Determining the Cause of Fuel Dilution of Engine Oil {1101, 1124, 1251, 1280, 1290}

(REHS3007-14)

SMCS - 1101, 1124, 1251, 1280, 1290 i08063367

Caterpillar Products
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Revision Summary of Changes
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This special instruction includes the recommended methods for verifying and measuring fuel

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dilution, and troubleshooting for sources of fuel dilution of the engine oil.

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Before you perform any procedure in this Special Instruction, read the information and

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understand the information that is contained in this instruction.

Safety c.
Work safely. Most accidents that involve product operation, maintenance, and repair are
caused by failure to observe basic safety rules or precautions. An accident can often be
avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary
training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other
persons. Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not
all inclusive. Ensure that any tool, procedure, work method, or operating technique you use
that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the
operation, lubrication, maintenance, or repair procedures used.
 Do not operate or work on this product unless you have read
and understood the instruction and warnings in the relevant
Operation and Maintenance Manuals and relevant service
literature. Failure to follow the instructions or heed the warnings
could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this

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document and by governing authorities and regulatory agencies
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may result in severe injury or death of personnel or machine
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Personal injury or death can result from improper maintenance

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procedures. To avoid injury or death, follow the procedures
exactly as stated below.
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Required Tools
c.
Table 2

Required Tools

Qty Part Number Part Name

1 1U-5566 Ultraviolet Lamp Gp

1 1U-5575 Additive

19 L (5 US gal) - Container for Fuel

164-3310
or
1 164-3320 Infrared Thermometer Gp
or
166-9030

Verifying and Measuring Fuel Dilution

Always determine fuel dilution by analyzing combination of low oil viscosity and percent of
fuel in oil. The flash test does not accurately detect fuel dilution. Perform the two tests listed
below to verify fuel dilution:

Oil Viscosity Test at 100° C (212° F)

Percent fuel content using Gas Chromatograph Fuel Dilution Test

Note: Both the tests should be performed to analyze and compare the result for verifying fuel
dilution.

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Fuel in oil in excess of 6% is required before troubleshooting fuel dilution.
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If a gas chromatograph dilution test cannot be performed at the dealership, an oil sample can

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be submitted to a Caterpillar regional SOS Service lab for analysis.
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Note: Low viscosity does not necessarily mean fuel dilution.
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Refer to Table 3 for minimum viscosity by oil grade.

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Table 3
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Step 1
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Step 2 Step 3

Viscosity Oil
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Fuel Dilution as
Grade Viscosity
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Measured by Gas Action

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at 100° C
Chromatograph
(212° F)
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0W-40

5W-40 Less than

Greater than 6% If conditions in Step 1 AND Step 2 are both
10W-40 11.0 cSt met, investigate the cause of fuel dilution or
reduce the engine oil change interval.
15W-40

0W-30 Refer to Section "Troubleshooting for Sources

Less than of Fuel Dilution".
5W-30 Greater than 6%
8.0 cSt
10W-30

Troubleshooting for Sources of Fuel Dilution

The following troubleshooting procedures can be performed to find the source of fuel
dilution:

Note: Caterpillar recommends performing these procedure one after the other and record
the values to help further troubleshooting, if required.

Duty cycle of the Engine/Machine

 Fuel system

Oil quality

Duty Cycle of the Engine/Machine

For engines operating normally, the machine application or the duty cycle may be
contributing to unacceptable fuel dilution.

Engines with higher idle time

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Engines with higher fuel and ambient temperatures

Engines that run cold

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Engines operating under light loads 104
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Use the following procedure to determine the cause:

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1. Verify the fuel dilution by low viscosity and gas chromatograph fuel dilution test. The fuel

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dilution percent must be equal to or greater than 6%. Refer to Table 3 for minimum

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viscosity by oil grade.
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2. Initially, reduce the engine oil change interval by 50 hours. Submit oil samples for
evaluation at one half of the new interval and at the time of the new interval.
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3. If the reduced interval produces acceptable results from the oil analysis, continue
operation with the same interval.
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4. If viscosity and fuel dilution are still unacceptable, reduce the service by another 50
c.
hours. Evaluate the results from each oil sample. Refer to Step 2.

5. Continue the above process until acceptable results for gas chromatograph fuel dilution
test and oil viscosity are obtained.

Investigating Fuel System Leaks

Use the following procedure to determine the locations or sources of fuel dilution around the
electronic unit injectors under the valve cover.

The required tools are listed below:

1U-5566 Ultraviolet Lamp Gp

1U-5575 Additive

19 L (5 US gal) container for fuel

Note: The engine must be at the operating temperature or nearly close to the operating
temperature to perform this test.

