2003 HPDI 200hp Completely bogs down after 1/2mile

[Lunchman]

I am pulling my hair out.I'll start from the beginning,bought this motor in 04 as a left over 600hrs and NEVER had a problem til the economy tanked and so did my business.So I couldn't afford to use her for a little over two years. I treated the fuel during that time, as recommended. Long story short last Fall when I tried to run her in the river she was bogging down. Everything I read and heard said it was the injectors and it also recommended that a mechanic do the injectors. So in the Spring I sent it to a mechanic who said he cleaned five injectors and replace one, he dumped all the fuel (90 gals) and replaced all fuel filters, water separators and O2 sensors. Got the boat back she ran for 4 miles at 4500 RPMs and then cut down to zero. I've since replaced both low pressure fuel pumps and the high pressure pump in the VST tank. Spark plugs were changed, fuel lines replaced. Now, she gets up on plane but only runs 1/2 mile before completely bogging down. She seems to run with no issues at lower RPMs. Any and all suggestions would be appreciated as I am running low on money and can't keep chasing my tail around.

As stated earlier, the motor never gave me any problems at all until after she sat for two years without running her.

[Sequoiha]

There are 2 filters i guarantee did not get changed. Basket filters in the high pressure pump. Very easy to change. Take the fuel pipes off the back of the pump, remove the 2 ten mm bolts and the 2 twelve mm bolts, take the back off the pump, there are 2 small basket filters that can be removed with a #10 screw and a pair of pliers. Filters are available on the Internet.

[99yam40]

some one should be monitoring the fuel pressures to see if they are a problem when it bogs down

[rodbolt17]

two ways to fix it.
stand back 10 feet and throw wads o cash OR actually test fuel rail pressures.

[Lunchman]

There are 2 filters i guarantee did not get changed. Basket filters in the high pressure pump. Very easy to change. Take the fuel pipes off the back of the pump, remove the 2 ten mm bolts and the 2 twelve mm bolts, take the back off the pump, there are 2 small basket filters that can be removed with a #10 screw and a pair of pliers. Filters are available on the Internet.

Thanks for the reply Sequoiha,I'm still not sure where you are talking about.You say in the high pressure pump is that not the round pump in the VSA tank? I was told the one in the tank is the high pressure pump the 2 behind the tank are low pressure.Was I misinformed?

[Lunchman]

some one should be monitoring the fuel pressures to see if they are a problem when it bogs down

Thanks for the reply
I have to admit I'm a driveway mechanic,So I don't a pressure gage.how and where do I check the pressure.Is it called a fuel pressure gage,and do know if I can rent one?

[Lunchman]

two ways to fix it.
stand back 10 feet and throw wads o cash OR actually test fuel rail pressures.

Rod Thanks for the reply.
Thats my problem I don't have the cash to keep throwing at it.That's what started this whole thing.Was letting her sit,due to lack of money NEVER had a problem before that.
Forgive me if this is a stupid question,Is fuel rail pressure the same as fuel pressure? How do I test?
Thanks for any help yo can give.

[rodbolt17]

on the hpdi there are 3 fuel subsystems.
the low pressure also known as lift or supply pumps.

the medium pressure that's the one in the VST that supplys the HIGH pressure with 50 PSI of fuel at all RPMs
the high pressure is the belt driven pump that feeds the injector rail at 1100 PSI or so.
all 3 have to do the dance or the party suxs.

[Cobia270]

Hey lunchman the high pressure pumps are at the rear of the engine. The pumps you are talking about to the rear of the vst are the low pressure pumps or lift pumps. Good chance it is the high pressure pump not putting out enough pressure. Get a mechanic to hook it up to the yds and check pressure.

[Lunchman]

Having a little trouble getting the filters out on the High pressure pump.
I have tied the #10 screws,it feels like its grabbing it but when I pull the screw out it lets go.
Anyone have any tricks on getting these filters out?

[Lunchman]

Hey lunchman the high pressure pumps are at the rear of the engine. The pumps you are talking about to the rear of the vst are the low pressure pumps or lift pumps. Good chance it is the high pressure pump not putting out enough pressure. Get a mechanic to hook it up to the yds and check pressure.

Thanks Cobia,I see what your talking about now

[99yam40]

Having a little trouble getting the filters out on the High pressure pump.
I have tied the #10 screws,it feels like its grabbing it but when I pull the screw out it lets go.
Anyone have any tricks on getting these filters out?

The pumps can be sent off to have them gone through if there is a problem with it.

[Cobia270]

Try threading the screw in a little more. I just did mine recently. Just make sure when you pull the screw out the whole filter comes out with it.

[Sequoiha]

That's correct, screw it in about 4 turns, and pull it out with a pair of pliers.

[Lunchman]

Well after finding the mystery filters,I dumed her in the water to test her.
She ran terrible,I took her home to go over the motor again.Turns out I didn't not connect a oil feeding tube (I know stupid move)
Anyway after connecting the tube I tried to start her,now she won't start.
Does anyone have any idea what I could have done,or why she isn't starting.
The only good thing to come from this is I'm REALLY starting to get to know every inch of my motor.