Everything posted by Mopar1973Man
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Are Cold Air Intakes Worth it?
Are Cold Air Intakes Worth it? There has always been a big hype about getting a cold air intake. Well its been brought to my attention that cold air intake doesn't work as expected on turbocharged engines. My second in command on the forum ISX is a wizard of sorts when it comes to figuring out math formulas and calculating different things on the Cummins engine. From his research in this, there is such a small difference in volume that you'll never see a measurable difference in power. Quote ISX post. I've run the numbers and had a temperature probe on the air filter and the highest I saw on a hill pulling the trailer at 100°F was 20 over (120°F). After plugging in all the numbers, you end up with a 0.5% gain in air mass in the cylinder when compared with what a cold air intake would provide (100°F air). As a reference, 0°F - 100°F ambient changes air mass by 21%... In other words, because of the intercooler, the cold air intake and heat shield stuff is null and void. You will never notice a 0.5% increase plus that is only under high load conditions, most of the time I was only seeing a 10°-15°F rise and in the winter, I saw almost no rise over ambient. Even if the temp was 50°F over ambient, it's still only 1.5% more air mass. It's all because of the intercooler. I know a lot of guys run heat shields and stuff and I'm not trying to say they are bad I'm just throwing the numbers out there. There could be something to how much boost is produced with hot air vs. colder air within the turbo. But turbo efficiency has more to do with it than anything IMO. So what I'm suggesting for the 2nd generation crowd is just get a BHAF for an air filter. As for colder intake temperatures you could upgrade intercoolers but the stock intercooler is already like 90% efficient. So there is going to little to no change in air temperatures with even a upgraded cooler. This will, of course, change as your performance demands change. But for mostly stock to mildly modified truck, the stock intercooler is going to work just fine. Typically for the 24 valve engine, there is a roughly +40°F temperature rise in the manifold because of the coolant jacket in the intake manifold. Also, the coolant jacket is within a few inches of the IAT sensor. So there is always going to be warmer air in the manifold.
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BHAF (Big Honkin' Air Filter)
There are several different kits and filters available for assisting Cummins Turbo Diesels to breathe more efficiently. The following are some of my personal findings when considering and using BHAF’s (Big Honkin' Air Filter). Firstly, there are air filters on the market that are washable and re-useable. These air filters also claim to prolong the life of the air filter and save money. I have found this claim to be invalid. When a air filter is washed it puts unneeded wear on the media and eventually creates holes in it. These holes in turn allow the passage of dirt. Another issue of washable air filters is they need re-oiled once washed. Most people over oil these air filters, which causes the turbo to pull oil onto the compressor wheel. Once the turbo wheel gets dirty it can cause damage to the turbo. Here is typical results of using washable media filters like K&N air filters. What I want you to take notice to is not the amount of oil but I want to to pay attention to the grit and dust stuck to the turbo housing. If this filter is doing its job this dirt and grit should not be present at all in the turbo. Here is my turbo after 195K miles and using the BHAF (Big Honkin' Air Filter) since 50K miles (145 total miles) and only on my second filter in 9 years. There are several good qualities when considering a BHAF (Big Honkin' Air Filter) or similar air filter. The first quality is it is a completely sealed unit. Being completely sealed there is no way for dirt to pass through the air filter into the engine. The second quality of a BHAF (Big Honkin' Air Filter) is it is roughly 3x bigger than a stock panel air filter. Being bigger allows more air to enter the engine unrestricted. The third quality of a BHAF (Big Honkin' Air Filter) is the media used in it is a dry paper element. Dirt will not stick to this type media, thus almost eliminating the potential of premature plugging. An accessory to consider with using a BHAF (Big Honkin' Air Filter) is the Outerwear for it. The outerwear is and works as a pre-filter for the BHAF (Big Honkin' Air Filter) It will protect the filter from heavy dust and water, as well as prolongs the life of it. The outerwear is also washable. I have been very happy with my BHAF (Big Honkin' Air Filter) as I now have 109K miles and 5 years on it, and it is just now starting to show dirt. Listed below are the different part numbers used for a BHAF’s: Fleetguard NAPA WIX Donaldson Baldwin Hastings Afe AH19037 2790 42790 B105006 PA2820 AF1012 20-40044 Carquest John Deere Big A Caterpiller Fleetrite Luber-Finer Fram UNI 87790 PMAH19037 93790 3I0005 AHR819037 LAF2531 CA6818 908 You can find a BHAF at Vulcan BHAF Link Amazon BHAF Link How to test the filter minder BHAF (Big Honkin' Air Filter) Life in Idaho Taking A Closer Look At K&N Filters As for the life of a BHAF (Big Honkin' Air Filter) I've gotten up to 130K miles and 6 years and still never pulled the filter minder down. But started thinking I'm pushing my luck so I change out the filter at 130K miles and 6 years of back country dirt roads and forestry roads. As you can see the filter minder still hasn't moved... Heat Shield Template for The BHAF (Big Honkin' Air Filter) Here is the template for the heat shield shown in my pictures above. Alternate BHAF (Big Honkin' Air Filter) Part Number This is copied from smokey burnouts at http://www.cumminsforum.com/forum/98-5-02-performance-parts-discussion/65116-bhaf.html#post643174 Well this is just info for all who might be interested: NAPA BHAF (Big Honkin' Air Filter) number is: 2790, which most of us know and is priced at about $70-75 But i got a NAPA 6637 which is a very large filter for only $54...might save some folks some cash...and it fits on the factory hose!!! Mopar1973man... 6637 is another you can add to you list of filters BHAF_Template.doc
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AirDog 100/150 Filters Numbers
AirDog 100/150 Filters Numbers AirDog 100 & AirDog 150 Part Number FF100-10 (10 Micron) Fleetguard FF5617 FF100-5 (5 Micron) Fleetguard FF5587 FF100-3 (3 Micron) Fleetguard FF5613 2 micron fuel filter NAPA 3626 WS80 (Water Separator) Fleetguard FS19768 WS100 (Water Separator) Luber-Finer LFF9594 SuperDog Filter Numbers SuperDog 200 Part Number FF200-10 (10 Micron) Fleetguard FS1054 WS200 (Water Separator) Fleetguard FS1023 PureFlow P/N Cross Reference P/N Manufacturer AirDog FF100-10 FF5617 - Fleetguard 10um absolute, 60GPH AirDog FF100-5 FF5587 - Fleetguard discontinued AirDog FF100-3 FF5613 - Fleetguard 5um absolute 60GPH AirDog WS80 FS19768 - Fleetguard 0% emulsified water/50% free water sep 20 GPH AirDog WS100 LFF9594 - Luber-Finer 95% free water/75% emulsified water sep 90 GPH NAPA Part # 3626 2 micron fuel filter works on the airdog!!! 6um nominal! More numbers supplied by 1lowdiesel @ CumminsForum (AirDog Tech) Napa / Wix 3527 & 33527 Napa / Wix 3697 & 33697 Napa / Wix 3420 & 33420 Napa / Wix 3616 & 33616 CAT 1R-0751 CAT 1R-0750 Donaldson P551315 Baldwin BF1275 Fleetguard FS19768 Baldwin BF7634 FleetGuard FF5324
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Finally started working out again!
I know what it's like to live with a serve ADHD child. Devin was a step-son from a girlfriend I was living with years ago. Sorry to say Devin never made it pass the age of 7 where "Unknown brain virus" took his life. All I can say I know exactly what your up against with the ADHD problem. All the doctors figure the ADHD is what allowed the virus to take hold and end his life. As for cures for ADHD I really don't think you can cure this. Maybe mild cases of of ADHD but not at the level that Devin was. We tried everything from herbalistic stuff, doctors, prescription drugs, etc. You name it.
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Excessive Cranking Fuel Pressure / Difficult Starting Hot
Excessive Cranking Fuel Pressure / Difficult Starting Hot The hard starting problem is caused by a Bosch VP44 injection pump with a damaged diaphragm internally. A torn diaphragm is typically caused from a Bosch VP44 injection pump that was operated at below 10 PSI for an extended period of time. So technically you should replace the Bosch VP44 injection pump to repair the damaged diaphragm but most rig up an oil pressure switch or a starter delay relay. Since Revision 027 the Bosch VP44 Injection pump has not had a rubber diaphragm. So the other reason that woul cause hard starting is excessing cranking fuel pressure. So this little mod will turn of the lift pump dring cranking to ease starting the engine. Here is my idea... This will cause the lift pump to remain off during the period of timing the starter is operating as soon as the key is released the lift pump will function normally and remain controlled by the ECM.
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Fuel Pressure Specification For Bosch VP44 Injection Pump
Fuel Pressure Specification For Bosch VP44 Injection Pumps Here is a copy of the fuel system specifications from the Dodge Factory Service Manual. This is for your Dodge Cummins Turbo diesel truck with a Bosch VP44 injection pump. Fuel pressure Normal fuel pressure should float about 14-15 PSI running down the pavement. It should never fall below 10 PSI at all. Here is a colorize fuel pressure gauge to give you a clue of the fuel pressure span you want. You want the needle to stay in the green at all times. Yellow zone is a warning that you should check the fuel filter, lift pump performance, overflow valve, etc. This is undocumented maximum pressure is 20 PSI. Now take notice to the overflow valve is set for 14 PSI so excessive pumping of fuel does nothing for performance except create more heat in the fuel, which in turns reduces the cooling ability of the fuel and adds more stress to the lift pump. So a little extra fuel pressure is a good thing because it ensures the Bosch VP44 injection pump stays cooled and lubricated properly. However, excessive fuel pressure will heat the fuel and reduced the cooling ability of the fuel. Now always remember that the only lubrication the Bosch VP44 injection pump will see is the fuel itself so if you don't have enough fuel pressure it will cause damage to the Bosch VP44 injection pump. It's like the same as running the engine with low oil pressure it will continue to run, but the damage to the engine will occur. On the other hand, the Bosch VP44 injection pumps, which happen to be about $1,200 to replace. Pressure Drop The amount of fuel pressure drop between idle and wide-open throttle. 2-3 PSI drop from idle to WOT is normal. However, 5 PSI or more pressure drop from idle to WOT is pointing out a failed lift pump, plugged filter, and/or plumbing restrictions. 2-3 PSI Is Normal Dropping more than 5 PSI is pointing towards a failed lift pump, plugged filter, or restrictive plumbing. Just to show you the difference in the stock plumbing which is 6mm ID plumbing and most performance pumps come with 1/2" ID plumbing. These pictures will give you an idea... The first picture is a Big Line fitting over the top of the stock plumbing. Then the second picture compares the stock 6mm ID steel lines to a 1/2" ID Big Line hose. The best way to show this example of restrictions is to let's say your house is on fire. You know your garden hose has 80 PSI of pressure, but the garden hose is only 5/8" ID hose. Your wife calls 911 and gets the fire department coming in the meantime you keep fighting the fire with your little 5/8" garden hose and losing the battle. The fire department shows up and pulls a 2 1/2" hose off the truck and charges it at 80 PSI and now winning the battle. Your fire is put out! What is so different? No matter what the size of the fuel line will dictate how much volume can be pushed through the fuel line. Like the story above the water pressure was the same at 80 PSI, but the hose size jumped from 5/8" to 2 1/2" ID hose and the volume changes are the size of hose. So the same thing applies to the stock fuel system. The stock banjo bolts and 6mm ID pipes are just too restrictive and cannot supply enough volume of fuel for that Bosch VP44 injection pump demands. This why I highly suggest you go up to 1/2" ID plumbing. Reasons Why Fuel Pressure Is Critical Let's take a look at a Bosch VP44 injection pump. I've labeled the fuel lines supplying fuel and return line plus the overflow valve. Now I know there is a ton of rumors on the internet of all kinds of minimum pressures for a Bosch VP44 injection pump. I'm going to say stick with the Dodge Factory Service Manual Specifications for fuel pressure. Now let's talk a bit more about the flow of the fuel. The lift pump supplies pressurized fuel to the Bosch VP44 injection pump the overflow valve regulates how much fuel pressure is held. Excessive fuel pressure is returned to the fuel tank. The picture below is of the bleed hole in the overflow valve this image was magnified x10 to show you how small the bleed hole really is. Give you an idea the size of the hole use a single strand of 14 AWG copper wire, and it will NOT fit the hole. The bleed hole is there solely for bleeding air out of the system which air will pass through this tiny hole rather easy but fuel will not. However, if you're looking for long life from a Bosch VP44 injection pump, I would personally suggest you adjust your minimum pressure to 14 PSI this will ensure the overflow valve remain open and a constant fuel flow through the Bosch VP44 injection pump and keep it cool all the time. Let me play out a simple scenario. Let's say my fuel pressure is roughly 10-11 PSI. I'm going to drive up into the back country approximately 40 miles with my Dodge Cummins towing an 8x8 utility trailer. Now the whole trip heading uphill into the mountain towing an empty trailer is going to be enough fuel flowing to the injectors to keep the Bosch VP44 injection pump happy. However, I've spent the day and loaded up with firewood and now coming back down the mountain loaded. I'm using my exhaust brake and coasting most of the way down taking it slow and easy. At this point, the injectors are no longer firing so the Bosch VP44 injection pump is not pumping fuel out to the injectors. Furthermore, the overflow valve closes at about 10-11 PSI so let's say it did close. Now where is the fuel going??? Nowhere! It is pooled up in the injection pump and gaining heat and being broke down. You've also removed the cooling and lubricating of the Bosch VP44 injection pump so now it actually taking on damage. To give you a feel for the fuel flow coming from the injection pump with an AirDog 150 at 17.5 PSI of fuel pressure, I've got a video to explain that quickly. I've heard rumors of some people trying to develop a cool down system for the Bosch VP44 Injection pump but after making the video above, there is just no way to cool down the injection pump using the lift pump of even the AirDog/FASS series. The whole problem is the restrictions inside the Bosch VP44 injection pump and the overflow valve as seen in the video above. So the only way to keep the Bosch VP44 injection pump cool is to keep fuel flowing through it at all times. So to keep the overflow valve open I suggest the 14 PSI minimum pressure. I'm currently at 136K miles on my Bosch VP44 injection pump and still going strong using a 16 PSI minimum pressure and an 18 PSI idle pressure. Here is a short video of stable fuel pressure from 55 MPH to 70 MPH at WOT. Here is another video done with idling, cruising, and WOT operation. Yes. I got a bit carried away and sloshed the fuel in the tank and sucked an air bubble and the pressure fell off. Cranking Pressure Test Here is a simple test on how to do the test for cranking fuel pressure. Pull the fuel pump relay in the PDC and then attempt to start the engine. Pay attention to the fuel pressure gauge during cranking. Be aware this test will trip a P1689 code and light the CHECK ENGINE light. Excessive cranking pressure can lead to difficult starting problems. Suggested Lift Pump Replacement You should replace the stock fuel system completely since it cannot supply enough fuel for even stock requirements without causing damage to the Bosch VP44 injection pump or adding stress to the lift pump. The pumps I suggest are proven and come with a lifetime warranty. These pumps come with a full kit and replace everything from the fuel tank to Bosch VP44 injection pump. AirDog 100, 150, or 165 Raptor 100 or 150 FASS 100 or 150 FASS DDRP (DDRP Ver.2 - 89 GPH) I don't suggest these pumps... Because they don't address the pump location, plumbing restrictions, or come with much of warranty. Stock Carter or Carter Campaign Pump (4090046) Holley Blue or Holley Black FASS DDRP (DDRP Ver.1 - 40 GPH) AirTex Mopar's Notes: That was true for the DDRP Ver.1 However, DDRP-02 is rated at 89 GPH and will hold pressure. It is listed as a Stock replacement pump designed to perform better than the Stock pump, but not for Chips that add fueling. I place a Power Puck on my truck with the DDRP-02 and saw no difference in FP at either idle or WOT, (PP is a timing chip doesn't change the amount of fuel). That said the PP is currently removed from my truck as I overpowered my clutch both loaded and unloaded, back to the stock clutch is fine. Looking for a Valair possible DD organic, or SD Kevlar/Ceramic. It is currently in the stock location and giving 15 psi at idle and 10 at WOT. Information Provided By: rhagfo http://www.cumminsforum.com/forum/98-5-02-powertrain/404412-fass-ddrp-02-a.html#post4197714 Additional Information (About Performance Crowds & Fuel Pressure) I've seen several times where people will link back to performance pump builders and quoting where they say, "(Un-named) proved that 5 PSI, under load, made all the horsepower the VP44 pump could make, even with stock fuel lines, fittings and supply pump." This might be true but there is nothing ever said about the life span of the pump at these conditions. So... Please do not follow these performance crowds into destroying a perfectly good Bosch VP44 injection pump. The fact still remains from Bosch the actual designer of the Bosch VP44 injection pump states that injection pump should return 70% of the fuel back to the fuel tank for cooling and lubrication purpose of the VP44. Being the only way a Bosch VP44 injection pump can do this is to have fuel pressure above 14 PSI to open the overflow valve. Then if the stock Bosch VP44 injection pump with an enhancement box say an Edge Comp on 5x5 can consume 15-20 GPH that means the stock 35 GPH pump cannot keep up with Bosch's design of 70% return volume. So this why products like AirDog, Raptor and FASS was created because they actually meet the demands of the Bosch VP44 injection pump. Then another fact that Bosch will let you know of is that diaphragm damage occurs from operating the Bosch VP44 injection pump at low fuel pressures. Making matters worse is that no Bosch injection re-builder will void warranty a VP44 injection pump with diaphragm damage. Dead give away that you had a bad lift pump or low fuel pressure problems. Please view the Bosch VP44 exploded view page to see there is no diaphragm in the Revision 027 Bosch VP44 Injection Pump Then the other fact is right from the Dodge Factory Service Manual has the minimum fuel pressures (picture at the top of the page). It even states the pressure that the overflow valve requires to open. Refer to the Overflow Valve Testing from the Dodge Factory Service Manual and see that the overflow valve should remain closed at 10 PSI and open by 14 PSI. So if the overflow valve is close by 10 PSI, then you extra cooling and lubrication just disappeared. So ultimately it suggested having a fuel system of no less than 100 GPH supply that can maintain a minimum pressure of 14-15 PSI at WOT. This will great extend the life of the VP44 because it keeps the electronics cooler longer and keeps the rotating parts lubricated properly. So please people let the facts and information from the actual designers of the injection pump (Bosch) and engine (Cummins) provide you proper information for your fuel system for your engine. Don't be swayed by performance shops claim of high horse output with little fuel pressure. As I proved right here doesn't work for the longevity of the VP44 injection pump... Another thing to bring up there are people that are increasing fuel pressures above 20 PSI. Please don't do this. The return port leaving the VP44 pump isn't very big at all. The return port is on the left and supply is on the right. As you can see increasing fuel pressures above 20 PSI put you at risk for shaft seal failure. Increasing the pressure above 20 PSI isn't going to improve the return flow. I say stick with the 14-20 PSI pressure range for seal safety. Additional Information (About Maximum Flow Rates) Here are some calculated flow abilities of the stock fuel system vs. 1/2" big line kits. This is not calculating bend, turns, offices just straight flow for open end plumbing and this is a rough calculation. Pipe Size Gallon Per Hour Flow Rate Gallon Per Minute Flow Rate 6mm ID pipe 75 GPH @ 15 PSI 1.2 GPM @ 15 PSI 1/2" ID pipe 570 GPH @ 15 PSI 9.5 GPM @ 15 PSI Use The banjo bolt Shrader valve to test for fuel pressure, Item 3 in the above diagram. If you have a 98-99 truck the port might be on top of the fuel filter housing. You can see the 90* bend fitting coming out of the top of the fuel filter housing in the below picture. Install a Shrader valve and test from there. I'm hearing of tales of shops, mechanics, or dealers doing the old hook up the fuel pressure gauge and only checking fuel pressure at idle. This is wrong. Because I've seen lots of cases where fuel line restriction, fuel filter plugging, gelling fuel and other thing causing fuel pressure to drop out under load. Like this video from a friend of mine, you'll see he's got awesome fuel pressure at an idle (where most shops gave him the green light). However, what the shops did not test for is WOT at highway speed, and you'll see in the video, he can pull way down to 0 PSI. Anything under 14 PSI is a concern... Anything under 10 PSI is a serious problem. As for having a gauge in the cab all Dodge Cummins trucks should have a fuel pressure gauge in the cab. Because like you seen bench testing with an idle pressure is meaningless if you can't see the WOT pressure at highway speed. View full Cummins article
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Fuel Pressure Specification For Bosch VP44 Injection Pump
Fuel Pressure Specification For Bosch VP44 Injection Pumps Here is a copy of the fuel system specifications from the Dodge Factory Service Manual. This is for your Dodge Cummins Turbo diesel truck with a Bosch VP44 injection pump. Fuel pressure Normal fuel pressure should float about 14-15 PSI running down the pavement. It should never fall below 10 PSI at all. Here is a colorize fuel pressure gauge to give you a clue of the fuel pressure span you want. You want the needle to stay in the green at all times. Yellow zone is a warning that you should check the fuel filter, lift pump performance, overflow valve, etc. This is undocumented maximum pressure is 20 PSI. Now take notice to the overflow valve is set for 14 PSI so excessive pumping of fuel does nothing for performance except create more heat in the fuel, which in turns reduces the cooling ability of the fuel and adds more stress to the lift pump. So a little extra fuel pressure is a good thing because it ensures the Bosch VP44 injection pump stays cooled and lubricated properly. However, excessive fuel pressure will heat the fuel and reduced the cooling ability of the fuel. Now always remember that the only lubrication the Bosch VP44 injection pump will see is the fuel itself so if you don't have enough fuel pressure it will cause damage to the Bosch VP44 injection pump. It's like the same as running the engine with low oil pressure it will continue to run, but the damage to the engine will occur. On the other hand, the Bosch VP44 injection pumps, which happen to be about $1,200 to replace. Pressure Drop The amount of fuel pressure drop between idle and wide-open throttle. 2-3 PSI drop from idle to WOT is normal. However, 5 PSI or more pressure drop from idle to WOT is pointing out a failed lift pump, plugged filter, and/or plumbing restrictions. 2-3 PSI Is Normal Dropping more than 5 PSI is pointing towards a failed lift pump, plugged filter, or restrictive plumbing. Just to show you the difference in the stock plumbing which is 6mm ID plumbing and most performance pumps come with 1/2" ID plumbing. These pictures will give you an idea... The first picture is a Big Line fitting over the top of the stock plumbing. Then the second picture compares the stock 6mm ID steel lines to a 1/2" ID Big Line hose. The best way to show this example of restrictions is to let's say your house is on fire. You know your garden hose has 80 PSI of pressure, but the garden hose is only 5/8" ID hose. Your wife calls 911 and gets the fire department coming in the meantime you keep fighting the fire with your little 5/8" garden hose and losing the battle. The fire department shows up and pulls a 2 1/2" hose off the truck and charges it at 80 PSI and now winning the battle. Your fire is put out! What is so different? No matter what the size of the fuel line will dictate how much volume can be pushed through the fuel line. Like the story above the water pressure was the same at 80 PSI, but the hose size jumped from 5/8" to 2 1/2" ID hose and the volume changes are the size of hose. So the same thing applies to the stock fuel system. The stock banjo bolts and 6mm ID pipes are just too restrictive and cannot supply enough volume of fuel for that Bosch VP44 injection pump demands. This why I highly suggest you go up to 1/2" ID plumbing. Reasons Why Fuel Pressure Is Critical Let's take a look at a Bosch VP44 injection pump. I've labeled the fuel lines supplying fuel and return line plus the overflow valve. Now I know there is a ton of rumors on the internet of all kinds of minimum pressures for a Bosch VP44 injection pump. I'm going to say stick with the Dodge Factory Service Manual Specifications for fuel pressure. Now let's talk a bit more about the flow of the fuel. The lift pump supplies pressurized fuel to the Bosch VP44 injection pump the overflow valve regulates how much fuel pressure is held. Excessive fuel pressure is returned to the fuel tank. The picture below is of the bleed hole in the overflow valve this image was magnified x10 to show you how small the bleed hole really is. Give you an idea the size of the hole use a single strand of 14 AWG copper wire, and it will NOT fit the hole. The bleed hole is there solely for bleeding air out of the system which air will pass through this tiny hole rather easy but fuel will not. However, if you're looking for long life from a Bosch VP44 injection pump, I would personally