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Archived Truck wont start after modifing the fuel system

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Archived Rob Thomas, looking for a coat hanger....

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Well about 6 month ago I had noticed a decline in my fuel pressure and decided to add a pusher pump back by the tank. I installed a carter pump ,6 PSI at 100 GPH. cycled the key a few times and started the truck with no problems.



Then about 1 month ago started getting a hard start problem due to excessive fuel pressure. so I rewired the pusher with another relay to cut off power in the start position. Bingo no more hard start problem. However fuel pressure is slowly going down.



At this time I decided to change out the Lift pump. Using a Carter 14 PSI 100GPH pump. This is what I did last night.



I removed the fuel filter assy and removed the banjo and replaced them with the Weber fittings. Then I had removed the lift pump and drilled out the electrical connector to install on the new pump to retain the factory connection. I installed the new pump and hooked up the wiring and then I reinstalled the filter housing.



I then had to DISCONNECT the VP-44 to make is easier to run the hose from the new pump to the filter to the VP-44. Kept the Banjo at the VP-44, waiting on a fitting before I replace that one. hooked up the electrical fittings to the filter.



I crawled under to add a filter before the pusher pump. It is the summit racing version of the Fram competition fuel filter.



The Hose size goes as follows.



From the stock steel line to rubber hose with a -6 end. in the filter as -6 out as -8, in and out of the pusher as -8 and up to the lift pump as -8, from the lift as -6 in and out of the filter as -6 and into the VP-44 using the stock banjo.



HERE IS MY PROBLEM



After almost all was hooked up turned the key to the run position and bumped the started to build pressure and bleed off air. I did this 4-5 times and tried to start the truck. The truck would not start. I cracked open the banjo at the VP-44 and bumped the starter to bleed any air. [ Tried to start and no go. So I cracked open #4 injector and no Fuel... Noticed the I had not reconnected the VP-44. Reconnected and still no start. cracked injector # 1 4 5 got fuel. but no start. Tried to start at WOT, this worked when I installed DDII injectors Truck started ran very rough for about 5-10 seconds and died. tried recalibrating APPS no restart tried again and started reved up to 1600 rpm dropped to 800 rpm reved to 1200 rpm and died.



I checked the computer and got the standard companion code.

Disconnected the batteries last night and this morning tried to start and no go.



HELP.



I guess I wont have to pour the concrete today.



TIA

Brian
 
Sounds like there is still air in the system. Most likely there is air in the vp44 circuit which is pushing the "old" fuel out... then the air comes out, then the "new" fuel. I've seen this happen before (eh merrick? :) ). Some just start right up, some have to be beaten into submission.



I'm assuming you've verified pressure at the vp44.
 
Yes I have verified pressure. That is why i have not replaced the banjo at the VP-44. I am using the schrade valve to get my fuel pressure reading from. pressure is greator than 15 PSI and around 3 PSI during cranking.



I am going out to get a new fuel filter and try it all over again.
 
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