Troubleshooting Fuel Pump Failure in Detroit 60 Series Diesel Engines

Common Fuel Pump Problems in 60 Series Detroit Diesels

The 60 Series Detroit diesel engine was introduced in 1987 as an upgrade over the popular 6V92 two-stroke engine. The 60 Series includes the 6V92T, 6V71T, 6V53T two-stroke engines, and the four-stroke 6V92TA DDEC I, 6V92TA DDEC II, 6V92TA DDEC III, 6V92TA DDEC IV engines. These engines were installed in a variety of heavy duty trucks including Freightliner, International, Kenworth and more.

One common issue with the 60 Series Detroit diesel is fuel pump problems. The fuel pump is responsible for supplying pressurized fuel to the injectors. When it fails, the engine will exhibit symptoms like hard starting, low power, hesitation under acceleration, and shutting down completely.

Causes of Fuel Pump Failure

There are several reasons why the fuel pump can fail in a 60 Series Detroit:

• Wear and tear - The pump has many precision-fit components that wear over time. After hundreds of thousands of cycles, clearances open up leading to loss of pressure.
• Contamination - Small debris particles in the fuel can jam the pump or cause excessive erosion.
• Low oil level - The fuel pump is lubricated by engine oil. Running low on oil can cause premature wear.
• Defective O-rings - The pump relies on seals and O-rings to maintain pressure. When these degrade, fuel pressure drops.
• Electrical issues - The pump is operated by the engine computer. Electrical faults can prevent proper pump operation.

Identifying Fuel Pump Failure

Here are some ways to diagnose whether the fuel pump is bad in your 60 Series Detroit:

• Fuel pressure gauge - Connecting a gauge to the fuel rail will indicate if pressure is low or fluctuating.
• Listen for buzz - A bad pump may make a buzzing or grinding sound that gets louder as it wears.
• Check for leaks - Look for fuel leaks around the pump housing, fittings and fuel lines.
• Hard starting - Difficult cold starts and stalling indicate low fuel pressure.
• Monitor computer - The engine computer may log fault codes for fuel pressure or pump issues.

Replacing the Fuel Pump

Once diagnosed, the only permanent fix is to replace the faulty fuel pump. Here are some tips for 60 Series Detroit fuel pump replacement:

• Use OEM pump - Stick with a genuine Detroit fuel pump rather than aftermarket.
• Replace gaskets/seals - Be sure to install new gaskets, O-rings, etc. during the job.
• Check connectors - Fuel pump electrical connectors should be clean and tight.
• Prime the system - Before starting, prime the new pump to fill it with fuel.
• Verify operation - Start the engine and check for leaks. Go for a test drive to confirm normal operation.

Fuel Pump Maintenance

You can maximize the life of your Detroit 60 Series fuel pump with proper maintenance:

• Change fuel filters - Clogged filters tax the pump and contaminate the fuel system.
• Use quality fuel - Buy clean, high quality diesel from reputable stations.
• Fix leaks - Small leaks let air enter causing pump cavitation damage.
• Check oil level - Maintain full oil level to keep the pump lubricated.
• Clean connections - Keep fuel line connections and battery cables corrosion-free.

When to Call a Diesel Mechanic

Fuel pump replacement is an involved job best left to experienced diesel technicians. The pump is located low on the engine, with limited access. Special tools and procedures are required to remove and install it. And the job requires priming the fuel system, timing the engine, and reprogramming the ECM.

A diesel mechanic shop that specializes in Detroit Diesel engines will have the expertise to diagnose and fix any fuel pump issues with your Series 60. They can handle the entire job from start to finish using proven techniques that get your truck back on the road fast.

Don't take chances trying to fix major engine components yourself. Call a professional Detroit mechanic at the first sign of fuel pump trouble. They have the skills, tools and experience to get your Series 60 back to peak performance.

FAQs

What are the most common symptoms of a failed fuel pump?

Hard starting, stalling, lack of power under load, and inability to start are common fuel pump failure symptoms. You may also hear buzzing or grinding noises from the pump area.

Does low fuel pressure always mean the pump is bad?

Not always - clogged fuel filters, leaks, electrical issues, and problems with the fuel pressure regulator can also cause low pressure. But the fuel pump itself failing is by far the most common cause.

Is it safe to drive with a bad fuel pump?

No, you should not drive a vehicle with a faulty fuel pump. The engine can cut out without warning, potentially stranding you in an unsafe situation. Get the pump replaced before driving the vehicle.

Can I replace the fuel pump myself?

Fuel pump replacement is a difficult DIY job on the 60 Series Detroit engines. The limited access and involved removal procedure is best left to a professional diesel mechanic.

How can I prevent fuel pump problems?

Regular maintenance like fuel filter changes, using quality fuel, fixing leaks quickly, and maintaining proper oil level will help keep your Detroit fuel pump in good operating condition.