TECHNICAL BULLETIN

Fuel Dilution in Gasoline Engines from

Direct Injection
Within the last decade, there has been a shift in gasoline engine technology. Since the
beginning of the internal combustion engine, fuel and air have been mixed in the intake before
being pulled into the combustion chamber and ignited. With the advent of direct injection, that
is no longer the case. Now, the fuel is directly sprayed into the combustion chamber under
extremely high pressures, in most cases in excess of 2200 psi. This has allowed for much
greater control to allow a more precise combustion process, making the engines more fuel
efficient and creating more power with smaller displacement engines.

What does this mean for oil analysis?

With the older port injection (or older carburetors) the fuel mixes with the incoming air before
being pulled into the combustion chamber. This allowed the fuel to atomize before coming into
contact with the cylinder walls and the oil coating. With direct injection the fuel is being
sprayed directly into the cylinder allowing larger droplets of fuel to come into contact with the
oil coating, washing down the cylinder walls. This leads to higher amounts of unburned fuel in
the crankcase, showing higher fuel dilution on your reports.

How much is acceptable?

While OEMs do not publish acceptable numbers, the common range used by most is that 3-
7% can be acceptable as long as there is not a noticeable increase in wear or drop in lubricant
viscosity. Most OEMs are using low viscosity oils that tend to be more tolerant of higher
amounts of fuel.

Our laboratory will report fuel dilution by two methods. The first method will be an estimate
based on the viscosity result. If the viscosity has not dropped further than one centistoke from
the midpoint of the SAE grade identified for the sample, an estimate of <1% fuel will be
reported. However, if the viscosity has dropped further than one centistoke, the sample is then
tested for fuel dilution using Gas Chromatography (GC) method ASTM D7593 for an exact
percentage of fuel. The unleaded gasoline fuel dilution method by GC is calibrated up to 5%. If
the GC registers a result higher than 5%, a result of >5% will be reported. Exact percentages
above 5% cannot be reported due to the calibration limits.

What do you need to watch?

Higher percentages of fuel dilution are not ideal as fuel does not have the same lubricating
properties of oil and can lead to early wear. Monitoring wear metals becomes paramount to
determining if the oil is maintaining the proper lubricant film. You will also want to monitor the
lubricant viscosity as well as the other lubricant properties such as base number, oxidation
and nitration. If the wear metals are increasing and the viscosity is decreasing, reducing the
interval time or increasing the viscosity of the oil may be recommended.

1 | Fuel Dilution in Gasoline Engines from Direct Injection

Copyright © 2018, All rights reserved
With the advancement of oil technologies and the shift in gasoline engine technology, it is
important to have a laboratory monitor lubricant condition as well as equipment health. A
proper fluid analysis program with trending results will help monitor and detect equipment
issues early. For most programs, our Advanced Engine test package provides adequate
testing for fuel dilution in gasoline engines.

2 | Fuel Dilution in Gasoline Engines from Direct Injection

Copyright © 2018, All rights reserved