Note: Do not exceed 745 kPa (108 psi) of fuel pressure in the rail of the cylinder head when
pressurizing the fuel system with a priming pump.

1. Add dye to the fuel in the container as per the instructions for the dye and mix well.

2. Put the inlet and return lines for the fuel in the container with dyed fuel.

3. Start the engine. Operate the engine until at least 11 L (3 US gal) of fuel is used, or
operate the engine until the dyed fuel has returned to the container. Stop the engine.

4. Remove the valve covers.

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5. Cap the fuel line and pressurize the fuel system with a priming pump.

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Illustration 1
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g06534309
(A) Normal leak as viewed with dyed fuel
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Illustration 2
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(B) Leak from O-rings as viewed with dyed fuel

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6. Use the black light to inspect all the unit injectors. A leak is indicated by a definite streak
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of dyed fuel at the leaking location.

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The areas on the unit injector where leaks are normal is shown in Illustration 1 shows .

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The areas on the unit injector where service may be needed is shown in Illustration 2.

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Illustration 3 HS 05: g06534306
(C) Area A
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(D) Weep hole
(E) O-ring seal

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(F) Lower O-ring seals

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Replace the fuel injector if fuel is leaking in Area A (C).

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Weep hole (D) fuel leakage is normal.

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Replace the O-ring seal (E) if fuel is leaking in this area. Do not replace the fuel injector.

Worn out lower O-ring seals (F) will not cause fuel to oil leak.

Check the torque for the unit injector clamp retaining bolts. - Ensure that the unit
injectors are properly installed into the cylinder head.

Leaking from the Cracked Body of the Unit Injector. - Confirm the leak is from a damaged
unit injector body. Remove injectors that are suspected of having a damaged body and
inspect the injectors for visible cracks.

Excessive Leakage from the Unit Injector Tip or a Broken Unit Injector Tip. - Look for
signs of damage to the unit injectors. If necessary, replace the unit injectors that have
damaged tips. Use 164-3310 Infrared Thermometer Gp, or 164-3320 Infrared Thermometer
Gp, or 166-9030 Infrared Thermometer Gp to identify excessive tip leakage while the engine
is running.

Low-Pressure Fuel System Sources for Increased Fuel

Dilution
Verify system pressures at idle, high idle, and immediately after shutdown -

Measure the fuel pressure at the following locations to ensure that the pressure meet the
Application and Installation Guide specifications.

Inlet to cylinder head

Outlet of cylinder head before return pressure regulator

Outlet of return pressure regulator

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Verify that there are no restrictions -

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Excessive restrictions may cause elevated system operating pressure, which would result
in increased leakage rate. Verify that there is no debris lodged in the pressure regulator.
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If pressure is maintained on the head after shutdown -

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Verify that the electric priming pump (if equipped) is not powered when the key is off.
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Verify that the purge orifice in the pressure regulator is not plugged.

© 2Shaft Seal
Leakage of the Drive 00Transfer Pump
300on the Fuel
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Ensure that the weep hole for the fuel transfer pump is not plugged. Inspect the front of the
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pump for signs of leakage. If necessary, repair the fuel transfer pump or replace the fuel
transfer pump. erp
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Illustration 4 g06534430
Fuel transfer pump

For complete inspection, fuel transfer pump may need to be removed to inspect seal on the
input shaft.
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Cracked Cylinder Head or Leaking
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Check for symptoms of a damaged cylinder head or a damaged cylinder head gasket. Inspect
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the cooling system for contamination of fuel. Inspect the crankcase for dilution of the engine

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oil. Dilution may be a sign of a cracked cylinder head or a leaking cylinder head gasket.

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C27 and C32 Cylinder
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Illustration 5 g06534450
(G) Holes
Plug the side of the cylinder head that returns the fuel. Ensure that the fuel rail is full of fuel.
Pressurize the fuel rail from the intake side of the head. Do not exceed 550 kPa (80 psi).
Check under the valve covers for fuel that is leaking from holes (G).
Low viscosity without fuel dilution
For low viscosity fuel dilution, perform the following checks:

1. Verify oil type.

a. Viscosity grade of oil (example 10W-30, 15W-40, and so on).

b. Performance level (example – Cl4 , CK4, and so on).

c. New oil viscosity from storage tank or dispensing container.

2. Ensure that the oil type meets Operation and Maintenance Manual recommendations for
performance and viscosity.

3. Verify that oil sump has not been contaminated with lower viscosity fluids such as
hydraulic fluids, cleaningfluids, and so on.

4. Determine oil hang up from previous oil change is not lowering oil viscosity. Make sure
that oil pan is completely empty when oil is drained.

5. Verify that oil change interval is not impacting low oil viscosity.
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