suggest you adjust your minimum pressure to 14 PSI this will ensure the overflow valve remain open and a constant fuel flow through the Bosch VP44 injection pump and keep it cool all the time. Let me play out a simple scenario. Let's say my fuel pressure is roughly 10-11 PSI. I'm going to drive up into the back country approximately 40 miles with my Dodge Cummins towing an 8x8 utility trailer. Now the whole trip heading uphill into the mountain towing an empty trailer is going to be enough fuel flowing to the injectors to keep the Bosch VP44 injection pump happy. However, I've spent the day and loaded up with firewood and now coming back down the mountain loaded. I'm using my exhaust brake and coasting most of the way down taking it slow and easy. At this point, the injectors are no longer firing so the Bosch VP44 injection pump is not pumping fuel out to the injectors. Furthermore, the overflow valve closes at about 10-11 PSI so let's say it did close. Now where is the fuel going??? Nowhere! It is pooled up in the injection pump and gaining heat and being broke down. You've also removed the cooling and lubricating of the Bosch VP44 injection pump so now it actually taking on damage. To give you a feel for the fuel flow coming from the injection pump with an AirDog 150 at 17.5 PSI of fuel pressure, I've got a video to explain that quickly. I've heard rumors of some people trying to develop a cool down system for the Bosch VP44 Injection pump but after making the video above, there is just no way to cool down the injection pump using the lift pump of even the AirDog/FASS series. The whole problem is the restrictions inside the Bosch VP44 injection pump and the overflow valve as seen in the video above. So the only way to keep the Bosch VP44 injection pump cool is to keep fuel flowing through it at all times. So to keep the overflow valve open I suggest the 14 PSI minimum pressure. I'm currently at 136K miles on my Bosch VP44 injection pump and still going strong using a 16 PSI minimum pressure and an 18 PSI idle pressure. Here is a short video of stable fuel pressure from 55 MPH to 70 MPH at WOT. Here is another video done with idling, cruising, and WOT operation. Yes. I got a bit carried away and sloshed the fuel in the tank and sucked an air bubble and the pressure fell off. Cranking Pressure Test Here is a simple test on how to do the test for cranking fuel pressure. Pull the fuel pump relay in the PDC and then attempt to start the engine. Pay attention to the fuel pressure gauge during cranking. Be aware this test will trip a P1689 code and light the CHECK ENGINE light. Excessive cranking pressure can lead to difficult starting problems. Suggested Lift Pump Replacement You should replace the stock fuel system completely since it cannot supply enough fuel for even stock requirements without causing damage to the Bosch VP44 injection pump or adding stress to the lift pump. The pumps I suggest are proven and come with a lifetime warranty. These pumps come with a full kit and replace everything from the fuel tank to Bosch VP44 injection pump. AirDog 100, 150, or 165 Raptor 100 or 150 FASS 100 or 150 FASS DDRP (DDRP Ver.2 - 89 GPH) I don't suggest these pumps... Because they don't address the pump location, plumbing restrictions, or come with much of warranty. Stock Carter or Carter Campaign Pump (4090046) Holley Blue or Holley Black FASS DDRP (DDRP Ver.1 - 40 GPH) AirTex Mopar's Notes: That was true for the DDRP Ver.1 However, DDRP-02 is rated at 89 GPH and will hold pressure. It is listed as a Stock replacement pump designed to perform better than the Stock pump, but not for Chips that add fueling. I place a Power Puck on my truck with the DDRP-02 and saw no difference in FP at either idle or WOT, (PP is a timing chip doesn't change the amount of fuel). That said the PP is currently removed from my truck as I overpowered my clutch both loaded and unloaded, back to the stock clutch is fine. Looking for a Valair possible DD organic, or SD Kevlar/Ceramic. It is currently in the stock location and giving 15 psi at idle and 10 at WOT. Information Provided By: rhagfo http://www.cumminsforum.com/forum/98-5-02-powertrain/404412-fass-ddrp-02-a.html#post4197714 Additional Information (About Performance Crowds & Fuel Pressure) I've seen several times where people will link back to performance pump builders and quoting where they say, "(Un-named) proved that 5 PSI, under load, made all the horsepower the VP44 pump could make, even with stock fuel lines, fittings and supply pump." This might be true but there is nothing ever said about the life span of the pump at these conditions. So... Please do not follow these performance crowds into destroying a perfectly good Bosch VP44 injection pump. The fact still remains from Bosch the actual designer of the Bosch VP44 injection pump states that injection pump should return 70% of the fuel back to the fuel tank for cooling and lubrication purpose of the VP44. Being the only way a Bosch VP44 injection pump can do this is to have fuel pressure above 14 PSI to open the overflow valve. Then if the stock Bosch VP44 injection pump with an enhancement box say an Edge Comp on 5x5 can consume 15-20 GPH that means the stock 35 GPH pump cannot keep up with Bosch's design of 70% return volume. So this why products like AirDog, Raptor and FASS was created because they actually meet the demands of the Bosch VP44 injection pump. Then another fact that Bosch will let you know of is that diaphragm damage occurs from operating the Bosch VP44 injection pump at low fuel pressures. Making matters worse is that no Bosch injection re-builder will void warranty a VP44 injection pump with diaphragm damage. Dead give away that you had a bad lift pump or low fuel pressure problems. Please view the Bosch VP44 exploded view page to see there is no diaphragm in the Revision 027 Bosch VP44 Injection Pump Then the other fact is right from the Dodge Factory Service Manual has the minimum fuel pressures (picture at the top of the page). It even states the pressure that the overflow valve requires to open. Refer to the Overflow Valve Testing from the Dodge Factory Service Manual and see that the overflow valve should remain closed at 10 PSI and open by 14 PSI. So if the overflow valve is close by 10 PSI, then you extra cooling and lubrication just disappeared. So ultimately it suggested having a fuel system of no less than 100 GPH supply that can maintain a minimum pressure of 14-15 PSI at WOT. This will great extend the life of the VP44 because it keeps the electronics cooler longer and keeps the