starting issue

[DMorris]

external fuse for Fass pump blown ! replaced, blew new fuse. Wires good to pump motor, no short to ground ! guessing Fass pump motor bad ! Now what ? Sheeze just dumped $$$ into the "hot set up", not so hot.

 

[TCDiesel]

Another Fass Failure. . What support have they offered?

 

[JaredH]

FASS Troubleshooting guide states the following:



"3b. Fuel Pump Stops

Check the fuse. While replacing the fuse, even if there appears to be a good fuse, it

is a good idea to remove and install the fuse several times. This will scratch

and clean the surface. Before installing the fuse the final time apply dielectric

grease into the fuse holder, this will help prevent corrosion.

Make sure there is proper power to the motor and a good ground. Check first on the

fuel pump side of the male and female electrical connection. If there is not

the proper power and ground try the opposite side. If that has the same

result go to the source. Is there a relay in this harness? Grounding to the

frame is not a good ground! If there is proper power and ground to the

motor go to the next step.

Lightly tap on the end of the motor. Tap hard enough to slightly jolt it but not break

anything. The object of tapping on the motor is to see if the brushes are

sticking. If the pump starts after tapping refer to “Service Topic” File No.

2005-002 dated 4-28-05. It would be a good idea to review this “Service

Topic” and see if it applies or could just help prevent future problems. If this

is not the problem go to the next step.

Check the brushes. New brushes are ¾” in length. If the brushes are less than 3/16”

they need to be replaced. An improper ground (high resistance) can cause

premature wear of the brushes, this is explained in the “Service Topic”, File

No. 2005-002.

If after performing these steps the problem has not been resolved call your dealer. "

 

[DMorris]

Another Fass Failure. . What support have they offered?

Well - I spent $285. 00 for a new pump motor, to be refunded if they find old one faulty upon return. So I guess at this point they made another sale, but if indeed I see my return after they get the old motor back,all is good. They did provide what I consider decent support and their people were pretty decent to deal with over they phone. Time will tell, so at this point I am disappointed in the early failure of the part-but machines of any sort can fail, yet very satisfied with how they handled it. Again, time will tell.

 

[Prairie Dog]

Great info ~ please keep us informed as to their decision. It could affect the choices others make in the future. .

 

[TCDiesel]

Well - I spent $285. 00 for a new pump motor, to be refunded if they find old one faulty upon return. So I guess at this point they made another sale, but if indeed I see my return after they get the old motor back,all is good. They did provide what I consider decent support and their people were pretty decent to deal with over they phone. Time will tell, so at this point I am disappointed in the early failure of the part-but machines of any sort can fail, yet very satisfied with how they handled it. Again, time will tell.

Good to hear,One thing is common with all electronic pumps they all will fail,At times one will out live the other. My support is simple replacement when it fails,or have another backup. It disappoints Me that the factory mounted pump is discriminate against,I have seen this pump still on 03 models with 200k plus its simple to replace, (Less then 30 minutes in a parking lot if necessary) and cost $160/180. those frame mounted pumps don't last long around here,the chloride will destroy it in quick order. the In tanks may last 1 or 2 years longer, but will leave you stranded and a tow bill plus 4 times the cost to replace then the can mounted pumps. We have eliminated all the risk in lift systems with the dual Bracket and in Cab switch,We have sold over 300 of these You would be hard pressed to find 1 compliant.

 

[JaredH]

TCDIESEL,



Can you answer the earlier questions or provide a link to where you may have answered the same question in the past on another post? Just trying to learn/understand... .



https://www.turbodieselregister.com...3-2007/226671-starting-issue.html#post2188170



Question 1) Are you leaning toward injectors since it dies after starting... meaning the PRV is most likely good since it will start (not leaking at the PRV during cranking)?



https://www.turbodieselregister.com...2007/226671-starting-issue-2.html#post2188171



Question 2) Sometimes cracking an injection line will allow the truck to start as normal for a while. Why is that? Does it allow the fuel to drain out of the line, thus the CP3 thinks the injectors are "receiving" fuel as they should? Or... ?



I would really appreciate the knowledge!!

Thanks!

 

[TCDiesel]

Common Rail Injection does not conform to logic. Their are SOoooo many variables,Just Yesterday had customer with hard start,We found the banjo on the back of the head to be the culprit. Also feel free to call today. We are having a blizzard,so I'm not going anywhere.

 

[DMorris]

Replaced fass pump motor and new one works perfectly. Well not perfectly, truck still has hesitation during starting- . You would sure have thought having the lift pump out would have been the problem ! As far as fass goes ,we will see how they handle the warranty. I will let you know-seems a lot of people do not have faith in fass and their standing behind the product.

