Why Does a Fuel Pump Fail in Diesel Engines?

The fuel pump is normally one of the first things to fail in a diesel engine due to the high pressure and particular operation that diesel systems require. Diesel fuel systems differ from their gasoline counterparts, where pumps in common rail systems must supply up to 30,000 psi of pressure, notably wearing down their components over time.
Contamination ranks high among diesel engine pump failures. Diesel fuel is normally contaminated with water, debris, or microbial growth that may destroy internal components of the pump. According to research carried out by ASME, 30% of all diesel fuel pump failures result from water contamination, which corrodes the pump, reducing its efficiency. The risk of this is minimized if fuel with the best quality is used and filters are changed every 15,000 to 30,000 miles.

Extreme heat is one of the major contributing factors to pump failure. Diesel pumps work harder compared to gasoline pumps, hence producing greater amounts of heat. If not cooled properly, the internal parts of the seal and bearing wear out faster. Running the vehicle when the fuel in the tank is below 25% invites overheating since fuel is supposed to cool the pump. This will reduce the life expectancy of the pump up to 40% if this condition continuously happens.

Low-lubricity fuel is another challenge for diesel systems. Modern low-sulfur diesel (ULSD) fuels provide less natural lubrication, increasing wear on the pump’s moving parts. Mechanics frequently observe pump failures in vehicles that run exclusively on ULSD without the use of fuel additives. These failures are preventable with lubricity enhancers, which improve the fuel’s protective properties.

Real-world examples show the impact of pumps failing. In 2020, a large-scale recall involving 250,000 diesel trucks addressed fuel pump issues linked to low-lubricity fuel and contamination. Drivers reported symptoms such as difficult starting, loss of power, and engine stalling, all traced back to failing pumps.

Diagnosis of pump failure includes fuel pressure testing and an inspection for contamination. Pressure readings below the manufacturer’s specifications usually point to pump wear or blockages. Regular maintenance, such as draining water separators and utilizing high-quality additives, minimizes the possibility of failure.

Replacement of a failing pump with a quality alternative such as Kemso Fuel Pumps provides longevity and a predictable service life. These pumps are designed for high-pressure diesel systems and to endure difficult working conditions.

See the Fuel Pump for more informative content and reliable replacement solutions. Preventive care with quality components will pay long-term dividends and eliminate costly repairs to the motor.

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