lubricate the moving parts of the injectors.
If your diesel car runs out of fuel, the damage to the injectors is already done, and there is not much you can do about it. Injector pullers can be expensive, and even if you have one, pulling the injectors usually requires removing the cylinder head, which is a big job. The best advice is to not let your car run out of diesel in the first place.
The high-pressure diesel is injected into the engine's cylinders as droplets. The smaller the injectors squirt, the finer the atomization. The only time an injector will break is typically when diesel runs out. This could be because you ran out of fuel or because the "check engine" light came on.
If your diesel car does run out of fuel, there are a few things you can do to get it running again. Firstly, find a safe place to pull over and make sure your hazard lights are on. Call for help, whether from a friend or relative who can bring you more fuel, or roadside assistance. If you have extra diesel nearby, the whole ordeal could only take a few minutes.
However, if your fuel pump has been sending air through your fuel system instead of gas, your vehicle will shut down and not restart until the air is removed. This process is called "bleeding" the fuel system and can take several hours, depending on your machine. Some machines have self-bleeding systems, but most require a service call.
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Fuel pump issues
If your diesel car runs out of fuel, your fuel pump may be damaged. The fuel pump is responsible for sending diesel to the injectors. When there is no fuel left in the tank, the pump starts to draw in air, which can cause it to overheat and eventually wear out. This is a particular issue for diesel engines, as diesel fuel is used to lubricate the pump's moving parts.
Additionally, the poorest-quality fuel settles at the bottom of the tank, and it is often full of sediment. When this sediment is drawn into the fuel system, it can clog or break the pump, filter, rail, and injectors. This can lead to costly repairs, with parts costing thousands of dollars.
If your fuel pump is damaged due to running out of fuel, you will need to bleed the air from the system before refilling the tank. This can be time-consuming and may require a specialist. Some newer vehicles have self-bleeding systems, but most will require a service call.
To prevent fuel pump issues, it is important to always keep your tank full and avoid driving on empty. If your car does run out of fuel, you may need to replace the fuel pump, filter, and injectors.
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Restarting the engine
If your diesel car runs out of fuel, the first thing to do is find a safe place to pull over and turn on your hazard lights. It is not safe to remain on the road or hard shoulder of a motorway.
Once you have refuelled, you can attempt to restart the engine. If your car has modern self-priming or self-bleeding technology, it may start up again with some cranking of the engine. However, if your car is older, you may need to bleed the air from the system by hand, which can be time-consuming and messy.
If your injectors have been damaged by a lack of lubrication, you will need to remove the cylinder head and use an injector puller to fix the problem. This can be expensive and time-consuming, with some estimates putting the cost of parts at around $6,000.
To prevent damage to your engine, it is always best to keep your tank full and avoid driving on empty.
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Bleeding the fuel system
- 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.
- Work with the fuel filter by turning off the engine and removing the ignition key from the cylinder.
- Locate the fuel filter and determine if it has a built-in bleeder screw. If it does, position a clean rag or towel beneath the bleeder screw to catch any fuel spills, and use a wrench or bleeder screw key to slowly loosen the screw in a counterclockwise direction.
- Cover all venting units to prevent spills, and then 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 the system. Pump multiple times until you see a steady flow of fuel, then tighten the bleed plug.
- Attempt to start your engine and evaluate its condition.
- If the engine starts, run it until it runs smoothly. This will bleed the other injectors.
- Finally, properly dispose of any spilled fuel, clean up, and return your tools to their proper location.
It is important to note that some newer diesel engines have self-bleeding systems, but a manual bleed is often recommended. Additionally, before attempting to bleed the air from the fuel system, ensure you have determined how air entered the system to prevent it from re-entering after the bleeding process. Bleeding the fuel system can be time-consuming and challenging, so if you encounter any difficulties or persistent issues, consult a professional diesel mechanic or the manufacturer for assistance.
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Cost of repairs
Running out of diesel can cause serious damage to your vehicle and lead to costly repairs. When your diesel car runs out of fuel, it will start sucking in air, which will cause problems when you try to start it again. This is known as "bleeding" the fuel system, and it can take several hours to complete.
The air in the fuel system disrupts the normal fuel flow and combustion process, causing the engine to sputter, misfire, or fail to restart. This abrupt shutdown can be risky, especially if you're driving on a busy road or highway, and it can lead to accidents or traffic disruptions.
The presence of air in the fuel system can also result in cavitation, where tiny air bubbles implode inside the fuel pump and other components, causing damage to the fuel pump, injectors, rails, and other vital parts of the fuel system. Repairing or replacing these components can be expensive.
Additionally, running out of fuel can stir up debris and sediment at the bottom of the fuel tank, clogging the fuel filter and damaging the fuel pump, filter, rail, and injectors. You might need to replace one or all of these parts, resulting in weeks of downtime and thousands of dollars in repair costs, depending on parts availability and the severity of the maintenance issues.
To avoid these costly repairs, it is important to keep your diesel fuel tank full, especially when travelling down unpredictable or unfamiliar routes. Regularly monitoring fuel levels, following maintenance schedules, and addressing warning lights promptly can help prevent this situation.
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Frequently asked questions
If a diesel car runs out of fuel, the engine will shut down and the injectors may be damaged. The engine may start again after adding more fuel, but if not, you will need to bleed the fuel system by removing the air that has been sent through the system instead of fuel.
Bleeding the fuel system can be time-consuming and costly. You will need to remove the air from the fuel lines and injector pumps. Some modern vehicles have self-bleeding systems, but most require a service call.
If you don't bleed the system, your engine will not start or run properly.
The fuel pump, filter, rail and injectors can be damaged by sediment from the bottom of the fuel tank. This can clog or break these parts, and you might need to replace them.
Always ensure that you have a full gas tank and avoid driving on empty.
