Regan Brown
Diesel fuel pumps are an integral part of any diesel engine, and their optimum operation is essential for peak performance. There are four primary systems for injecting fuel: individual pump and injector for each cylinder, combined pump and injector for each cylinder (unit injector type), one pump serving injectors for several cylinders (distributor type), and pumps in a common housing with injectors for each cylinder (common rail system). The main job of a diesel injection pump is to use pressure to send fuel from the fuel dispenser to the engine cylinders. Diesel fuel pumps are designed to be durable and robust, but their durability depends on various factors, including maintenance, design, and operating conditions. Poor fuel system maintenance and the use of contaminated diesel fuel can lead to expensive repairs. To ensure the best performance and longevity of your diesel engine, it is important to choose a suitable fuel pump and maintain it properly.
| Characteristics | Values |
|---|---|
| Purpose | To pump fuel into the cylinders of a diesel engine |
| Timing | Fuel is injected very slightly before the top dead center of the cylinder's compression stroke |
| Pressure | 10,000-30,000 PSI; newer systems can be 15,000 PSI or more |
| Lubrication | Diesel fuel pumps are lubricated by diesel fuel |
| Design | Four types: common rail, distributor, in-line, and rotary |
| Installation | Easy installation is critical for aftermarket success |
| Performance | Increased flow and pressure capabilities, durability, and functionality |
| Durability | More durable than petrol pumps due to design and operating conditions |
| Emissions | Reduced emissions compared to lesser-quality pumps |
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What You'll Learn
Diesel fuel pump types
The primary function of a diesel fuel pump is to use pressure to pump fuel from the fuel tank to the injectors. There are several types of diesel fuel pumps, each with its own unique design and functionality. Here are some of the most common types:
Common Rail Fuel Injection Pump
This is an electronically controlled diesel fuel supply system that was developed to meet strict 21st-century exhaust gas regulations. It consists of a supply pump, common rail, electronically controlled injectors, sensors to detect the engine's running condition, and a computer that controls all these devices. The common rail distributes the fuel to the injectors, which are mounted on each cylinder of the engine. This type of pump is known for its high-pressure capabilities and is becoming increasingly popular for on-road applications.
Distributor (Rotary) Fuel Injection Pump
The distributor injection pump is a compact and lightweight pump that is perfect for small engines. It is controlled electronically by sensors, an electronic control unit, and an actuator. The distributor uses a single plunger for all injectors and is designed to distribute pressurised fuel to each cylinder. This type of pump may be found on older engines.
Inline Pump
The inline pump is characterised by its individual cylinder operation, allowing them to fail separately. Each cylinder operates with its own plunger mechanism, which is placed in a line position. This type of pump is commonly used in off-road vehicles and industrial machines.
High-Pressure Common Rail Pump
The high-pressure common rail pump has a unique design with revolving pistons and one inlet and one or two outlets. The outlets are connected to a rail that supplies pressure to the system, and the ECU controls fuel distribution. This type of pump is known for its high-pressure capabilities and is often compared to the HEUI oil pump.
It is important to note that the specific type of diesel fuel pump required depends on various factors, including the vehicle's make, model, and engine type. Additionally, proper maintenance and the use of clean fuel are crucial to prevent expensive repairs.
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How diesel fuel pumps work
A diesel fuel pump is a device that sends pressurised fuel to the combustion chamber through different components in the engine. The basic principle of fuel injection is that the right amount of fuel must be injected at the right time to satisfy horsepower demands.
Diesel fuel pumps are categorised as low-pressure components, along with the fuel tank and fuel filter. The main job of a diesel injection pump is to use pressure to send the fuel from the fuel dispenser to the engine cylinders. The fuel is distributed to each cylinder individually. The diesel fuel pump provides the necessary fuel flow to run consistently.
There are four primary systems for injecting fuel:
- Individual pump and injector for each cylinder
- Combined pump and injector for each cylinder (unit injector type)
- One pump serving injectors for several cylinders (distributor type)
- Pumps in a common housing with injectors for each cylinder (common rail system)
The common rail system is becoming increasingly popular for on-road applications. The in-line and distributor types are used on off-road vehicles and industrial machines.
The injection pump is often a rotary plunger-type unit with an individual piston for each cylinder of the engine. Alternatively, it may be a single chamber pump that meters fuel to each cylinder using a sleeve or scroll system. In either case, the pump sends a small amount of fuel through the high-pressure fuel line to each injector in the appropriate sequence. When the fuel pressure exceeds the injector nozzle's pre-set pressure limitation, it opens, and fuel is injected into the combustion chamber.
Any excess fuel is sent out through a return line back to the fuel tank. A diesel engine requires a governor to regulate fuel delivery and keep the engine from overspeeding. Diesel engines are not self-speed-limiting because the air (oxygen) entering the engine is always the maximum amount.
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Diesel fuel pump maintenance
Visual Inspection and Cleaning:
- Regularly inspect the pump, engine, and associated components for any signs of wear, damage, or leaks.
- Keep the pump clean to preserve its functionality and hygiene. Use a degreaser and gentle cleanser for routine cleaning.
- Address spills and stains promptly. Soak up excess fuel with spillage absorbent granules, then use a pressure washer for stubborn stains.
Fuel and Filtration:
- Ensure that clean diesel fuel is used and that it meets the brand's requirements. Deposit the diesel for at least 48 hours before use.
