[Mudmovers]

Hi all, New to the forum, looks like a wealth of information here, perhaps you can be of some assistance to me.
A few weeks ago I was driving home from a class I'm in, and my truck just died. 2004.5, LLY CCLB 4x4 6.6 vin 2 . It was as if I shut the key off, but nothing else died. Just a light sputter and died. As I coasted to a stop I popped into neutral and tried to crank, but no start. No previous cel problems, had filled up with fuel the night before (had about 1/4 tank fuel). Checked around a bit before having it towed home. At home, I had fuel at the bleeder, and solid fuel while priming. Had serviced the truck right before new years, so the fuel filter is pretty fresh. Cranks, but won't start. Scanned ecm, no current codes. Had 2 history codes, one being lost comm with FICM, the other a FPR ckt malf, but not current. I cleared codes, cranked several times, nothing reappears, and no pending codes either. no fail since clear either. I also tried to look over every inch of harness on the engine, and don't see any rub through or short isues. I have a buddy with identical truck so we swapped FICM just to be sure, his truck runs with my FICM, so no prob. there. I've replaced the fuel filter during my testing, solid fuel out to the bleeder, and removed vaccuum ck port fitting and have solid fuel out to there. Placed a vaccuum gauge in line at ck port, have no draw while cranking. I do have voltage out to fuel regulator solenoid , and can hear it whine from the current flow. My residual line pressure showed at about 150psi, requested is about 5500, pressure while cranking got max of 250-350. Again, no draw at ck port though. It appears to me that my fuel pump has taken a dump on me. I removed the Fuel regulator solenoid and supplied it with 12v, and the plunger moves no problem. The only issue I am having is that I don't see anywhere where anyone seems to be having problems with these pumps. Has anyone else had any issues with their pumps failing on an LLY? I see lots of fuel regulator solenoid issues, but not the actual pump. Anyone have any thoughts on this? I believe I've covered my bases pretty well....all signs point to a pump failure. The other thing I did notice is very small aluminum particulate on the top of my fuel filter when I removed it. I don't know if some of that particulate may have passed into my pump, and if so I could see that causing a failure, but it sure seems that it would have been caught by the filter prior to entering the injection pump as that is pretty much the last thing in the way on the inlet side. Thoughts? Experiences?

Your information is certainly appreciated, It looks like I'm looking at about $700 or so for a reman pump, so not the end of the world. I would just feel better about it if I could find a few other people that have actually had this problem.

THanks again, :help

Jon

 

[Mudmovers]

I should also add that I removed the fuel filter bracket and inspected for cracks and didn't see anything noticeable. With solid fuel to the ck port when I hit the priming button, I figure I should see a draw from the pump if its working. Just seeing no draw on the vaccuum gauge.
Thanks again,
Jon

 

[crdmax]

man i have no idea....but i will bump it for you!!! good luck and welcome to the df

 

[FREIGHTTRAIN]

welcome to df

 

[dieselthemeatbag]

I have not heard of any going out either sorry I cant help but I have and IH Scout too

 

[bluebowtie]

Is it tuned?
Welcome to the DF

 

[Jonsey181]

If you can get a diagnostic tool, I would scan for two things, Balance rates to see if there is any leaks in the injector, or maybe the return system. It is uncommon for a Cp3 to go out I believe, and your right FPR is more common but if you say that is not the case, I would also check fuel rail pressure, for your desired and actual fuel rail pressure, If your FPR is bad you wont keep a desired fuel rail pressure which should show up on the diagnostic tool

If you dont have a tool that can read these I would say a good thing to do would be go to Wyo tech in Long beach usually places like that wont have a problem diagnosing your problems, I know UTI's around here have the tech II if you call them and ask one of them if they need a truck to diagnose they might set you up with a time to come in during a class..... unless their assholes

 

[bigeddie1300]

check your ICP and IPR

 

[bigeddie1300]

Those Will Cause Them To Have The Same Symptoms Your Experiencing

 

