Um ok....that's great but unfortunately that will not help you as you have a FASS and don't need to hand make a Walbro setup. The thread was started by a rather controversial chap named Superduty who stuffed a Cummins CR into a Ford and needed a way to solve the lift/pusher pump problem. He used a Walbro like the thread said and that was the original birthplace of the Walbro from guys like Glacier as we know it today.

So...back to your problem. Are there any codes, do you have the fuel going through the fuel filter housing, do you have the fan harness problem?

 

Hmm the fan harness problem sounds good. I did finally pick up a fan speed code 04863? cant remeber. I did talk to dealer about this. But I also told him after I put the high preasure pump on that I ran the truck for about 10 secounds without the surpinteen belt on (ops) . That that could have caused code. I did not pick that code up before CP3 installation.

Dealer just called - asked if I had messed with either of the fuel controll acutators? He ssid on is on the pump and the other is near the rail. Isaid no. They have been poking at it all day and have not yet made a diagnosis. I am at least glad they aren't jumbing to something

What are symptoms of fan harness problem. I think the service writer mentioned this problem when we first talked.

Fuel is going through the housing.

Yea I dont so much like the continuos pumping that superduty is doing through his filter. Nor did I see support for over preasure damage.

But - I did not install a bypass on my FASS - nor id the direections indicate that I should.

What keeps the fass from over pressuring or buring out. Does FASS have an internal bypass?

If the FASS helps my truck run noticably better or CP3 last longer then I am happy to have installed it. But I will have to come up with a way to queit the beast. I bolted it to a unibody molded support rail just forward of the fuel tank. on my short bed quad this is under the drivers seat. May try some rubber grommets between rail and mounting braket. Its location is good because I ran supply along existing fuel lines and pump is close to inling with these lines. I dont want to mount it to my frame because that would requier mounting to bottom frame rail using supplied braket. I could weld new mount to frame rail, but I had rather not go through the trouble. I lke my current location because it is as high as it can go (less chance to snag) and is lined up with fuel line (less restriction) .

 

There is only one FCA and that's on the back of the CP3 which is why I asked earlier if you replaced that along with the CP3. The FASS has me a little confused. If it is the full FASS then you don't have to plumb it through the stock filter housing. If you did it is just redundent and could explain the large pressure differences in your idle and WOT. Second, do you still have the stock fuel filter in the housing? If not then that's your problem. If you do read on. The FASS is internally regulated so no problem there. It can burn out just like any other motor can but that's what warranty is for. The usual mounting for the FASS is along the frame rail using the front spring pack bolt as part of the mount. The FASS pump only (HPFP) uses the bed cross member above and to the front of the fuel tank. Either loation can utilize some sort of buffering from rubber grommets or the like to help with noise and NVH. Symptoms of the fan harness are no feedback to the ECU so it sees it as a problem with cooling and cuts fuel or the harness grounds out and causes an open circuit and can damage the ECU. Visual inspection and tracing of the harness will usually turn up that problem fairly quickly.

Now, the one thing we haven't really talked about is the rail pressure relief valve. One thing they may try is capping this off. At the end of the rail there is a relief that lets fuel pass in case of over pressurization of the rail for safety. Once that part is etched, it's useless and will cause low pressure on the rail which will result in some of the problems you are experiencing. I would have them check the FCA first and then the rail relief next.

Any codes from the key cycle yet? Just because no light is on doesn't mean no codes have been stored.

 

Nope not a faulty engine just a edge and diablo stack with some high egt's guess got the best of itand if you read my post a little better you will see I said I put alot more go fast goodies along with gettin my head worked which costed $1300 to be exact. I was just trying to help elimanate some possibilities that could be wrong but sounds like a fueling problem.

 

My FASS pump is without the filters - pump only - I pump to stock filters - mounted just forward off fuel tank

I didn't bolt anything to the CP3 so if FCA is mounted to CP3, it ws replaced with new CP3

I like the rail preasure relief valve.

The only codes I have gotten since 1st dealer worked on it is a fan speed code 4083 something like that

Thanks for all of the good information

 

Are you saying the filter is mounted just forward of the tank???

No, the FCA does not mount to the CP3, it is inside the CP3.
EDIT: Let me change this....I was thinking about the valve that gets altered, that is inside teh FCA. The FCA does mount to the ouside of the CP3. SO, that is my bad. So, sorry for any confusion there.

You like the rail pressure relief valve? (And on that note, it is PRESSURE, not PREASURE) What are you saying, that you like the IDEA of what was told to you about the RPRV? Or that you just like it?

Who pulled the codes? You? Or the dealer? When were the codes pulled?

 

I did read your post closely, because when I saw $10000 for a new head, I had to reread it to make sure I saw that right It still reads to me that you spent $10,000 on the head, and then you went and bought go fast goodies. But now you are saying $1,300 so I am REALLY confused now But the fact that this is not your thread nor mine, if you want to send an explanation, you can send me a PM if you like, but it really doesn't matter.

 

Does that code still come up when you cycle the key?

 

Hey Staarma, you are hitting ME up with some good idea's I had no idea about the harness you are talking about. And since I have an '03 (and 150K), I need to check mine. Thanks!

 

I'm glad someone is getting some useful info out of this.

I think this guy's truck is possessed. Now my truck is starting to act up.

 

All of our Dodge Cummins' are posessed, that's why we love them. When they are running properly, there's nothing better! That Rail Pressure Relief Valve is a high-dollar little beast, I'm thinkin' about $400. I wonder if Cummins sells it, it would certainly be cheaper. Blocking it off will fix it if that is the problem but you have to remember that it is plumbed into the banjo bolt on the front side of the fuel filter canister along with the return from the CP3. Ideally, you'd need a banjo bolt to replace the banjo bolt that holds the return line onto the Relief Valve that does not have a hole through it. However, in a pinch, I think it is a metric 12mm with 1.5 thread pitch so maybe a regular bolt of that size would work. Then you'd want to save your beer money for about 6 years until ya have enough to replace the Relief Valve. That is, if that's the problem.

 

The HPFP is internaly regulated and is designed to be dead-headed all day and not hurt the motor. So this is normal operation. We set pressures up to about 16-18 PSI on the stand.

As for the noise....if you mount this pump to the cab of the truck...this is why you are hearing it. We like to see them mounted to the bed cross support.....but its rather confusing on how you worded where you have it. If you have a Serial Number of the pump...i can look up if you have the quiet update or not.

 

My head hurts from reading this thread...

If someone already said this sorry did you have the dealer check the rail...sounds like the rail is dumping all the fuel.

 

Just keep in mind that the ONLY way you lose rail pressure is via a faulty Rail Pressure Relief Valve, or via an injector "sticking" open in such a manner that the fuel is returning back to the return side of the system. (this all assumes that the CP3 is functioning properly)

 

Serial # on my pump is 9221. I could not make from the picture included with the instructions were to mount the pump. However, I found a pic online of a pump mounted on a high frame rail just behind the cab. I like this location but on my quad short bed this location is taken by the cab. there is a frame cross memeber forward of my fuel tank but it is low and I could easily drag my pump off or snag a line inrough terrrain. I need the pump high. Consequently, I mounted to the FASS about 8" forward of my tank to a unibodr or molded body rail. So it is up and out of the way and within 3" of lining up with fuel line. I straped fuel line below existing fuel lines. I will try and post a pic after I get my truck back