Lift Pump Diagnostics - Diesel Truck Forum - TheDieselGarage.com
Thread Details Posted by Mopar1973Man, this thread has received 0 replies and been viewed 20407 times.

 
LinkBack Thread Tools Display Modes
post #1 of 1 (permalink) Old 01-02-2009, 03:28 PM Thread Starter
2nd Gen Guru
 
Mopar1973Man's Avatar
 
Join Date: Dec 2008
Location: New Meadows, Idaho
Posts: 2,641
Points: 54,969
Thanks: 9
Thanked 140 Times in 131 Posts
Garage
Send a message via Yahoo to Mopar1973Man
Lift Pump Diagnostics

Lift Pump Diagnostics TSB 14-002-03

Diesel Transfer Pump Diagnosis

Overview:
Improved diagnostic procedures are available which will greatly improve identifying a faulty fuel transfer pump. The improved procedures test the 'flow" capability of the transfer pump. It sufficient fuel reaches the injection pump from the low-pressure system, then the cause of engine performance problem(s) lies elsewhere.


* Un-documented Maximum Pressure is 20 PSI

Diagnostic Procedure:

The following procedure is to aid in evaluating the low-pressure fuel system performance in the absence of fault codes.

1. Inspect all fuel lines (including chassis) for kinks and leaks. Repair prior to proceeding.
2. Battery voltage must be greater than 11.5 volts. If not, charge batteries as required.
3. Remove the rubber fuel hose from the outlet side of the fuel filter (Fig, 1).



1 - TEST PORT FITTING
2 - VP-44 FUEL INLET LINE
3 - RUBBER FUEL HOSE
4 - FUEL FILTER OUTLET LINE
5 - HOSE CLAMPS (2)
6 - VP-44 INJECTION PUMP

4. Attach a 915 mm (36 in.) clear hose to the fuel filter outlet line (Fig. 1). Do not use the pressure test fitting.

5. Route the hose to a clean, empty 3.8 liter (1 gallon) approved diesel fuel container.

6. Purge all air from the lines by bumping the starter to activate the transfer pump (transfer pump should run for 26 seconds).

NOTE: THE TRANSFER PUMP WILL RUN LESS THAN 2 SECONDS (VARIES WITH ECU CALIBRATION) WHEN THE IGNITION KEY IS FIRST TURNED TO ON. WHEN THE STARTER IS BUMPED (DO NOT ALLOW THE ENGINE TO START), THE TRANSFER PUMP WILL RUN 25 SECONDS. IF THE ENGINE HAS BEEN RUNNING, THE IGNITION KEY MUST BE CYCLED TO ALLOW THE TRANSFER PUMP TO RUN.

7. If the transfer pump runs, proceed to step 8. If the transfer pump does not run, check electrical circuits as follows:

a. Verify 12 volts are present across the transfer pump connector Use test light to verity current flow.

b. If 12 volts are present - Measure the resistance across the transfer pump. If greater than 200 ohms or less than 0.2 ohms, replace transfer pump.

8. Empty the container of fuel.

9. Bump the starter to activate the transfer pump. Look for air bubbles. If no air bubbles are present, proceed to step 10. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat steps 6, 8, and 9.

10. Measure the amount of fuel in the container after the pump shuts off. If the amount of fuel in the container is GREATER than 1.33 liters (45 fluid ounces) and the fuel is bubble free, then the low-pressure fuel system is OK, the cause of engine performance problem lies elsewhere. No further testing of the low pressure fuel system Is required. If the amount of fuel in the container is LESS than 1.33 liters (45 fluid ounces), proceed to step 11.

11. Connect fuel pressure test gauge #6828, included In the #6i977 Diesel Fuel Pressure kit, to the pressure fitting located on the fuel filter inlet. If the vehicle is a 2002 model, install test fitting #6976, included In the #6977 Diesel Fuel Pressure kit.

12. Purge all air from the lines by bumping the starter to activate the transfer pump. Empty the container of fuel.

13. Bump the starter to activate the transfer pump for 25 seconds. Observe the hose for air bubbles. Record filter inlet pressure.

a. If fuel filter inlet pressure is greater than 34.8 kPa (5 psi), replace the filter element, and repeat step 12 & 13.

b. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat step 12 & 13.

c. If fuel inlet pressure is less than 34.8 kPa (5 psi), proceed to stop 14.

14. If the fuel quantity continues to be LESS than 1.33 liters (45 fluid ounces), connect a fuel vacuum test gauge #6828 using the fuel pressure test adapter #6631 between the transfer pump and the chassis mounted fuel lines.

15. Purge all air from the lines by bumping the starter to activate the transfer pump.

16. Empty the container of fuel.

17. Bump the starter to activate the transfer pump for 25 seconds. Observe the hose for air bubbles. Record transfer pump inlet vacuum.

a. If inlet vacuum is greater than 152.4 mm/Hg (6 in/Hg), excessive restriction exists between the tank and the transfer pump. Inspect/repair the chassis fuel lines and/or fuel tank module for kinks and/or restrictions. After correcting the restriction, repeat steps 15, 16, & 17.

b. If bubbles are present, check the lines/connectors between the fuel tank and the transfer pump for conditions allowing air to be drawn into the fuel system. Correct the condition and repeat step 15, 16, & 17.

c. If the fuel quantity continues to be LESS than 1.33 liters (45 fluid ounces) and no bubbles are present, replace the transfer pump

FAILING GRADE

Michael Nelson - 2002 Dodge Cummins & 1996 Dodge Ram 5.9L Gasser
116K Miles On My VP44 - 4 Years of 2 Cycle Oil Diet! - Mixed at 128:1 Ratio - 25.3 MPG maxed out!

Last edited by Mopar1973Man; 01-02-2009 at 07:35 PM.
Mopar1973Man is offline  
Closed Thread

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Diesel Truck Forum - TheDieselGarage.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
05-07 4" lift and also a level kit for 05-08 AmarilloSD Whats Been Sold 12 02-19-2009 02:01 AM
Carli/King 4.5" lift ruger311 General Ford Truck and Excursion 94 01-22-2009 04:07 PM
Lift and Tires OOWeaver68 Supporting Vendors Forum 14 01-05-2009 03:22 PM
Revtek 4" Lift Kit 99-04 F250/350 Steel Whats Been Sold 1 12-31-2008 04:37 PM
Custom Walbro Lift pump install............ triton Dodge - Modification instructions, Product installs and Tech Articles 0 12-23-2008 08:47 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome