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.

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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.

Bosch Diesel Fuel Injection Pump

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.

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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??? 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. 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 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. 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. We have detected that you are blocking our advertisers. We pay our operational bills with advertising and donations. Please add Mopar1973Man.Com to your whitelist of sites on your adblocker. If you register as a member and submit a donation to the website, the advertising amount is reduced the more you donate. This will allow you to keep you adblocker turned on for other sites and allow to display advertising here. Thank you, for understanding and whitelisting Mopar1973Man.Com.

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Bosch Vp44 Diagram

.WIRE TAP OKAY. Pump has a one year warranty. This pump is built with a Brand new Bosch Computer VP44027TAP 1998.5-2002 235HP pump that will fit Dodge Cummins Turbo Diesel with Automatic or 5-speed 215HP & 235HP Dodge 5. Most common pump found on Dodge Pickup Trucks. Can support 650HP with the proper supporting mods. Pumps are rebuilt by a certified Bosch shop and have all Bosch upgrades and updates including new electronics and steel housing. One Year/ Unlimited mile warranty.

The VP44 is the most advanced pump Bosch has made. It uses the computer or PSG to control both fueling and timing. It is also more sensitive and dependent on the lift pump for cooling and lubrication. If the lift pump fails or is unable to keep 5psi (recommended is 13psi) of fuel pressure your pump is susceptible to damage, overheating and failure.

Free shipping and return shipping to 48 states. Core: Core deposit of $400 required unless core sent in advance. If a rebuildable core (ie.

Not seized, damaged, contaminated, disassembled) is not received in 30 days from date of shipment a reduced core credit of $200 applies for late cores. International orders have 45 days. IF YOU PURCHASE AN SO 235HP PUMP, YOU MUST RETURN AN SO 235HP PUMP. ANYTHING OTHER THAN AN SO 235HP PUMP RETURNED WILL RESULT IN 1/2 CREDIT. Shipping: Free shipping on the pump and Free return shipping of the core for 48 states.

HI, AK, PR and International orders do not qualify for free shipping or a free return shipping label. VP44 DISCLAIMERS: Failure to replace feed pump along with the Injection Pump may result in damage not covered under warranty.

It is highly recommended that the feed pump be changed along with the injection pump. The VP44 pump uses fuel to cool and lubricate the pump.

Bosch Vp44 Diesel Fuel Pump Manual

The tolerances between the head and the rotor are very tight. Performance chips affect the cooling rate of the pump. The pump will become hotter due to excessive RPM??s from the chips programming. When the throttle is backed off, the fuel to the pump is reduced, and the pumps cooling capabilities are greatly reduced. Since the pump is hotter from the increased RPM??s, the rotor seizes in the head and the pump fails. An alternative to cutting/tapping into the pump wires is to use a larger set of injectors or/and a chip that plugs directly into the trucks ECM. This approach will allow for an increase in HP while not excessively heating the fuel pump.

Troubleshooting: Often if your VP44 failed, the root cause is a bad or failing lift pump. The stock lift pump does not supply sufficient pressure for stock power. It is mounted to the engine block and has to push through some small fittings and lines that act as a restriction, even worse the pump has to pull fuel all the way from the tank. Electric pumps are designed to PUSH not PULL fuel. The in tank pump recommended by Dodge dealers is not much better. It may flow a slightly higher volume but at pressures even lower than the stock pump. It is placed inside the fuel tank to keep it cool and reduce failures, but when it fails you are out another $500 for the dealer to drop your tank and replace the pump again.

Defective VP44 Codes: The retrieval of codes does not constitute an engine diagnosis. However, there are some codes that usually indicate a defective injection pump. A current P1688 always means that the pump is bad, there is no further diagnosis required. Code P0216 is probably the most common code for VP44 Pumps. If transfer pump pressure has been checked and is O.K., the injection pump is defective. It is rare to get a P0216 for contamination but it may be worth trying some quality diesel fuel cleaner/conditioner with the small percentage that it may clean the internals of the pump to remove varnish and allow the pump to time fuel delivery correctly.

Other codes that are less common are P0180, P0181, P0215, P0251, P0252, P0253, P0254, P0370, P1287, P1689 and P1690. These codes USUALLY, but not always indicate a defective pump. There are wiring and power checks to be performed if these codes are present.

These codes relate to Dodge pickups only, and are not for any other ISB application. Cross Reference: VP44027 is also known as: SO, Standard Output, 027, 215Hp 235HP, 027, 05015721AA, 05019658AA, 05019658AB, 05019658AC, 05019658AD, R5011041AA, R5011041AB, R5013925AA, R5015721AA, IPVR11X, IPVR12X, IPVR15X,. VP44028 is also known as: HO, High Output, 245HP, 028, or IPVR17X, 05018495AA, 05019657AA, 05019657AB, 05019657AC, 05019657AD, R5018495AA, R5019657AA, R5019657AB, R5019657AC, R5019657AD, 3937159RX, 3937670RX, 3937687RX, 3946370RX, 3947031RX, 3947159RX, IPVR14X, and IPVR17X. VP44029 is also known as: Midrange, 029, IPVR13X, IPVR16X, 3964555RX, 3944983RX, 3943506RX, 3937672RX, and 3937167RX.

Installation: Please make sure that the keyway is aligned properly to avoid damaging it and causing a timing error and P0216 code. VP44 Install And Removal Part 1: VP44 Install And Removal Part 2: VP44 Install And Removal Part 3: VP44 Install And Removal Part 4: VP44 Install And Removal Part 5: VP44 Install And Removal Part 6: Diesel Auto Power would like to thank 'Diesel Dan' MacDonald for posting these informative videos! Additional Information.