rotating parts lubricated properly. So please people let the facts and information from the actual designers of the injection pump (Bosch) and engine (Cummins) provide you proper information for your fuel system for your engine. Don't be swayed by performance shops claim of high horse output with little fuel pressure. As I proved right here doesn't work for the longevity of the VP44 injection pump... Another thing to bring up there are people that are increasing fuel pressures above 20 PSI. Please don't do this. The return port leaving the VP44 pump isn't very big at all. The return port is on the left and supply is on the right. As you can see increasing fuel pressures above 20 PSI put you at risk for shaft seal failure. Increasing the pressure above 20 PSI isn't going to improve the return flow. I say stick with the 14-20 PSI pressure range for seal safety. Additional Information (About Maximum Flow Rates) Here are some calculated flow abilities of the stock fuel system vs. 1/2" big line kits. This is not calculating bend, turns, offices just straight flow for open end plumbing and this is a rough calculation. Pipe Size Gallon Per Hour Flow Rate Gallon Per Minute Flow Rate 6mm ID pipe 75 GPH @ 15 PSI 1.2 GPM @ 15 PSI 1/2" ID pipe 570 GPH @ 15 PSI 9.5 GPM @ 15 PSI Use The banjo bolt Shrader valve to test for fuel pressure, Item 3 in the above diagram. If you have a 98-99 truck the port might be on top of the fuel filter housing. You can see the 90* bend fitting coming out of the top of the fuel filter housing in the below picture. Install a Shrader valve and test from there. I'm hearing of tales of shops, mechanics, or dealers doing the old hook up the fuel pressure gauge and only checking fuel pressure at idle. This is wrong. Because I've seen lots of cases where fuel line restriction, fuel filter plugging, gelling fuel and other thing causing fuel pressure to drop out under load. Like this video from a friend of mine, you'll see he's got awesome fuel pressure at an idle (where most shops gave him the green light). However, what the shops did not test for is WOT at highway speed, and you'll see in the video, he can pull way down to 0 PSI. Anything under 14 PSI is a concern... Anything under 10 PSI is a serious problem. As for having a gauge in the cab all Dodge Cummins trucks should have a fuel pressure gauge in the cab. Because like you seen bench testing with an idle pressure is meaningless if you can't see the WOT pressure at highway speed.
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moisture from lower vent
Just rethinking a second. The drain is most likely plugged up. The Defrost setting will run the A/C compressor. It could be condensation. Check the drain for a plug first.
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Snow Chain Advice
I tend to agree with Wild & Free the front wheel drive with chains on would do much better than RWD Cummins with chains on the rear. Like my truck since I'm 4WD, I would put the chains on the front axle being there is 4,400 pounds on the front axle vs. my rear axle at less than 3,000 pounds at times. This where you see people throwing engine blocks or harden bags of concrete in the bed of their trucks to add weight over the driving axle. Most of the ranchers will chain up the front axle of the trucks knowing a simple fact the front axle is typically heavier.
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Finally started working out again!
That's the thing about humans... Everyone is different. Some people require much more activity and other don't require much at all. Yeah, my optimal weight would be right around 190-200 pounds. I'm very stable at 205-215 pounds. I'll usually gain a bit more during the winter time but loose most of it in the summer.
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Finally started working out again!
One of many work outs... Even MoparMom gets in on the exercise...
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Finally started working out again!
Hey Hammer... Just come up here to Idaho I can fix most of your problems. By the time March-April comes around it busy time for me. Typically I'm hitched up to a trailer with a friend and out hauling firewood. Work outs are cheap out here just find a tree to fall, buck it up, load it up, haul it, unload, split it up, stack it up. Come summer time I get all the hiking I could want Search & rescue calls up and tells me there is a lost hunter or hiker. Off I got to hike the mountain to find this lost soul. Then heat of the summer start doing fire fighting. Dragging heavy fire hoses, carrying gear, hiking some more.
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Would there be any interest in a interior refinishing write up?
Darker color dashes prevent windshield glare. In the same token, they also promote more dash cracking because of the dark color absorbing more heat and UV rays.
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wanting to move.
Then I highly suggest you create your own business right here and now. No one said you "must" be employed by a company. Then you have better control of your life. That is one of the beauties of work for yourself. You have full control of what you'll work on, how long you'll work and what days you get off. I know JAG1 is another self-employed person, but he's kind at the extreme end of working too hard. I go through spells of working so darn much that I can't seem to get time to just slow down and smell the flower and other times I'm so slow that I wish I had something to do.
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wanting to move.
The cost of living is pretty low over here if you can adapt to the slow lifestyle. Like I said over and over most everything is quite a distance away. Local products can be expensive. There are several folks here like my Fire Chief which he does insulation work for his own business. Like the folks that hired me to be their diesel mechanic is in the field of rubberized roof coatings has a fleet of trucks that need servicing. So you have to be creative on what you're going to do for income. You can't exactly say you're going to only do one thing for a living. Like myself, I'm all over the map from computers, server administration, diesel work, firewood, firefighter, search and rescue... If you're flexible then you might fit the mold for Idaho.
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Gov't back at it giving away everything...
- wanting to move.
I'm sure if you stop by here in the summer time MoparMom will hire you to paint two houses.- wanting to move.
