DEF in fuel lines

Tiny
MOTOR MOTIVATED
  • MEMBER
  • 2014 DODGE RAM
  • 3.0L
  • 6 CYL
  • TURBO
  • 4WD
  • AUTOMATIC
  • 75,000 MILES
Hello!

I’m in urgent need of help. To make a long story short I accidentally put 2.5 gallons of DEF in a full 30 gallon fuel tank, I ran the engine for about ten seconds and got about three feet from where it was parked before the engine started shaking, turned on the water in fuel detected sign and turned off and wouldn’t run anymore.

What I have done:
1. Took off fuel tank and emptied the whole tank.
2. I cleaned the tank with water and a bit of soap and let it dry completely overnight, then installed it back on and put new diesel in.
3. I changed the fuel filter.
4. I disconnected the fuel lines and ran the fuel pump so that it would clear out whatever DEF was still in the lines a couple of times.

Truck still wouldn’t turn on after having done that. So I checked with scanner and it was throwing a code P0008 Low Fuel Pressure Rail.
So I figured it had to be clogged somewhere so I started trying to follow the lines and and check where it could be. I disconnected and took out the high pressure fuel sensor and it was completely covered in a white chunky substance which I can only assume was DEF. I cleaned it up and cleared it all and put it back on and BOOM! The engine ran.

Fast forward four days and everything was working great, until the engine starts shaking and the water in fuel lines icon pops up again. So I purged it from the fuel filter like your supposed to and it worked; the water detected symbol went away and the truck ran fine. I had to do this a couple of times through out the following two days. On the third day (seventh day from the initial day everything started) I changed the fuel filter again, and figured I would be changing them quite a bit until it cleared up any DEF residue.

The next day everything comes back again as the first day. Engine shaking, and then died. Didn’t want to run anymore. Had it towed back to the house and Hooked up the scanner, same code as last time P0008 Low Fuel Rail Pressure, so I checked the fuel pressure sensor but there was no DEF this time clogging it. Now I don’t know what the problem is and truck will not run at all.

Any help would be appreciated! I owe $30,000.00 on the truck and have no money to send to a shop. Have heard this type of issue can run up to $20,000.00 to fix!

Anything helps! Thank you so much!
Sunday, March 24th, 2019 AT 10:16 PM

2 Replies

Tiny
JOETECHPRO
  • MECHANIC
  • 705 POSTS
Hey MOTOR MOTIVATED,

I have attached the information we have for incorrect fuelling below.

Essentially the issue will be removing residue from the high pressure fuel system. Generally speaking the entire high pressure fuel system will need to be replaced in the circumstances you describe. Some manufacturers will require replacement of the low pressure side also eg. From tank all the way to injectors.

The issue is that the DEF is corrosive and abrasive and will clog injectors and damage the high pressure pump.

Have you checked with you insurance to make sure you are not covered for an incorrect fuelling situation?

Have a read through, don't hesitate to ask any further questions.

Regards, Joe
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Monday, March 25th, 2019 AT 10:12 AM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good afternoon,

Most likely the DEF is in the lines to the high-pressure pump and injectors.

DEF is a killer to injectors and the pump.

Roy
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Monday, March 25th, 2019 AT 10:14 AM

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