On to next step of trouble shooting.

 

[JaredH]

Sorry to hear the continued troubles... So after the new FASS was installed it doesn't die after starting, just long crank times?



Injector Test (In the event that the FCA and PRV test OK):

There's always hope tightening the connector tubes down to the correct torque could help! As stated in the below article...

Issue 66 pg 124

https://www.turbodieselregister.com/magazines/Issue_066.phtml

 

[DMorris]

I assume the banjo bolt to crack loose on the rail for pressure relief is the the one sticking straight up ? Going to test that today.

yesterday moved truck and while idling got the ghost dinger I sometimes get except this time I happened to be looking at the bottom of my dash and noticed a flicker of red light, bet its my engine light ! (bottom right). Also notice during idle it would stumble once and a while. All else fails I am going to get it scanned monday when it goes in to correct my Revs per mile for my new tires.

Hope this is till going to be self repairable, I used to love trouble shooting, now its just a bunch of trouble.

 

[TCDiesel]

DMorris, you'll Be OK, it just take patient.

 

[DMorris]

scan showed no codes ? Guess it is time to check rail pressure.

 

[DMorris]

Here I am again, just getting back to look at this issue. I did loosen the banjo bolt (hope I did the correct one- one sticking straight up nearly straight under the dip stick tube). Before I even started the motor fuel seemed to seep a little. Stated motor and it pumped out. I only turned it about a turn loose, not even a credit card thickness of gap. I would say maybe . 030 of gap and the fuel poured out as soon as I started it. Seemed to start coming out as soon as the lift pump started to run, but really poured after starting. So now what do I

do from here ? I believe it was said no fuel should have came out ?

thank you in advance !!!

 

[TCDiesel]

DMorris Please call Me... .

 

[DMorris]

I will shoot you a call tuesday. Thank you

 

[DMorris]

I disconnected the FCA and put a hose on the relief. fuel pumped out of the banjo fitting and a little crept up the hose on the valve but I had to shut it down due to fuel every where. so ??



I know most of you are probable backing up a few posts to see where I got this idea, it was a pm and a phone call. I am just posting my findings to look for more input and make public what is going leading to what will ultimately be the problem/solution.

 

[TCDiesel]

The banjo is plumbed in with the COV and return fuel form Injectors, Nothing needs to be connected to the Valve. The banjo line will spray fuel everywhere,The banjo line fuel MUST be deverted in some type of container, the Valve should NOT leak any fuel . .

 

[DMorris]

A update. I did find that fuel came out of the relief- new one on its way :-laf.



hopefully that is the end of my starting issues for the time being.

As far as FASS goes, well ??? Two weeks go buy and no reimbursement on my pump motor, I called, left message per their request, no return call. Called late in the day and they said they didnt get it, I offered the tracking with delivery conformation info, then they said they must have it and were testing it to be sure it was bad-- hmmmm, but I thought you didnt get it ? Well again I heard "Friday" it will be credited back- if they find it bad?

So I am starting to worry, a lot of people have had bad experiences with Fass- I hope to not be one of them. There is still hope, I think.

 

[DMorris]

Update :



Well the saga still does go on. At this point I have only started the truck twice after replacing my PRV. The first time was out of the heated shop and it started good, then last night when I got back to the shop I tried it after sitting out in 25 degree temperature. It did start after the normal couple cranks, but also did seem to slightly stumble. My bet is that this morning it will require a extra long crank to get it to fire. I will post my findings after I get my self moving here. But where do I look next if problem persists ? Todd from T&C (who has been a great help so far, even had me call and walked me through some stuff) , seemed to feel if the PRV doesnt do it then we may be looking at injectors. Well ??? Tell me it aint so. He also is not a big fan of the Edge products which coming from a man of his knowledge bothered me a bit, I had never heard bad about the juice before. Have some of you guys running a juice had premature injector (almost sounds dirty) failure ? Maybe caused by the juice ?

As always , I really appreciate all the help I have gotten and am going to get.



A little update on FASS. I hate to bash the company, but I will say that people were correct in saying "good luck". As of today, one month since old pump was sent in, 3 rd fallow up phone call, and second time hearing same exact story: didint get the return- I say I have delivery conformation- then they say it must be on the bench for testing and never got logged in. I got a little excited ( I can get pretty pissy over money :-{} ) and told them their reputation is fading quickly on the forums because of situations like this and accused them of dragging it out and hoping I go away (which I will not go away). Finally he agrees to credit me ( heard that before). So I will find out later today if I got my credit or if I need to barrow a few blood pressure pills from my dad and get back on the horn with them.