Professional Documents
Culture Documents
LOG IN R
Forums Gallery Tools Marketplace New Posts Google Search Search Forums
Notices
The New Garage Talk App is Live for both Android & iOS!
98.5-02 Cummins 24V 5.9L VP-44 Tech Talk Tech Articles for the 2nd Generation Cummins 24V 5.9L VP-44 Engines.
09-15-2007, 06:49 PM #1
Site Mascot
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 1/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
the same time! You can install our Low Fuel Pressure Warning
Kit and it will diagnose low fuel pressure too. To diagnose lift
pump performance click the ignition key to the start function
quickly, so the engine doesn't start, and let go, leaving the key in
the run position; the lift pump should run 25 seconds. If you don't
hear the lift pump, test for 12 volts going in to it and if it doesn't
run with 12 volts going into it, replace it. If you do hear it run and
it doesn't make at least 5 PSI replace the fuel filter. If, after
changing the filter, it DOES make at least 5 PSI go DRIVE the
truck UNDER LOAD. If it doesn't make at least 5 PSI after
changing the filter, or if you have to pressurize the fuel tank to
bleed the system to get the truck to run, then change the lift
pump. Revving it up proves NOTHING. If DRIVING UNDER LOAD
the pressure drops below 5 PSI, replace the fuel filter (if you
haven't already done so) and if that doesn't fix it, you need a new
lift pump if the fuel lines arent rusty and or sucking air. We
proved on a dynomometer in 1998 that if you have 5 PSI, under
load, you can make all the power available from a VP44. We do
not recommend running more than 12 PSI or you will diminish
fuel delivery to the rotor and make the truck run worse at high
RPM and possibly overheat and damage the fuel bypass solenoid.
This diagnosis is only for the lift pump, but is necessary for the
successful diagnosis of injection pump issues. If you dont have
enough lift pump pressure it will cause low power or bucking
under load. All other drivability issues usually are caused by the
injection pump.
If you see the code 216, or if there are injection pump codes, or
even if you have NO codes for the injection pump AND you have
ANY of the above listed drivability complaints, YOU NEED AN
INJECTION PUMP! Code 1693 only means there are codes in the
other computer, which have NOTHING to do with the fuel system.
There are basically only two other components to the fuel system
in a VP44 fueled truck and they are the ECM (Engine Control
Module) and the injectors. Neither of these give any trouble
typically. In 13 years of doing ONLY Dodges every day I have
never seen or even heard of a bad ECM and or injector. It is highly
improbable that either component could cause any of the
aforementioned drivability issues. Symptoms are different for
these components.
The housings on the VP44 wear out due to low fuel pressure from
weak lift pumps causing the diaphragm in the front of the VP44
pump to rupture. This causes the steel timing piston to vibrate in
the aluminum bore of the housing and the result in a short time is
the housing wears to the point that fuel bypasses the piston and
full advance cannot be accomplished which causes the code 216.
This makes perfect sense to me as it explains why as 24 valve
trucks get older the fuel mileage goes down steadily, and when
we replace the injection pump with one that has a new housing
we get the mileage back! In a typical competitor's rebuild, if the
case isn't worn out completely and the timing can be reached on
the test stand then it passes the test and a partly worn out case
gets to the customer, just to fail sooner. It should also be pointed
out that the replacement housings we use, have an insert for the
timing piston, which the original housings did not have. The code
216 only tells you that the housing is worn out, but does NOT
cause any drivability issues, other than lost power and fuel
mileage. As these symptoms come on slowly the driver isn't
aware of the change until they drive one of our replacement units
and get back the power and mileage.
The Following 4 Users Say Thank You to Whit For This Useful
Post:
00' Quad Cab, 1Tondiesel, 0Diesel Dawgs Performance, Truck
Guy99
09-15-2007, 06:55 PM #2
Site Mascot
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 3/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
In the case of the VP44 it is more common for the rotor to seize in
the distributor because the pressures are MUCH higher and
therefore mechanical tolerances have to be much smaller. Add the
fact that the rotor was not "deburred" enough or correctly during
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 4/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
manufacture, and these failures can be easily explained. Under
the higher working pressure in the VP44, the edge of the slot in
the rotor deflects and interferes with the distributor. Sooner or
later the result is a galling of the two parts and then binding and
then seizure. The seizure causes the "Drive Plate" to break and
the truck stops running, never to start again until the VP44 is
replaced. There is less than a half a thousanth of an inch
clearance between the two parts, so it doesn't take much to make
the rotor interfere with the rotor. Pumps made recently (since
about 2000) are experiencing fewer of these kinds of failures, it
seems to me.
A lot of people have heard about bad lift pumps and think they
are the cause of VP44 drivability issues and therefore electrical
failures; NOT SO! Starting with the early 98s, not only were they
weak pressure wise, but also had exposed terminals on the
bottom that corrode off in salt environments. The way to tell if
you have a corrosion sensitive pump is to see if the electrical
connection is a plug on a 6-inch pigtail coming from the bottom of
the pump. If the plug is on the top cover of the pump youre all
set, for that problem anyway!