Hmmm... That's a tough one for Idaho. Most of the smaller towns are doing poorly for an economy base. Like Riggins, ID most are bailing out because employers just can't pay enough to satisfy most folks living here. Like most of the central towns are nice small town most along a river with winters.- Winter is coming
Thankfully Idaho summers reach 100*F plus temps where I'm at but the humidity levels are way low like 8-20% humidity.- Bosch VP44 injection pump key part numbers
Bosch VP44 injection pumps key part numbers key# Cummins# 026 - 3944021 027 - 3944022 028 - 3944023 029 - 3944024 030 - 3944025 031 - 3944026 032 - 3944027 033 - 3944028 034 - 3944029 035 - 3944030 036 - 3944031 037 - 3944032 038 - 3944033 039 - 3944034 040 - 3944035 041 - 3944036 042 - 3944037 043 - 3944038 044 - 3944039 045 - 3944040 046 - 3944041- Bosch VP44 Injection Pump Overflow Valve
Bosch VP44 Injection Pump Overflow Valve Overflow Valve Description The overflow valve is located on the side of the Bosch VP44 injection pump. It is also used to connect the fuel return line (banjo fitting) to the Bosch VP44 injection pump for your Cummins powered Dodge truck. Overflow Valve Operation Fuel volume from the fuel transfer (lift) pump will always provide more fuel than the fuel injection pump requires. The overflow valve (a check valve) is used to route excess fuel through the fuel return line and back to the fuel tank. Approximately 70% of supplied fuel is returned to the fuel tank. The valve opens at approximately 97 kPa (14 psi). If the check valve within the assembly is sticking open, fuel drainage of the Bosch VP44 injection pump could cause hard starting. If a Diagnostic Trouble Code (DTC) has been stored for “P0168 decreased engine performance due to high injection pump fuel temperature”, the overflow valve may be stuck in closed position. Overflow Valve Diagnosis And Testing A rubber tipped blow gun with regulated air line pressure is needed for this test. 1. Clean area around overflow valve and fuel return line at Bosch VP44 injection pump before removal. 2. Remove overflow valve from Bosch VP44 injection pump and banjo fitting. 3. Discard old sealing gaskets. 4. Set regulated air pressure to approximately 97kPa (14–16 psi). 5. Using blow gun, apply pressure to overflow valve inlet end ( the end that goes into Bosch VP44 injection pump). 6. The internal check valve should release, and air should pass through overflow valve at 97 kPa (14–16 psi). If not, replace overflow valve. 7. Reduce regulated air pressure to 10 psi and observe overflow valve. Overflow valve should stay shut. If not, replace overflow valve. 8. Install new sealing gaskets to overflow valve. 9. Install overflow valve through banjo fitting and into Bosch VP44 injection pump. 10. Tighten to 30 N·m (24 ft. lbs.) torque. Overflow Valve Removal The overflow valve (pressure relief valve) is located at the outside of fuel injection pump. It connects the fuel return line (banjo fitting) to the pump. The overflow valve has no internally serviceable parts and must be replaced as an assembly. Two sealing gaskets are used. One gasket is located between pump and banjo fitting. The other is located between the banjo fitting and end of the valve. 1. Clean area around overflow valve and fuel return line at injection pump before removal. 2. Remove valve from pump and banjo fitting. 3. Discard old sealing gaskets. Overflow Valve Installation The overflow valve (pressure relief valve) is located at the outside of fuel injection pump. It connects the fuel return line (banjo fitting) to the pump. The valve has no internally serviceable parts and must be replaced as an assembly. Two sealing gaskets are used. One gasket is located between pump and banjo fitting. The other is located between the banjo fitting and end of the valve. 1. Install new sealing gaskets to valve. 2. Install valve through banjo fitting and into the pump. 3. Tighten to 30 N·m (24 ft. lbs.) torque. Few notes... Here is a close up of the bleed hole in the overflow valve. This picture is magnified X10 so you can even see the tiny hole used to bleed air from the system. There is a lot of controversy about the operation of the overflow valve on a Bosch VP44 injection pump Cummins selected. From my personal opinion that the overflow valve is the last check valve to hold the pressure up to 14 PSI for the injection pump. As for the bleed hole in the side that hole is so small, it can't possibly create enough flow to aid in cooling the Bosch VP44 injection pump unless the overflow valve is opened which listed above requires 14 PSI to be open.- 1 comment
- 3 reviews
- Bosch VP44 Injection Pump Replacement
Bosch VP44 Injection Pump Replacement Removal 1. Disconnect both negative battery cables at both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at cylinder head and injection pump ends. Thoroughly clean Bosch VP44 injection pump and supply/return lines at side of pump. 3. Disconnect 9–way electrical connector at Fuel Pump Control Module (FPCM) (Fig. 22). 4. Remove fuel return line at side of Bosch VP44 injection pump by removing overflow valve (Fig. 23). Place rag beneath overflow valve to catch excess fuel. 5. Remove fuel supply line at side of Bosch VP44 injection pump by removing banjo bolt (Fig. 23). Also remove same line at top of fuel filter housing (banjo bolt). 6. Remove all high-pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips, electrical cables at intake heaters and engine lifting bracket. a. Remove the APPS sensor. Just unbolt the APPS and unhook the wires and tuck it back towards the firewall with the throttle cable attached. b. Remove the intake elbow 4 bolts and remove the air pipe on the driver side. As for the dipstick tube it can be move out of the way by twisting it carefully. c. Remove grid heater leaving the wires attached to the grid heater and tuck back out of the way. Mopar's Notes: Now you only need to remove 1,2,4 high pressure injector lines. The other 3,5,6 can remain attached to the engine but need to be removed from the Bosch VP44 injection pump. 7. Remove hose clamp at crankcase vent hose (Fig. 24) and remove the hose from the canister. 8. Remove (unscrew - right-hand thread) canister (Fig. 24) from gear cover. 9. Remove nut and washer retaining injection pump gear to Bosch VP44 injection pump shaft (Fig. 25) 10. The engine can be rotated with a barring tool such as Snap-On No. SP371, MTE No. 3377371 (Cummins Tool Division, or an equivalent. The opening for barring tool is located in rear flange of the engine on exhaust manifold side (Fig. 26). Remove rubber access plug covering this opening. A 15/16" socket on the alternator can be used as a barring tool. 11. Insert barring tool into flywheel housing opening (Fig. 26). 12. Rotate engine until keyway is at 12 o’clock position (Fig. 27). 13. Use T-bar type puller (Fig. 28) to separate injection pump gear from Bosch VP44 injection pump shaft. Attach two M8 X 1.24 MM (metric) screws through puller and into two threaded holes supplied in pump gear. Pull injection pump gear forward until it loosens from injection pump shaft. Pull on gear only enough to loosen it from the injection pump shaft. Pulling gear too far may cause damage or breakage to gear cover. 