- Strengthen the cleaning and maintenance of the diesel filter. Clean or replace the filter element timely.
- Completely clean the fuel tank, removing any sludge, moisture, and impurities.
Operational Checks:
- Conduct weekly operational checks to verify the pump's functionality.
- Inspect the piping and valves in the cooling system for any leaks or corrosion.
- Run the pump to ensure it starts and operates correctly, including checking pressure and flow rates.
- Test alarm and control systems to ensure proper communication with the fire alarm control panel.
Preventative Maintenance:
- Change engine oil and coolant when necessary.
- Regularly check the seal of the oil valve coupler to assess the wear of the plunger and the working condition of the oil pump.
- Maintain the accessories of the fuel injection pump, such as the side cover, dipstick, filler plug, oil spill valve, etc. Repair or replace any damaged or missing parts.
Monthly and Annual Services:
Diesel fire pumps should typically be inspected and tested monthly, with more comprehensive services performed annually. These services may vary based on local regulations and manufacturer recommendations.
Addressing Common Issues:
- Water in the injection system is a common issue. It can lead to seizure, sticky metering components, and governor/metering component failure. Use additives to prevent premature failure.
- Keep an eye on the fuel supply advance angle and camshaft bearings. Adjust or replace them if the clearance becomes too large, preventing erratic engine performance.
By following these maintenance procedures, you can ensure the optimal performance, durability, and longevity of your diesel fuel pump.
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Common issues with diesel fuel pumps
The fuel injection pump is the heart of a diesel engine's fuel delivery system. It meters and delivers fuel to the engine cylinders at high pressure and with precise timing. However, it is susceptible to various issues, which, if left unchecked, can lead to costly repairs and vehicle downtime. Here are some common problems associated with diesel fuel pumps:
Leaking Fuel Injectors or Seals
Leaking fuel injectors or seals can pose safety risks, waste fuel, and harm the environment. Leaks can be identified by fuel puddles under the vehicle and a strong fuel odour. It is crucial to replace damaged components, such as injector seals or O-rings, to prevent fuel system contamination and maintain safe operation.
Clogged Injector Nozzles
Over time, residue, grease, and grime can build up in the diesel fuel supply system, clogging the injector nozzles. This clogging can cause the engine to sputter or hesitate during acceleration. Regular injector cleaning and the use of high-quality diesel fuel can help prevent this issue.
Lack of Lubrication
Diesel fuel itself acts as a lubricant for the fuel pump bearings. Running the vehicle with a near-empty fuel tank can lead to a lack of lubrication, causing premature wear and tear on the pump bearings. This, in turn, affects the fuel pressure delivered to the injectors, compromising cylinder performance.
Water Contamination
Water in the injection system is a common issue that can lead to rapid oxidation of ferrous metal components. Water contamination can result in injection component seizure, sticky metering components, and governor/metering component failure. The use of fuel additives can help prevent water-related issues and improve lubricity.
Overheating
Continuous operation at high temperatures, insufficient lubrication, excessive load, or inadequate cooling can lead to overheating. Overheating can cause premature wear and tear on internal components, affecting the overall performance and longevity of the diesel injection pump.
To mitigate these issues, it is essential to adhere to the manufacturer's recommended maintenance schedule, including fuel filter replacements, injector cleaning, and system inspections. Regular maintenance can help detect and address potential problems early on, ensuring optimal performance and longevity of the diesel fuel pump and the vehicle as a whole.
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Diesel fuel pump manufacturers
Cornell Pump Company is a top-ranked manufacturer and supplier of a diverse range of pumps, including centrifugal pumps, agricultural pumps, and industrial pumps. They cater to various sectors such as agriculture, municipal water systems, mining, and food processing.
Motor Components, LLC is a global leader in the electronic fuel pump industry, manufacturing the well-known Facet® and Purolator® electronic fuel pumps. Their pumps are used in a wide range of industries, including automotive, agriculture, construction, military, marine, and power sports.
S&S Diesel Motorsport is another manufacturer that has been focusing on high-pressure fuel pumps. They have also developed reliability solutions for common issues, such as addressing problems with newer CP4 pumps and introducing a new DCR high-pressure pump for the 6.7L Powerstroke.
FASS Diesel Fuel Systems offers superior filtration with their Titanium Signature and Industrial Series fuel systems, making them suitable for modified applications or vehicles with ineffective OEM pumps.
Adam Pumps S.p.A. is an Italian manufacturer of pumps and meters for gasoline, diesel fuel transfer pumps, and transfer kits for transporting urea. Their products are used in waste management plants, petrochemical industries, and oil and gas refineries.
Other notable diesel fuel pump manufacturers include US Motor Works, LLC, American Fleet Inc., and Goldfarb and Associates, which offer products from brands like Bosch, Delphi, and Zexel.
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Frequently asked questions
Some signs that your diesel fuel pump may need to be replaced include sudden surges in speed, rising car temperatures, and decreased gas mileage.
There are four types of diesel fuel pumps: common rail, distributor (rotary), in-line, and unit injector. Common rail and distributor pumps are electronically controlled, while in-line and unit injector pumps are mechanically driven.
A good diesel fuel pump is one that is properly maintained and uses uncontaminated fuel. It should also be manufactured to meet or exceed original OEM specifications and be designed to increase flow and pressure capabilities, durability, and functionality.
