Engine/Transmission (1998.5 - 2002) VP-44, lift pumps, fuel level and turbo oh my

[MThornhill]

First I'd like to say I’m new to the site I should have joined years ago! My problem stated when my 2001, 2500 stock 4X4 223Kmiles started having problems with acceleration the truck would just not go over 35MPH but only when the truck is warm (but not by running) if it was a hot day out the truck would not go over 35 without fully depressing the pedal then it would take off (it would also run correctly when the engine warmed up. I took it to Dodge suspecting the APPS but asked them for a diagnostic test! I believed they just read the codes (a waste of 86 bucks and 4 hours of my life) anyway the following codes came up

P0216 Fuel Inj pmp timing failure

P0230 Transfer pump out of range

P0234 Turbo boost limit exceeded (they quoted me $316. 00 for a new sensor)

P0460 Fuel level unit no change over miles (gauge works good) so what is this?

P01693 (twice)

Anyway they quoted me a new VP-44 $2400. 00, new lift pump installed in tank $975. 00, Turbo sensor $316. 00 and some other minor stuff.

Anyway my truck runs good once its warm what should I do?

Thanks for your time!

R/Mike

 

[RDHamill]

try Diesel performance parts and accessories. Diesel injectors, pumps, filters, kits, additive, gauges and apparel. for the VP-44 kit. if the "turbo sensor" is really a MAP sensor, get it direct from Cummins ( $71 last time I got one). good luck

 

[KFranco]

Welcome to TDR

Welcome to TDR the best place to diagnose, troubleshoot and fix your truck. One of the reasons for the TDR is to better help yourself fix and/or diagnose your truck instead of counting on the all too often expensive and didn't fix it anyway dealership. One of the first questions I have is how handy are you with vehicles. I'd bet with the help of the TDR you could fix everyone of the problems yourself for a significant savings and then invest those savings on one of the first items you should purchase for the cummins... gauges. Gauges are your best friend for this engine. If you don't already know do a search on gauges. Particularly Boost, Pyrometer and Fuel.



It is not normal for your truck to run poor until warmed. Stock lift pumps (lp) draw fuel from your tank and supply it to your injection pump. These pumps are noted failures waiting to happen. Here is why you need a fuel pressure gauge. When the injection pump doesn't receive enough pressure (most would agree less than 5psi) then you run the risk of injection pump failure. Even with the intank swap you will want to have a gauge to monitor the fuel psi. Personally I would go with something aftermarket that is better. I'm guessing you have low fuel pressure which has resulted in a bad injection pump.



Well this is start for ya. I'm sure other will chime in. Got to get the kids to bed now. I'll check in later

 

[MThornhill]

VP-44, lift pumps, fuel level sensor and turbo!!

Thanks for your response! I’m pretty handy, have overhauled small diesels before. I guess I was a little shocked when I got the list from the dealer I’ve always had luck with my diesels had a 91 2500 with 297K. I checked the codes myself last night and was thinking about it went to Blue chips sight I liked what I read and I will do a little more research on the gauges. I wanted to take the truck up to NJ for thanksgiving I might still make it but I am not looking forward to removing that pump and installing the new one looks a little tight in there. I did not understand the P0460 code "fuel level unit no change over miles" is this for the gauge or the tripometer thingy any way I will talk to blue chip on Monday or Tuesday I like the computer upgrade option thanks again for everyone’s response. . R/Mike

 

[klaybus]

VP time. Pick up a VP & you should be good to go. Did mine a couple of months ago & it wasn't that bad. Get a hold of a factory service manual... . Invaluable! Then print off the VP R&R from TDR. Together it was pretty simple.

Best of luck!

Clay

 

[BevanB]

Check with Industrial Injection Diesel Performance. They have great prices and their product is very good. I have had very good success with their service. A must call in my book! You may need to see if I'm right but they have been good to me.

 

[John - K5AWO]

I also vote for a new VP44 for your truck. Classic symptoms for a bad one.

 

[Vaughn MacKenzie]

I definitely wouldn't do the in-tank lift pump, there are good aftermarket lift pumps out there better than factory. I relocated my factory LP to back where the tank is and ran wires back there, theory has it the pump pushes fuel better than sucking it, and it doesn't have engine heat back there to kill it either. Mine worked great back there.



Definitely address the lift pump before replacing the injection pump. Good news is it's not too terribly difficult to do yourself, having it done for $2400 is pretty pricey.