If the lift pump is not delivering fuel pressure the truck stays
running because there is a gear pump in the front of the injection
pump, which keeps the fuel flowing, albeit at a much lower
pressure than desired, and hopefully maintains lubrication to the
rotor. As long as there is return fuel flow from the injection pump
there is lubrication to the rotor, so low fuel pressure and certainly
less return fuel makes it much easier to starve the rotor for
lubrication. The only accurate way to test a lift pump is to monitor
pressure UNDER LOAD and if it is above 5 PSI, no performance is
lost and the pump is OK. If pressure is less than this, a modest
reduction in horsepower results. The usual scenerio is a customer
puts a performance box on his truck and the lift pump can't
produce enough fuel to make more horsepower, and the
performance product gets the blame.This sympton is most always
a "Buck" as opposed to a "Surge" under load.
The Following 2 Users Say Thank You to Whit For This Useful
Post:
0Diesel Dawgs Performance, OneBadBia
09-15-2007, 09:23 PM #3
BOMBARDIER
Let me add this to this guide so folks can tie all the problems
together and understand more of why these problems happen.
This guide will start with the fuel tank and make its way step by
step through the system. I am sure there will be other things to
add to this but these are the problems I have come across.
1. Fuel Tank:
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 6/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
tank. The fuel pickup tube on the early models of 2nd generation
trucks have a tendency to corrode and leak air into the system
right on top of the module where the fuel line connects to it. If it
cracks on the inside your truck will run fine until your fuel level
gets below the crack. Then it will pull air mixed with the fuel. This
is the same thing as putting a hole in your drink and trying to
suck through it, you will get some drink but it is mixed with air.
This will create low fuel pressure and a loss of power.
C. Fuel Pickup Screen clogs with debris inside the tank. On the
bottom of the pick up tube is a fine mesh screen that sometimes
will clog itself up if you have gotten bad fuel. This will sometimes
fall lose when you shut the truck off and then re-occur as your
driving. No real way to diagnose this except to get inside your
tank and check it.
2. Lift Pump:
A. There is only one thing to say about the stock OEM lift Pumps,
regardless of which type you have. They are not sufficient to
provide enough dependable fuel flow to the VP44 to keep it cooled
off. If you are running any type of performance mods this just
increases the weakness of the stock system. A fuel pressure
gauge that is visible to you as you drive is the only assurance you
can have to know if your lift pump is functioning properly. You can
have 20psi at idle, but when you get on the go pedal that could
drop to 0psi and then the very expensive VP44 is on its way to the
graveyard. If you only do one Mod to your truck, make it a fuel
pressure gauge.
3. Fuel Filter:
A. The Water Drain Valve sometimes leaks fuel. If your lucky you
can jiggle it around and break lose whatever is blocking it from
closing completely, if not it will need to be replaced.
4. Injector Pump:
A. Also known as the VP44, the injector pump is fuel cooled. The
lift pump is expected to not only pump enough fuel to feed your
injectors but enough excess to provide cooling action to this
pump. The main failures to this pump are to the electronics that
overheat and lose there ability to control the fuel flow. There are
many different symptoms associated with this. Among them are a
noticeable loss of power, loss of fuel mileage, hard starting when
warm and/or a code of 0216 on the code reader.
5. Banjo Bolts:
09-26-2007, 08:22 PM #4
Diesel Enthusiast
http://www.turbodieselregister.com/u...&albumid=17275
10-24-2007, 07:08 PM #5
Site Mascot
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 8/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
USUALLY, but not always indicate a defective pump. There are
wiring and power checks to be performed if these codes are
present. These codes relate to Dodge pickups only, and are not
for any other ISB application.
11-19-2009, 01:33 AM #6
BOMBARDIER
Check out these threads for more info on these issues and the
Timbo APPS. Seems as though a noise filter also fixes some of
this.
https://www.dieselbombers.com/24-val...up-issues.html
https://www.dieselbombers.com/24-val...up-issues.html
https://www.dieselbombers.com/24-val...i-believe.html
https://www.dieselbombers.com/24-val...imbo-apps.html
Related Topics
Thread Thread Starter Forum Replies Last
Post
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 9/10
12/13/2017 DIAGNOSE THE VP44 FUEL SYSTEM* - Diesel Bombers
P-pump 24v info* | 5.9 Cummins 24V Injector nozzle installation*
Posting Rules
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off
Forum Rules
All times are GMT -5. The time now is 09:07 PM.
-- Bombed Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service - Top
We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees
by linking to Amazon.com and affiliated sites.
https://www.dieselbombers.com/98-5-02-cummins-24v-5-9l-vp-44-tech-talk/4940-diagnose-vp44-fuel-system.html 10/10