14. Remove 2 rear/lower pump bracket bolts (Fig. 29). 15. Remove 4 Bosch VP44 injection pump-to-gear housing mounting nuts. 16. Remove Bosch VP44 injection pump from gear housing. Take care not to nick injection pump shaft on aluminum gear housing when removing the pump. Also, be very careful not to drop pump keyway into gear housing. WARNING: Whenever the Bosch VP44 fuel injection pump is removed from the engine, the pump drive gear is laying loose on the camshaft drive gear. Never attempt to crank or rotate the engine with the pump removed from the engine. Serious damage will occur. To prevent pump/gear keyway from falling into gear housing, the engine must be rotated until keyway is at 12 o’clock position (Fig. 27). If gear retainer nut, washer or key drops into gear housing, the cover may have to be removed to retrieve them before the engine is started. Installation 1. Inspect pump mounting surfaces at the pump and the mounting flange for nicks, cuts or damage. Inspect o-ring surfaces for nicks, cuts or damage. 2. Clean injection pump mounting flange (Fig. 31) at gear housing. Also the clean front of the injection pump. 3. Install new rubber o-ring (Fig. 33) at pump mounting area. 4. Apply clean engine oil to the injection pump o-ring only. The machined tapers on both injection pump shaft and injection pump gear (Fig. 34) must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening. 5. Clean pump gear and pump shaft at machined tapers (Fig. 34) with an evaporative type cleaner such as brake cleaner. Keyway Installation: 6. The pump/gear keyway has an arrow and a 3–digit number stamped at top edge (Fig. 33). Position keyway into pump shaft with the arrow pointed to the rear of the pump. Also be sure 3–digit number stamped to top of keyway is same as 3–digit number stamped to injection pump data plate (Fig. 35). If wrong keyway is installed, a diagnostic trouble code may be set. Mopar's Notes: A suggestion is once you ready to place the key in the shaft take a few drops of super glue and glue it in place. This will keep the key from falling out during installation of the pump. 7. Position Bosch VP44 injection pump assembly to mounting flange on gear cover while aligning Bosch VP44 injection pump shaft through back of injection pump gear. When installing pump, dowel (Fig. 34) on mounting flange must align to hole in front of pump. 8. After Bosch VP44 injection pump is positioned flat to mounting flange, install four pump mounting nuts and tighten finger tight only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) Bosch VP44 injection pump to gear cover using mounting nuts. Damage to pump or gear cover may occur. The pump must be positioned flat to its mounting flange before attempting to tighten mounting nuts. 9. To prevent damage or cracking of components, tighten nuts/bolts in the following sequence: a. Install Bosch VP44 injection pump shaft washer and nut to pump shaft. Tighten nut finger tight only. b. Install 2 rear/lower pump mounting bolts finger tight only. c. Do preliminary tightening of Bosch VP44 injection pump shaft nut to 30 N·m (15–22 ft. lbs.) torque. This is not the final torque. d. Tighten 4 Bosch VP44 injection pump mounting nuts to 43 N·m (32 ft. lbs.) torque. e. Tighten 2 rear/lower Bosch VP44 injection pump bracket-to-pump bolts 24 N·m (18 ft. lbs.) torque. f. Do final tightening of Bosch VP44 injection pump shaft nut to 170 N·m (125 ft. lbs.) torque. Use barring tool to prevent engine from rotating when tightening gear. 10. Install canister (Fig. 24) to gear cover. 11. Install crankcase vent hose (Fig. 24) to canister and install hose clamp. 12. Using new gaskets, install fuel return line and overflow valve to side of Bosch VP44 injection pump (Fig. 23). Tighten overflow valve to 24 N·m (18 ft. lbs.) torque. 13. Using new gaskets, install fuel supply line to side of Bosch VP44 injection pump and top of fuel filter housing (Fig. 23). Tighten banjo bolts to 24 N·m (18 ft. lbs.) torque. 14. Install all high-pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips, electrical cables at intake heaters and engine lifting bracket. Tighten the fuel line(s) at the head to the injector connector(s) to 38 N·m (28 ft. lbs.) torque. 15. Connect 9–way electrical connector to Fuel Pump Control Module (FPCM) (Fig. 22). 16. Connect both negative battery cables to both batteries. 17. Bleed air from fuel system. 18. Check system for fuel or engine oil leaks.- 1 comment
- 2 reviews
- Winter is coming
36*F outside and snowing. Forecasted to drop down to +10*F tonight. Bad part is by tomorrow I got to find a way find a way to get the fire truck off the mountain at the Chief's house.- Bosch VP44 Injection Pump Requirements
Bosch VP44 Injection Pump Requirements I'm going to do a quick article on requirements for long life from a Bosch VP44 injection pump. Here is the list of thing that are required to keeping a Bosch VP44 injection pump happy in your Cummins powered Truck. Fuel Pressure Fuel Filtration Fuel Lubricity Clean DC Power Fuel Pressure I know there is a lot of controversy about fuel pressure but I'm going to be to the point I suggest 14-20 PSI for optimal return flow for proper cooling and lubrication of the VP44. Fuel Filtration With the all the different fuel pump and fuel systems out there. I've been quite pleased with my Airdog fuel system. I've got a pre-filter and water separator before the pump then the 3-micron filter after the Air Dog pump. Then I kept the stock filter as well and dropped a 10-micron Fleetguard filter in place. This has worked flawlessly on polishing fuel for the Bosch VP44 Injection Pump. Also being the AirDog flows a majority back to the fuel tank it tends to continually polish the fuel in the tank. I always will suggest in purchasing fuel from a high volume station like truck stops. Fuel Lubricity Bosch back in the day when designing the Bosch VP44 injection pump they based the design off of Europian fuel standards of 460 HFRR or less. Just about the time the Bosch VP44 was being introduced to the Cummins engine the US fuel was not adhering to any standards. So even before ULSD (ultra low sulfur diesel) came to be the US fuel had numbers as high as 500-600 HFRR. After a whole diesel industry getting damaged by the fuel the US standard was made at 520 HFRR. But that not going to meet the Bosch standards of <450 HFRR. So hence, the 2 cycle oil concept was born to band-aid this issue. Clean DC Power There have been so many years where people made claims of the electronics in the Bosch VP44 failed because of heat cycles. Well, that might have been true. Never the less there is another killer that I've uncovered is how clean is your power? Batteries are clean DC power just as they are but when you hook an alternator to the batteries there is always going to be some sort of ripple from AC waveform being converted to DC power. As alternators age the diodes start to fail and more and more AC power starts to leak out. I've set the limit at no higher than 0.1 AC volts measured at the batteries. The whole AC power problem could create these codes. P0215 P0251 P0252 P0253 P0254 P1688 P1689- Cowboys Head Porting Endeavor
I'm waiting to see it start up with it fresh head and gasket... - wanting to move.