Stumped on this 24 valve
 

This is the first cummins i am working on, i usually work on 6.5s but a guy needed me to try and diagnose this truck so here it goes.

I am working on an 02 2500 5.9 24valve 116,000 miles stock except cold air intake and 4 inch exhaust. so it does this more when it is cold then when its warm. I start it up let it idle for a few minutes, then i take off about 5 minutes down the road i loose all power, i shut it off it runs great it does this till it is up to full operating temp then it runs fine. It does not blow excessive black smoke no white or blue. I am at a loss of where to start. No light but if i read codes it comes up p0216. i am going to try to clear it after work see what it does. I've read it could be as simple as a sensor to as complicated as an injection pump. Also its not that it runs bad when it looses power it is just that it doesnt get up and go at all.

Thanks for the help in advance.

more then likely the injection pump is bad. upgrade lift pump and new ip and you should be golden.

P0216 = timing control circuit malfunction.

that is one of the vp44 death codes.

what is fuel pressure like on this truck?

monitoring fuel pressure is critical on 2nd gen 24v cummins engines as they are VERY sensitive to it.

these things should have come stock with a 0-30psi fuel pressure gauge. I highly suggest hooking up a fuel pressure gauge to it and checking fuel pressure. if it goes under 10psi in any conditions other than engine off... then the lift pump needs replaced and/or fuel filter.

should hold over 10psi at ALL times. this means wide open throttle, cruising, and idle. over 14psi under all conditions would be ideal as it keeps the overflow valve open to have fuel constantly cycling through the vp44 to help cool it.

typically a P0216 is caused by the electronics in the vp44 overheating and causing electronic failure which I am sure you are familiar with since you know your way around a 6.5L chevy diesel which is notorious for electronics failure due to overheating. though the 6.5L can separate the electronics from their injection pumps... the vp44 can't and is not a serviceable part. if the electronics go in the vp44, the whole pump needs replaced. so your best chance at keeping it alive is keeping constant fuel flow through it so it stays cool.


I run 20psi fuel pressure at idle, 18psi cruising, and 16psi @ WOT

check that fuel pressure and address it if it is too low then post back. :pca1:

So it is possible for it to be something other than the IP i will test fuel lift pump when i get home this evening

I think Jigabop is right.. the VP44 needs at minimum 8-9 psi while running. if even at one time it drops below that.. its more than likely your VP will be done for.

I hear "taps" playing in the background...:nope:

Fuel pressure is correct it has the lift pump in the tank I dont know if that is better than the frame rail or if it is not. The think is if i let it warm up for ten minutes, shut it down and immediately restart it it runs flawlessly, but if i try taking off without shutting it down its low on power. For instance i let it warm up this morning and shut it down then drove to work i didnt have any symptoms the rest of the way. But the day before i let it run for 2 minutes instead of 10 and jsut got in and drove to work i had to restart it 4 times till it was up to operating temp then it dove flawlessly the rest of the way.

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I mean Fuel pressure is 15 when at idle and it has 10 at WOT

sounds like the vp44 is on borrowed time.

start saving up...

$1k in parts alone to replace it.

10psi is technically adequate pressure, however I wouldn't even drive my truck if it dipped down that low in pressure.

You could try this https://www.dieselbombers.com/98-5-0...ronic-fix.html Its no guarantee but it could save you some money

a grand... wholly moly

Cleaned then connection on the IP and it seems like It fixed it but i think the injection pump is on borrowed time it is the original pump and lift pump with 116000 and i just got the okay from the dealership to get a new FASS lift pump and Industrial Injection IP that is the next project,

injection pump is all done took about 3 hrs to complete thanks for the help

well a little late on here. but was about to work on a 2002 24v. pretty much same deal seamed just to fall on its face and wouldnt have enough speed to shift. was about to get a rebuild pump and called the people to order. they guy asked whats it doing he was informed and he said they have been having a lot of problems lately. people replace the pump thinking its the problem. but he said if its the pump turning it off wouldnt fix the problem, but it seams like a problem with the stock fuel filter. something about it causes too much pressure and wont let the ip operate right. the cure is to bypass the stock one with a aftermarket. anyone heard of this?

I have to say that is false. Why after all these years are ppl suddenly having problems. They arent. It's not necessarily the internal injection pump a lot of times the Electronic fuel control box ontop of the VP is what fails that is why when you shut it off it runs good. i just got done replacing the vp and its not that big of job and that was definately the fix. Unless you have a lot of upgrades i wouldnt worry about your fuel filter.