Trying to drive on a failed fuel injection pump will only lead to one place.
The breakdown lane.
You’ll know it’s coming too. Things start happening before your engine completely refuses to turn over.
Maybe your engine starts sputtering. It’ll lose power. That’s when you know things are about to go downhill.
But until you’re sitting on the side of the road wondering what your next move is, it’s time to learn about your options.
What you’ll learn:
- New vs. Rebuilt Fuel Injection Pumps
- How Do I Know If My Diesel Fuel Injection Pump Has Failed?
- Why Do Fuel Injection Pumps Fail?
- How To Choose Between A New Diesel Fuel Pump vs. Rebuilt Pump
- How To Make A New Pump Last Longer
New Diesel Fuel Pump VS Rebuilt Pump
As soon as you realize your fuel injection pump has kicked the bucket you’ll be left with a decision.
New? Rebuilt?
Let’s dive in
A new diesel fuel pump is straight from the factory and made with all new components. These pumps come with zero miles and should include a manufacturer warranty. These are pricey.
A rebuilt fuel injection pump is what’s also known as remanufactured. Companies take used fuel injection pumps, break them down and replace all the used parts to make like-new product. These meet OEM standards and are far less expensive than new pumps. Companies like Goldfarb have decades of experience supplying new and rebuilt fuel injection pumps to the diesel engine market. Goldfarb serves all major brands from light to heavy-duty trucks.
Both a new pump and rebuilt fuel injection pump can get your engine restarted. But there are pros and cons to both that are covered below.
Here’s the bottom line
If you’re working with an older vehicle or a fleet truck that you plan on keeping for a few more years, buying a quality rebuilt fuel injection pump is likely your best bet. If you’ve got a newer vehicle that may still be under factory warranty, going with new may be the right option. When you’re buying either a new or rebuilt diesel fuel injection pump, make sure it’s the correct one for your engine.
Signs That Show Your Diesel Fuel Injection Pump Has Failed
There are tell-tale signs that show your fuel injection pump is on its way out. The fuel injection pump is literally what feeds fuel to your engine. When things go wrong in the fuel injection system, they’ll usually give you a heads up.
Here’s some of the most common symptoms:
- Hard starting – or complete inability to start
- Loss of power when accelerating, under load, or climbing hills
- Engine sputtering when driving at high speeds
- Black smoke or white smoke coming from your tailpipe
If your engine is experiencing one (or all) of these issues… Turn it off. Don’t try to limp your vehicle to town and risk causing more damage. A failed fuel injection pump that’s pushed too far can send metal shavings through your engine. Swapping out the fuel injection pump suddenly becomes swapping out your fuel system.
How And Why Do Fuel Injection Pumps Fail?
You might be thinking that fuel injection pumps are designed to handle extreme pressure. They are! But that doesn’t mean they can’t be killed by bad fuel or wear out over time.
Most fuel injection pumps fail due to debris in the fuel, running the fuel tank too low or wear and tear. Diesel fuel contaminated with dirt or water is the number one cause of fuel injection pump failure. Simply put, those contaminants eat away at the inner components of your fuel injection pump.
But here’s a hint most people don’t know.
Allowing your fuel tank to run too low can be just as damaging. When your fuel gets low, it draws air into the fuel system. And that air wreaks havoc on the pump’s bearings.
Here’s another example from the real world.
In December of 2024 Ford issued a recall for nearly 300,000 diesel trucks due to fuel pump failures related to contaminated fuel. The issue was found in biodiesel built up in the fuel system causing blockages. This recall included Ford Super Duty trucks from F-250 up to F-750.
Engine timing issues or faulty electronic control modules can also cause failures. A lot of engines rely on electronic controls to time fuel injection events. If something goes wrong in that system, fuel delivery is affected.
How Do I Choose Between A New Diesel Fuel Pump vs Rebuilt?
You finally decided to take the advice and got your engine running. But now you have to make a decision.
New pump? Rebuilt pump?
According to RepairPal, the average cost to replace a diesel injection pump is between $1,985 and $2,879. Ouch.
So how do you know which route to take?
Ask yourself these questions.
How much money do you have set aside for this repair? Remember, rebuilt fuel injection pumps can cost 30-50% less than brand new ones. If you are trying to keep costs low, rebuilt is the way to go.
How old is your truck? How many miles are on the engine? If you’re pouring thousands of dollars into a high-mileage vehicle, you may want to consider a rebuilt just to get more life out of your engine.
Do you have warranty protection? Reputable companies that rebuild fuel injection pumps will offer warranties on their products. Make sure you know what you’re getting before making your purchase.
Do your research on who you’re buying from. As with anything, you get what you pay for. A cheap rebuilt fuel injection pump is more likely to fail sooner than the original pump. Stick with companies that have been in business for decades, specifically specializing in diesel fuel injection systems.
A quality rebuilt diesel fuel injection pump can perform just as good as a new pump. Don’t waste your money at a shop that cuts corners.
Steps To Take To Prevent This From Happening Again
You’ve made the big decision. Dumped a bunch of money into your truck and got it fixed.
Now what?
Don’t do anything to shoot yourself in the foot again.
Follow these simple tips to prolong the life of your fuel injection pump:
- Make sure you’re always putting good quality diesel fuel in your vehicle. Fuel kills more fuel injection pumps than anything.
- Change your fuel filters! Fuel filters are there for a reason. They catch debris before it can enter the fuel injection system. Do not skip this maintenance item.
- Don’t run your fuel tank too low. It’s good practice to never let your fuel tank drop below a quarter tank of fuel. Keeping fuel in your tank will prevent air from being pulled into the fuel system.
- Listen to your engine. If your engine starts hard starting, losing power or you hear clicking noises when you accelerate, don’t ignore those signs.
Keep these tips in mind and you’ll get plenty of miles out of your new fuel injection pump.
Final Thoughts
Having your fuel injection pump fail isn’t the end of the world. But making the decision between a new diesel fuel pump vs rebuilt can be.
Just remember, there’s pros and cons to both options. If done correctly, both new, or rebuilt fuel injection pumps will get your engine purring like a kitten.
The biggest take away from this should be to address the issue as soon as you notice symptoms. The longer you let the problem continue, the more damage you’re doing to your engine.
Knowledge is power. Now get out there and defeat death by fuel injection pump!