In an effort to reduce harmful emissions, the introduction of Ultra Low Sulfur Diesel, and the design and implementation of the Common Rail Diesel (CRD) Injection System for diesel powered engines, high technology is now an everyday part of diesel powered engines. Variable Nozzle Injector, Pressure Amplification, Closed Loop Control, Optimized Nozzle Technology, Multiple Pulse Per Cycle, and Ad Blue Injectors are all a part of the CRD technology that power most of today’s diesel powered vehicles.

However, with the higher technical performance levels required of the injection systems, the demands placed on the fuel in terms of purity and quality have also risen. As a consequence, the fuel must comply with pre-defined values for viscosity and lubricity, as components of the high pressure pumps and injectors are lubricated entirely by the fuel. Being free of any contamination that would lead to abrasive damage at the extremely high pressures involved is paramount to correct fuel delivery.

Major Problems With Ultra Low Sulfur Diesel Fuel

That is often where the problem starts. With modern diesel fuel having to meet the latest emission standards, stipulating that diesel fuel sulfur to be set at a very low level (from 5000ppm a few years ago, to 15ppm currently), it just happens to compound another problem…lubricity. At a time when fuel pumps and injectors rely even more on diesel fuel for lubrication, it has actually reduced. Because of the extremely fine tolerances in CRD systems, they are incredibly susceptible to fuel contamination. Very small amounts of water or contamination will wreck pumps and injectors. CRD Injectors often stick because of inherently low lubricity of the diesel fuel. This condition causes “Injector Rattle“ – an audible ‘machinegun-like’ noise from the engine. This condition is very serious and requires immediate attention to avoid expensive damage (Think sticking injectors causing gross over-fueling resulting in melted pistons!).

Repairing Modern Diesel Fuel Injection Systems Can Be Expensive

CRD Injectors and Fuel pumps are very expensive ($2000 per injector is not uncommon). They run incredibly fine tolerances, and are highly stressed due to enormous pressures and high temperatures. Compared to older technology diesel fuel systems, they are totally unforgiving. They’re pretty much non-repairable, so it usually means new components.

Common problems with CRD Injector systems are:

• Clogged injectors caused by contaminants – incorrect spray patterns cause a host of problems including loss of engine power, poor performance, excessive diesel smoke, excessive fuel consumption.
• Seized injectors due to lack of lubrication – caused by Ultra Low Sulfur Diesel fuel, produces over-fuelling which creates detonation inside the combustion chamber, which, if not corrected, will result in melted pistons! BIG $$$

Repairing diesel injector rattle problems can be incredibly expensive! – try CRD Fuel Enhancer before you rebuild!