Blue caps and green caps help you to distinguish between the fuel tank and the diesel exhaust fluid tank. A DEF tank has a blue cap, which is smaller than the fuel tank cap.The dispensing nozzle for DEF is smaller than the fuel dispensing nozzle. So, it is possible to pour DEF into the diesel fuel tank accidentally; in other words, the diesel exhaust fluid dispensing nozzle is finding its way into the fuel tank.

If you realize your mistake immediately, you should flush the fuel, or it needs to be repaired. But if you don’t find out your mistake and start your engine, you will realize your mistake as soon as possible because the engine will stop running, and it does not work.

So, this is a situation where you need to take the diesel engine to a professional to assess the damage and do any necessary maintenance.

The in-tank fuel pump has not begun if you never put the key in the ignition. So the damages will be limited to the tank, fuel pump module, and fuel fill pipe. These three parts need to be replaced to avoid more severe problems and the huge repair cost.

Further damage will occur when you touch the ignition, but do not start the engine. In this case, the fuel pump may have begun to pump fuel.

If you have already cranked the engine, it will be a calamity for you. So, the entire fuel system needs replacement. In addition to the tank, fuel pump module, and fuel fill pipe, you will have to replace injectors, the fuel rail, and injector return fuel lines.

How to Remove DEF from Diesel Tanks?

DEF is corrosive, so that it could be the worst contamination for diesel fuel systems. If DEF contamination has happened and the vehicle key has not been in on-position, the flush of the fuel lines and the fix could be straightforward. It is imperative to have the diesel engine towed to a service shop before the key is turned.

Conclusion

DEF is used to lower the concentration of NOx in diesel exhaust emissions. Usually, the diesel exhaust fluid tank filler is placed precisely next to the fuel filler. So it can sometimes confuse diesel engine owners to put this solution into the fuel tank. This mistake could be so expensive to fix!

DEF mixing with diesel fuel may cause enormous damage to the fuel system and the engine. So discovering the mistake and resolving the problem as soon as possible can significantly help limit the damages.

The best results are expected if you stop before touching the ignition key because the in-tank fuel pump has yet to start.

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