Engine/Transmission (1998.5 - 2002) FASS install, now truck won't start

[s2Mumford]

I have a 2001 24v 2500 2wd with 39k miles. I have a Banks Stinger kit.

Last week, the check engine light came on, checked the code sand got the 1593 and 0216. talked to Banks, they said "yank the yellow (spliced into the VP44 control) wire". I did, codes went away, truck ran fine without the Ottomind hooked up.



I guessed that the LP was going out, I had noticed it was noisier lately, so I ordered the FASS kit.

My install was a total success (as far as cleanliness goes), it's a nice product and the install went cleanly and smoothly.



After the pump was installed, I fired up the truck, it started and ran for about 3 seconds, then died.



I noticed the FASS pump wasn't making any noise (I'm not sure I had all the electricals hooked up right: I got the optional relay harness and may have skipped a connection in my enthusiasm to drive the truck), so I dove back under the truck and bypassed the relay harness and ran the FASS pump harness direct to the LP wire.



Now, the pump runs for the 25 seconds after I key the starter, but the truck won't start. I have tried to start the truck now 4 or 5 times to the point of heating up the starter, just hoping there is air in the system, but I still have had no fire.

The error codes present are 1693, 0216, and 0230.



Can anyone give me a step by step troubleshoot for this condition?



I did loosen the inlet at the VP44 and I know it's geting fuel...



Thanks

Stuart Mumford

Riverside CA

 

[E7mack96]

I'd try cracking an injector line or 2 and crank it 'til you get fuel at the injector.

 

[Aaron_A]

Did you prime the new FASS system before conecting it to the vp? If not it there is probably alot of air in the fuel system.

When I installed mine I filled the filters on the FASS with fuel,and before connecting the fuel line to the the vp I had the wife hold it in a 5 gallon bucket and I cycled the key a few times until fuel came out of the line it took a few times to get fuel but when it did the wife got her first diesel shower

 

[s2Mumford]

Thanks for the replies, I followed the install instructions from Jannetty to the letter, I should have filled the line with diesel. I reckon there may be a lot of air trapped in teh lines, I hope that's all it is.



When you say "Crack a line", I'm guessing you mean disconnect the fitting at the injector, right?

I will do that first thing in the morning and see what happens.



Thanks again

Stuart Mumford

Riverside CA

 

[Chipstien]

You do not need to take the injector line completely off. Just loosen it a half turn or so. Yep, this is your most likely your problem though when you start getting codes it is the begginning of something bad.

 

[dpetre]

I had the same problem when I installed my FASS. THe pump ran fine but the truck would not starter. I bled the injector lines and still got nothing. I finally just sat there and cranked it over and over and it took off. The problem was not with the fass but the injector pump. Even after I installed the FASS the truck would not fire up as quick as it did. I took the truck into the dealer checked the injection pump and it was going bad. Installed new injector pump and every thing works great.

 

[mmclaughlin]

When I finished with the FASS install, I cracked the fuel line going into the VP44, bumped the starter once and watched the VP44 for fuel to come out of the cracked fuel line. I think I had to do it twice to get all the air out. Be careful, once fuel starts coming out, it could go all over the place. Bump the starter when doing this, do not try to start the truck untill you get fuel out. After you tighten the fuel line going into the VP44, bump the starter again and check for fuel leaks all around. After that, fire it up!



Good luck.

 

[s2Mumford]

Cracked line at the VP44, took two times bumping the starter to get fuel there (!). Loosened 3 injectors a couple of turns, cranked starter and they foamed a bit, and the truck started.

Turned off the truck, retorqued injector lines, runs great.



I have a small leak right on top of the tank, I'm going to get in there tonmorrow and see exactly where it's coming from, I'm sure it's the return line, the pickup line from the tank to the FASS should be under vacuum, so it would be sucking air rather than leaking fuel, right?



Also, what did you guys do with the stock fuel line, LP, and filter setup? Just leave it there?

 

[dpetre]

I have ordered to more pieces to rehook the original cannister back up. I want the heater circuit instead of running hot water to the FASS.

Dennis

 

[IWeiny]

I left the original line in.

I got the extra fittings from FASS and hooked up to the stock filter canister.



I disconnected the line before the pump and blew it out with air. Wife loved holding the hose in a can for me...



Then hooked it back up. An M12 1. 5 bolt with tape will seal up the output of the lift pump and I duct taped the suction line at the tank. I removed and capped off the line from the stock lift pump to the stock filter canister and put it and the clip for the suction line on the tank in a bag. If something goes wrong with the FASS I can put the stock system back together on the trail...



Ira (former boy scout)

 

[pharlacher]

If you decide to leave the stock filter off like I did make sure you put the bolts back in the intake Manifold. You have to use some washers to make up for the filter housing. If you don't you will blow your intake manifold cover gasket. $12 and about 3 hours of knuckle breaking work to replace



I originally left my stock filter on but had pressure flucuations. Might have been problems with the electrical connections. I did everything over again. Went directly to the pump from the FASS get 15 steady and 13 WOT.

 

[RKrueger]

Just reading the posts brings a question to mind.

Is there a third party pressure sensor that can be installed to protect the Bosch pump from damage should the fuel tank pump start to give out?

I'm not much of a gearhead, but this appears to be the root of the problem, that being fuel pump failure leads to the Bosch pump failure as well because there is no sensor in place that will monitor the output of the tank fuel pump.



Thanks,

Robert

 

[GKarpen]

pharlacher: That is a very good point when removing the stock filter. I will put mine back in tonight.