Vaughn

 

[jkalchik]

As a bit of additional data, the Dodge dealer here wants $2,200 for a replacement VP44, the Cummins counter also wants the same, I got one from Vulcan Performance for around half that (replaced around Labor Day. )

Oddly enough, the Dodge dealer (Fury in S. St. Paul,) had no problem with me coming in with my own parts. And came in under book for the replacement.

 

[Mad Bomber]

VP time. Pick up a VP & you should be good to go. Did mine a couple of months ago & it wasn't that bad. Get a hold of a factory service manual... . Invaluable! Then print off the VP R&R from TDR. Together it was pretty simple.

Best of luck!

Clay

Note to self I know who to call if I have questions when that time comes for mine. LOL

 

[KFranco]

replace that IP

Alright thornhill the verdict is in. There has been a lot of good input. No doubt your IP is going south. IMO get a new lp system preferably aftermarket and then a new IP. Shortly thereafter invest in gauges. If you can't get them all start with fuel pressure gauge first. That is what I did. When I ordered the walbro system from galcier diesel I also purchased the 0-30psi liquid filled mechanical fuel pressure gauge. I purchased an entire system replacing the original fuel lines. It's easy to connect the fp gauge at this point. The only downside is you have to tape the gauge to the windshield to monitor fp every so often. Again, I did this for lack of money. However I am saving for an electric fp gauge so I can run it to the inside of my cab. I guess what I'm saying is if I had the money then for an electric fp gauge I would have. I does become tedious having to tape the thing to the windshield:-laf besides the funny looks you get



Good luck to ya!

 

[mhenon]

VP time. Pick up a VP & you should be good to go. Did mine a couple of months ago & it wasn't that bad. Get a hold of a factory service manual... . Invaluable! Then print off the VP R&R from TDR. Together it was pretty simple.

Best of luck!

Clay

This might help too. The VP had me a little intimidated until I saw Diesel Dan's video's. Doesn't look bad at all now.



VP 44 Install Tools Needed - Putfile.com

VP 44 Install Part II Under Hood Tour - Putfile.com

VP 44 Install Part III Pump Removal - Putfile.com

Part IV Bench Teardown - Putfile.com

Part V VP 44 Install on Engine - Putfile.com



Mike

 

[randrade]

+1 on diesel dan videos. I changed mine out after watching just once. I took my time and spent 3 hrs doing the job. Bought mine from Mid west diesel. Great service and you get 30 days to return the core before they charge you.

 

[MThornhill]

VP-44 puller

Ok so I got a VP-44 pump, Lift pump and low pressure light kit on order (should have it friday) watched diesel Dans video's! I picked up a couple of tools that I would need but could not get a pump puller SP-504 Snap On would not ship in time. Im a little nevous about dropping the pump key so my question is how can I get a suitable replacement in NC (very close to Virginia beach area) before the weekend any help would be appreciated I would be happy using somthing else but what else ?



Thanks

Mike

 

[KFranco]

Ok so I got a VP-44 pump, Lift pump and low pressure light kit on order (should have it friday) watched diesel Dans video's! I picked up a couple of tools that I would need but could not get a pump puller SP-504 Snap On would not ship in time. Im a little nevous about dropping the pump key so my question is how can I get a suitable replacement in NC (very close to Virginia beach area) before the weekend any help would be appreciated I would be happy using somthing else but what else ?



Thanks

Mike

I've heard of others using a steering wheel puller. Good luck

 

[MThornhill]

Mission accomplished thanks for the help!!

I got my rebuilt VP-44 friday and installed it and a new lift pump. The Injection pump caused me the most anxiety the pump came out hard and went in pretty hard causing me concerned about losing the Key. . Overall the job went easy and the results are very positive my truck has balls again (can I say Balls?) I got the parts from the MWFI (the diesel store) I was originally going to get the blue chip pump but being this close to the holiday it was too expensive. The rebuilt pump, lift pump, low pressure light shipping to and from came to $1335. 00. Hardest part of the job was using a mirror to line up the key way and sliding the new pump in I want to thank everyone for their words of encouragement and helpfully information especially diesel Dan. . This is the first replacement Injection pump and lift pump. Truck has 223K miles thanks again guys. .

 

[DCreed]

congrats! what did you end up using as a puller?

 

[MThornhill]

I used the steering wheel puller (and intake bolts) which made me a little nervus as the pusher bushing could easily fall into the housing. I wound up taking the bushing off after I realized how much force was required to pop the pump out of the housing. If given a choice I would use the Snap on tool.

 

[MKreiberg]

Where'd you get the pump rebuilt?

 

[MThornhill]

I got the pump from mwfi.com the VP-44 with a rebuilt housing and a new ecm module is $1046. 00 which includes shipping the pump and core shipping back