Emulsifier Damage to Diesel Fuel Injection System

Bill Technician Rosetown, Saskatchewan Posted   Latest   Edited  

I have read literature on emulsifier damage to diesel fuel injection systems, for example … which states "Emulsification of water in the fuel can allow water to get past the fuel filter/water separator, in most cases causing damage to other components of the fuel system."

Has anyone had any 1st hand experience with this type of damage? 

I wonder how long it takes, and what conditions cause the worst damage when using an emulsifier.

I recently had a vehicle in that had Diesel Melt added to a system that was using a demulsifier system (Additive and Filters). It should have never had the additive installed and fairly new injectors (60K KM) have failed in the vehicle. With the filter set up on the vehicle the fuel entering the system is the cleanest I have ever seen as far as particles. I am trying to have a better understanding from the experience of others whether or not the early injector failure could have been a result of the alcohol based additive.

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Albin Diagnostician
Leavenworth, Washington
Albin Default
 

In any diesel fuel system, water is a killer. It can take only a few drops of water getting past the filter to kill a system. Water dispersants should never be used in diesel fuel. Yes, I know that many diesel additives have that stuff in them, and that is why labels should always bee read before pouring the miracle juice into the fuel tank. The older fuel systems could stand more water than…

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

Thank you for the feedback Albin. I agree.

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Harm Technician
Fergus, Ontario
Harm Default
 

Is diesel fuel out there that questionable? What kind of vehicle / engine are you working on? Does it have an electric lift pump? I have seen a lot of aftermarket injectors failing in that time or less.

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

The fuel is questionable when it comes out of farm tanks. I have seen the aftermarket failures in short order as well. I have never used an aftermarket injector. Bosch or Bosch reman or I don't do the job.

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David Owner/Technician
St. Albert, Alberta
David Default
 

There will always be a bit of water in your diesel fuel, engine oil, hydraulic oil, etc. A tiny bit of H20 is mixed into it from atmosphere. Oil and water DO MIX! Just not in large amounts (PPM). As saturation occurs, the water will drop out to the bottom of what ever container the oil is in. Not good for what we want. The problem with emulsifiers, as I understand, is they keep the higher…

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Bill Technician
Rosetown, Saskatchewan
Bill Default
   

Thanks David, The fuel was supposed to be filtered from his farm tanks as I had recommend. It had a fass system for in tank cleaning. It ran through a CAT 175-2949 (edit... WIX 33522 was on the truck) then a 1R-0750 and finally through a TP3018. Periodic filter draining by customer. It was recommended to use stanadyne performance blue, and to NEVER use an emusifier. Never use anything but…

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Harm Technician
Fergus, Ontario
Harm Default
 

No aftermarket tune? or module. I had a gorrilla performance module go bad and go full fuel rail pressure on a cummins. it ruined all injectors and a few pistons.

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

No module. I believe I programmed it when I did the injectors to verify it was stock, but I am not certain on that. It does not feel programmed, and the programming part numbers match stock at least (no cal i.d's this year on scan tool). I pulled the program file with HPtuner, but have not reviewed it yet. It did have a P0089 set as history when it got here, and does have a bit of a regulator…

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Lee Owner/Technician
Jamesport, Missouri
Lee Default
 

What year Duramax are you talking about?

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

It is a 2003 LB7.

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Lee Owner/Technician
Jamesport, Missouri
Lee Default
   

I really think the reman injector quality for the LB7 is such that I won't install a stock set without warning the customer that very likely within 40,000 miles they will be blue smoking again. The only injectors I recommend for the LB7 is the newer SAC style 00 or 45s (the nozzles are the same style as the LLY and up) which are higher cost wise but they should be the last injectors you install…

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Bill Technician
Rosetown, Saskatchewan
Bill Default
   

Thank you Lee. What brand remans did you have issue with. These were legit bosch injectors. Not knock offs. I'll take a look at those options. Thank you for the input.

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Lee Owner/Technician
Jamesport, Missouri
Lee Default
 

Hey no problem Bill. Glad to share. The issues I had were with genuine Bosch remans. I had installed them in my Dad's 2002 that he has owned since brand new and it started white smoking at idle again after around 40,000 miles on the injectors. I also had extra filtration and a lift pump on his truck previous to the install. I thought that was completely unacceptable so I talked with John Kennedy…

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

I looked into the sac options last light. Pretty interesting, and the first I have heard of them. I wonder how many trucks they have a data base on. How may miles on your dads truck since install? On this truck I really would have liked to know how long it would have lasted if my recommendations were followed not to add diesel melt. I will never know. On top of that all my time invested into…

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Lee Owner/Technician
Jamesport, Missouri
Lee Default
 

I think they are a proven option by now. I did some checking and by now my Dad has put approximately 85,000 miles on the injectors since I had them switched to the SAC nozzles. I have several other customers running them as well and they like them. I've only installed the 45 overs so far. Either Lincoln Diesel or Kennedy would gladly answer your questions on data base. They are great to deal with.

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Bill Technician
Rosetown, Saskatchewan
Bill Default
 

Thank you lee! Very interesting stuff. I appreciate the input.

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Bill Technician
Rosetown, Saskatchewan
Bill Resolution
   

Got some pictures back of the injector and an opinion from a reputable test center. The opinion that water contamination caused the damage. On a system with a fass 150, TP3018, and Stanadyne blue usage from day one for this injector... Plus the addition, against recommendations, of diesel melt. My mind is made up that the water was in the separators and when the diesel melt was added it put the…

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