Condensation is one of the main causes of water entering the fuel tank. This is because, unlike petrol engines, diesel engines have no vapour pressure to displace air, so when the fuel tank heats up, the air expands and is forced out. But as soon as the tank cools down, the moist air flows back into the tank and the water condenses on the walls of the cooling tank, creating a problem.
But this is not the only cause. There are also other possible reasons. From simple human error, almost always due to carelessness when refuelling, to mechanical issues, such as water leaking into the tank. The problem is that water in the diesel fuel tank can cause a number of problems.
One of the most important is the formation of rust. Not for nothing does water cause rust when it comes into contact with iron and steel surfaces. And when small rust particles eventually find their way into the fuel, they can cause abrasive wear on parts, leading to part failure.
Secondly, it can cause corrosion. When combined with the acids in the fuel, water can corrode ferrous and non-ferrous metals. The effects are exacerbated when abrasion exposes metal surfaces that are susceptible to corrosion. Another problem that can occur is abrasion because water has a lower viscosity than diesel, so it does not lubricate moving parts as well as diesel, leading to increased wear.
Component pitting is another potential problem, as water contact with hot metal surfaces causes pitting of components. Finally, it can encourage microbial growth, which can produce sludge that fouls the fuel, acids that corrode your fuel tank and fuel system, and an inability to start as water damages the injection system.
The solution to prevent this is a diesel fuel filter water separator, which contains a filter with hydrophobic properties so that water cannot pass through, and a tap to drain the water. Because water is denser than fuel, it collects at the bottom of the filter, making it easier to remove. Some vehicles are equipped with a fuel-in-water (FIW) sensor, which indicates when there is a significant amount of water in the fuel filter.
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