[Mudmovers]

we read it with a tech II, didn't look for balance rates though. Keyed in on the fact that there were no current codes, coupled with the fact that my fuel rail pressure was ~250 psi while cranking, and the request was for 5500psi. Perhaps the FPR is the prob, the voltages available to it were identical from my truck to my buddy's truck, and as stated, when 12v applied directly to the solenoid, the plunger definitely pulled in, which led me to feel that it was operationally sound. If the balance rates were off would that be showing a leaky injector? and if so, I would think that would maybe cause smoke/misfire on start up, but not a completely dead truck, no? hmm...unless it being stuck wide open is causing me to completely lose rail pressure, hadn't thought about that.... but it would still show a good draw on the inlet side, even if an injector was stuck open, correct? I'm not showing any vaccuum at all on the inlet side (measured at the ck port by the EGR valve) Sadly, I am wishing it was a cummins right now (don't bash please...I work on them all day long at work, and would feel a lot more in my element. This is the first time I've really gotten into a Dmax). BTW, it is bone stock, no tuner, no exhaust, nothing yet. All hoped for, but not paid for yet I do have an Edge w/ Attitude sitting on top of my toolbox, but have never installed it. Another friend with an 05 LLY was having CEL issues with it, so he took it off and let me "have" it (for now). Thanks for the welcomes as well, sorry it had to be under these circumstances that I found you guys. I had really hoped someone was going to say that, "Oh yeah, mine did the same thing and we replaced the pump, fixed er' right up". I suppose there's a first for everything, but I would think it would happen to someone else first, not me. The truck has 104k miles too, forgot to mention that.

 

[Mudmovers]

check your ICP and IPR

ICP and IPR....what are those please?

 

[Mudmovers]

Okay I think I know what you're talking about...
Ignition Control Pressure Sensor.... Says ~250 while cranking, requested psi is ~5500
Ignition Pressure Regulator... ? That's the solenoid on my CP3 pump, correct? I get good/similar voltages to identical running truck, as well as once I removed it I gave it 12v from a power probe and the plunger sucks right in as expected. We also looked with the scanner to see if I had cam/crank signals present and both are there and seem normal. On identical truck we had about 3" vaccuum during cranking and once the truck started the fuel started travelling up the vaccuum hose. On my truck during cranking, I get no vaccuum at the check port. Good fuel to the check port (removed schrader valve adapter and hit the priming pump...solid fuel available to that point). We drew a vaccum on the port and pulled some fuel up into the line of the vaccuum pump and cranked engine, would not pull the fuel out of the line there...no draw at all. It all points to the pump failing, but again I was hoping that someone else had experienced this prior to myself. I really do appreciate the input and brainstorming, I guess I just need to suck it up and replace the pump. They have reman pumps available, so it has to have happened before I guess.

 

[Jonsey181]

The injector rates should be high if there is a leak in the injectors and the return side including the rail and the pump I believe, I didnt know you had a tech scan good thing you dont have to dick with the dealer than, the plunger may be moving but it depends on where it is regulating the fuel does the plunger have full movement? say it sticks open while running it would cause a higher desired pressure than like 22,000psi iirc, but 250 while cranking I guess could be both the regulator and the pump, sounds like you have diesel buddies if one of them has a lift pump handy or sitting around you could install that and set it to 10-12 psi and see if you can get your desired rail pressure with that and possibly a start?

sorry just throwing out guesses and opinions here

 

[bigeddie1300]

haha dont feel bad man i work on fords all day long lol so i know how you feel but once your on here its like crack man you'll find your self getting on everyday lol. did you find it?

 

[bigeddie1300]

no need for the hate man i had my ICP take a dump on me and mine fell dead just stating two possible cause for him to look into. and by the sounds of things it may just be his ICP if hes only producing 250 at crank and it calls for 5500. now im no math wiss but by those numbers that would be a point of interest to me.

 

[Mudmovers]

Well, I'm feeling a lot better about it being the pump now. Between a few hours yesterday and about an hour today, I got the little punk out. What a pain in the butt, I basically tore the whole front and forward half of the engine off to get the beast out. Upon removal (which, thank God I didn't have to pull the lower intake plenum off...It looks as if the turbo would have had to been removed to get to the rear lower bolts..If I had to pull the turbo I think I would have gone crazy) I rotated the pump gear and at first it didn't even want to turn, and then kind of broke free and rotated with very little resistance several times and then started to bind up again and made a snapping noise as I "forced" (gently, but with effort) it past the hard spot and then rotated just a bit and kind of bound up again. As if it had a broken rod, even though I believe it to be a gear pump. Makes me think I have some crap floating around inside that has jacked up the gears in there. Will open up tomorrow at work (probably...do you think it will void the core if I open it for examination?) I'll attach some pics in a few minutes of the engine and pump, and my truck. Gotta get an avatar set up in here.

 

[Mudmovers]

Man I hope this thing never goes bad again. What a pain in the butt to get to!