P0216 and P0602 codes, intermittent loss of power, weird MAP reading

[greenfun2]

My truck recently started having a intermittent loss of power, usually before the engine warms up.  It also seems to be easier to stall while backing up a hill with a trailer.  The check engine light never came on, but it did throw a P0216 and P0602 code.  The first time I cleared the codes, there was an episode of intermittent power loss and both codes came back.  The 2nd time I cleared the codes there was no power loss, and only the P0216 code came back.  

 

The truck is a 2001 5 speed. 

I replaced the VP-44 last year with a DAP pump and added a FASS lift pump.  I currently have 15-17psi fuel pressure. 

The alternator is about a year old, and is a 160 amp from a Durango.  I checked for AC noise and it was bouncing between 0.02 and 0.06 VAC measured between the alternator charging post and the battery ground post. 

 

One thing that I did notice that I don't understand is that my OBDLink is saying the MAP is reading ~2 atm and the boost is ~ 1 atm with the engine off, and while driving the MAP reading wont go above 75.0 inHG and the boost wont go above 22.3 psi.  I got a new MAP sensor from Napa and it showed the same the reading with engine off.  I didn't actually install it and drive with the new MAP sensor, because someone switched the MAP and IAT sensors around so I couldn't get my socket on the MAP sensor with it being back by the fuel return line.  I just plugged the new one into the harness and turned the key on.  Does this point to an issue with the ECM, or is my OBDLink reading it wrong?  Since the P0216 comes back, should I reach out to DAP about warrantying the VP-44?

 

 

EDIT:  Made the pictures smaller.

                                   

Edited July 28 by greenfun2
typo

[Tractorman]

Is your engine stock, or are using a tuner?  I use a Smarty S03 and the 0602 code is normal (as stated by Smarty). 

 

The 0216 code does not sound good, especially with good lift pump pressure.

 

Did the VP44 pump you bought from DAP use a remanufactured PSG or a new PSG (1 yr vs. 2 yr warranty)? 

 

You want to have a VP44 that has be run through a program on the Bosch 815 test stand - no exceptions.

 

- John

 

 

 

[greenfun2]

I don't have a tuner. 

 

New PSG.  I bought this one:

https://www.dieselautopower.com/bosch-027-vp44-fuel-injection-pump-standard-output-235hp-wire-tap-voids-2-year-warranty-vp44027

[Tractorman]

I recommend giving DAP a call and tell them what you have written here.  The P0216 sounds like a timing failure and is likely to be internal to the VP44.

 

From the FSM:

 

P0216 (M) Fuel Injection Pump Timing Failure High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.

 

Is your fuel pressure sensor located right at the VP44?  If so, assuming that your reading of fuel pressure is steady, then you don't have a lift supply problem. 

 

- John

[greenfun2]

It is.  I have a Vulcan big line kit between the factory fuel filter and the VP44, and the pressure sensor is in that line.  I put a mechanical gauge on and it was steady.  I'll reach out to DAP in the morning and see what they say.

[Tractorman]

Please let us know what DAP has to say.

 

- John

[greenfun2]

I talked to DAP on the phone this morning and explained my problem.  Mitchell said he'd get back to me and he actually did.  I pulled the pump this evening and will ship it back for warranty for. 

[Tractorman]

It's tough to have to do the job twice, but I'm glad to hear that DAP is taking care of you.

 

- John