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Fuel System Upgrade and Gauge Install


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I just joined the forum back a couple of weeks with the intention of giving back as I've been a lurker for a couple of years. I am preparing for a fuel system upgrade and gauge installation. Here is the list of components I will be installing in the next couple of weeks:DTT Assassin Mechanical Fuel Pump (3/8" lines)Vulcan VP MAX Dual Remote Filter Kit (20um water separator and 3um filter)ISSPRO EV2 Electronic Gauges w/ A-Pillar 3 gauge mount (Pyro, Fuel Pressure, Boost)Block Heater (I know nothing to do with fuel system, but while the truck is down might as well get it done before winter hits)A little background on the motivation for the upgrade. I bought my 2000 back in March (230,000 miles) after having a 1999 for a few years. I've been slowly working through issues and fixing things as they come up. On my way to Idaho City a couple of weeks ago I got the feared dead pedal and engine code. The truck would idle and then jump up to 1500ish RPM before dieing. I let it cool down for a bit and managed to limp it home. Reading the engine code when I got home I came up with a P1689 (ECM to Injection pump communication error). I worked through the less expensive options starting with the fuel system relay, which seemed to be the culprit on initial inspection. In the time since I have started a 2-cycle regiment and ordered the parts above hoping the VP44 was not damaged from low fuel pressure. I have continued to have the issue intermittently, but not as serious as the first occurrence. I am hoping the upgrade will help keep the VP44 electronics cooler and give me some more life.So I am starting this build thread to invite any questions as I go through upgrading my fuel system. If you would like to see a particular picture or step of the process let me know and I'll include the information as I update the thread. Thanks guys.

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  • 2 weeks later...

Just a quick update, I finally had time and finished my gauge install last night and will be putting the write-up together on that soon. All the gauges seem to be working great, and as suspected my fuel pressure is low. I am only hitting 10psi at idle and float between 7-8psi WOT. I opened my needle valve up all the way just to verify I was not restricting too much. Mike, I went through the process of adjusting the needle gauge from your video, but the electrical gauge is a little different on starter bump (not a slow pressure build). I closed it down as much as I could and still get a consistent reading, anyone have any suggestions on adjusting the needle valves for electric fuel gauges? Now I need the mechanical fuel pump and fuel line kit before I continue...Gauge write-up coming soon...

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