This truck is giving us all sorts of problems.

Spring of 2010 we put in a new VP-44, rebuilt RV-275 injectors and a Fass 150 pump. Fuel pressure was in the 13 psi range. However, we had hard start problems just like prior to the repairs. White smoke while cranking and at start up. Long cranks for start up. After a few months the VP-44 failed again...warranty. The truck has an Edge Attitude on it, pumped never tapped, using it for the display screen ever since the first VP was replaced.

Then the Fass pump failed. Changed/checked the factory fuel filter...it looked ok but put a new one in again. Got a 90 gph to replace the 150, apparently Fass said that since the warranty papers were not sent in within 30 days of the purchase, no warranty. We sent the papers the same day we got the pump. The dealer looked after us anyway. Nice.

After the pump is replaced, fuel pressure in the 12 psi range but still white smoke. I suspected it was the RV injectors. Vendor dismissed this. I still think its the injectors.

So the owner continues to drive a truck that has hard starts, white smoke and fluctuating fuel pressure. We decided to change out the dip tube...possibly getting air into the fuel system. Prior to this I pulled the MAPS and it looked good and I cleaned it. He was getting an over boost code P-0234. Not sure when or how this came up. Owner talked to a mechanic that said its probably the MAPS.
I started the truck and watched the fuel pressure go to 13, then drop to 8, 3 and then 0. The pump was dead...again. Then the owner tells me it did this to him earlier in the week so he tapped it with a hammer and it started again. So we tapped on the pump again and it started running. Started the truck, white smoke and idled, then the fuel pressure went to 0 again.

I had a Raptor 150 new in the box here and we decided enough with the fass and dropped the tank, put the new pick up tube in and installed the Raptor. Bumped the key and had power. Pump was working real nice...bumped the key again and then started the truck. Ran for about 30 seconds and died.
Tried priming again, no start. Changed out the factory filter again...no start.

Put the charger on the batteries and left it sit overnight.

It started yesterday and ran clean and then died after about 2 minutes. fuel pressure during all of this was 12-13.

Pulled codes and these are what we found...

I pulled 0463 and 1693

0463...Fuel gauge is working but float may have been stuck initially after install of the tank.

Will not start now. Just cranks. White smoke as it cranks.

I checked the oil...clean and normal...checked the coolant, same. I was thinking maybe a head gasket.

I am still leaning towards defective injectors but I get this feeling there is more wrong then what we have addressed already.

I do not know how to test a MAPS. Could the MAPS kill the engine?

Any help or feedback is appreciated. I am going to go check the turbo and shaft for play or damage but according to the owner, there was/is no power loss or lag.

We have no start and white smoke when cranking. I assume that is unburnt fuel, correct? Cracked injector?
No VP-44 codes this time.

 

Whats the companion code to the 1693?

 

I am hearing 'gurgling' when I turn the key off...at the tank. I think we may have an air leak in the fuel system.

 

Is it possible you've got a plugged tank vent and the gurgling you hear is actually from the fuel being pulled back into the tank when the pump stops running? Easy to check, just loosen the filler cap and try again.

This could also explain the dead transfer pumps as they're not designed to suck from a strong vacuum.

 

P-O234. P-0234 is the code that the owner says appeared. Its not there anymore. The other two codes I get are what are on the truck currently.

Adaminak posted that the 1693 code is the companion to the 0234.

Something else that 'might' be the problem...This Raptor pump is for an 05 or newer...its the one I had planned on putting on my truck this wknd. Since this fass was dead, we tried it on his truck. After I read through all of the instructions for the canister mods it says that there is a return line from the pump [raptor] to the tank and this return line connects to the factory original supply line. We blocked the factory supply line.

Not sure if this is the problem or not.

 

I heard it first when the filler cap was off/open. I closed it and could still hear the gurgling inside the tank. To me it sounds like there was either air or fuel being pushed back into the tank creating this sound. As I posted above, maybe the pump/kit we had here for my truck will not work correctly and we need a kit with a return line off the Raptor too. I sent a PM to Lary to try and fine out tomorrow.

Thanks for the replies.

 

White smoke is an issue. Usually means timing or possible coolant being burned. May be 2 problems at play here..

Any codes WRT the crank sensor? I wonder if its causing issues, not sure if the 2K units have the Cam sensor too.

 

I put a new cam sensor in on this truck when I changed out the VP-44.
After some more research I am thinking its a sensor more so then a head gasket or other coolant leak as the coolant level is unchanged and the white smoke smells like fuel.
The other two sensors besides the crank sensor may also effect the timing of this truck. IAT and MAPS. I pulled the IAT and cleaned it on Friday. Surprisingly it was not showing lots off soot. I am going to pull the MAPS and the IAT tomorrow and will check them and possible replace.

Now I have to find the crank sensor. J,do you know of the part numbers from Cummins for these sensors? I have the IAT # 3408345. I do not have the MAPS or the crank numbers.

The 0234 code and its companion code 1693 do point towards the IAT.

How is the 6.7 treating you? Mine is great!

 

If your pump is like mine, it will put out a lot of pressure, and as such, employs a relief valve that returns excess pressure (read as fuel) back to the tank. The relief valve on mine is downstream from the pump (towards the engine), just at a Tee in the fuel line. If you listen carefully with the cap off, you will hear the return anytime the pump is running if the tank isn't full.
Back to evening brew . . .

 

Scotty, you may need to reconnect the factory return line and run the one from the raptor in addition to the factory return. Check for a CMP code, if you do come up with one you may have another defective VP44. I have seen remanded injection pumps fail quickly do to poor reman procedures. Where did you get the pump?

 

Both pumps came from Harry out in BC...I think its PDR? The owner did the purchasing. The second pump was R&R'd by a local diesel shop as it was winter time, I did not have my shop built and the garage where we did the first was was too small/short to close the big door. LOL

Today I did some more checking and I tried to move the wastegate actuator arm. It will not move. If I recall correctly, I should be able to make that move, correct? I sprayed it with penetrating oil too...still no movement.
There is also oily residue on the turbo inlet.
This lack of movement could be the reason for the overboost code?

 

There is no return line on the raptor. Only the factory return line and its connected as it was on the tank.
I used the Raptor that was supposed to go on my 6.7. I looked at the pdf files on the Airdog site and did not see a return line for the Raptor [pump only] set up for a 2000 or the 05 and newer version I have. The complete AD kit with filters has the return line that goes to the factory supply line.

 

The raptor being for a newer truck isnt gonna matter. Its about the gph and psi. If you have white smoke just cranking sounds like fuel. Smell the vapors. If its fuel youll know. If it is fuel look athe the air heater or air heater relays. If he is running heavy injectors you may need some extra heat to get it started. VP44's are notorious for failing with no fuel pressure. They can not take any abuse. Or heat for that matter.