In an effort to reduce harmful emissions, the introduction of Ultra Low Sulfur Diesel, and the design and implementation of the High Pressure Diesel Injection System for diesel powered engines, including HPCR, HEUI and CRDi, 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 modern technology that power most of today’s diesel-engined vehicles and machines.

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 substantially. As a consequence, the fuel must comply with pre-defined values for viscosity and lubricity as most, if not all, of the components of the high pressure pumps and injectors are lubricated entirely by the fuel. Being free of any contamination that would lead to abrasive component damage at the extremely high pressures involved is paramount to correct fuel delivery and combustion.

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 modern high pressure injection systems, they are incredibly susceptible to fuel contamination. Very small amounts of water or contamination will wreck pumps and injectors. High pressure injectors (HPCR/CRDi/HEUI) can 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

Modern diesel injectors and fuel pumps are often very expensive ($2000 per injector is not uncommon). They run incredibly fine tolerances, and are highly stressed due to enormous pressures and very high temperatures. Compared to older technology diesel injection systems, they are totally unforgiving. They’re often non-repairable, so it usually means new components when total failure occurs.

Common problems with modern, High Pressure 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-fueling 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 ULS Diesel Enhancer before you rebuild or replace your injectors!