Engine/Transmission (1998.5 - 2002) FASS Install--Engine Power Problem

[MWmB]

Last weekend we installed a FASS 150-95 system on my 1998. 5 24-valve Dodge Truck. The installation went fine with no hitches. We bled the system and we have 15. 5 lbs. coming out of the pump. The truck starts and drives OK, the engine is much quieter but seems sluggish. I took it out and ran it up to about 85 and when I slowed down the check engine light came on. We coded it with a hand-held and got a P0216 code. We cleared the code, checked everything and tried it again. This repeated itself several times. The next day we pulled the fitting out of the injection pump to make sure there were no restrictions, bumped the starter to flow fuel without starting and ran a good clean flow into a bucket--saw no problems. We re-checked all of the electrical connections and the entire installation. We put everything back together and took it back out and ran it up to speed. We couldn't make the "check engine" light come on again. Solved??--I don't know. The problem is that the truck still doesn't have the power that it had before the installation. Any suggestions where to go from here?

 

[Chief USA]

P0216 is injection pump timing failure. You will have to replace the injector pump to fix this issue. I don't think the FASS had anything to do with the pump failure. It may have been marginal and finally failed when you tested the FASS on the engine. You cannot clear or remove the P0216 without replacing the pump. Sorry to be the bearer of such bad news.



The engine may still run and run for a long time but it may stop at any time when and if the injector pump seizes up. It would be best to replace the injector pump ASAP before it leaves you stranded at the worst time.

 

[DGamelin]

What was the lowest stock transfer pump psi required? What is the psi of a stock transfer pump?

 

[rjrkihap]

5 PSI is the lowest, however something is wrong if you are seeing 5PSI (failing LP or plugged filter). I never saw above 14PSI with my factory LP (engine mounted or near-tank mounted) and more commonly would see 11 to 12PSI at idle.



Ron

 

[RKrueger]

You didn't say in your original email, but where is the output line (pressure) going to?



On mine, I removed the original transfer pump, as well as the original fuel pump/strainer.

So the output goes directly into the inlet port on the injection pump.

The diesel shop, who does a lot of these, felt that the original fuel/pump housing would be a choke point, and advised going direct, especially due to the high output of the pump, and the additional HP adds I have made to the truck.

It's been working flawlessly, and it's a nice, clean install.



Robert