July / August / September 2022
Where have the updates been?
We have had quite a few requests for a bus update. Why has it taken us so long to get back on track? Unfortunately, in a very short time span we had several tragic losses in our extended family and circle of friends. We never experienced this much grief and sadness on a weekly basis during a two-month period. Even living in the comfort that they are now all rejoicing with the hosts of Heaven, the mental impact for those left behind takes huge amounts of energy and does not leave much room for anything other than keeping the girls and ourselves moving forward. Add to that: camps, COVID, and AHG, and any free time we might have had was claimed by activities.
Getting back to life
Now that things are calming down, we are resuming our quest. Once we finally managed to get back to the bus, we tried once more to start it. Of course, it did not turn over. Instead, flash codes 25, 63 and 49 showed up. We are working with the flash codes since we do not have a reader that we can plug in.
Flash code 25 is a boost pressure sensor or intake manifold sensor issue.
Flash code 63 is a Fuel pressure warning
Flash code 49 is an inlet heater relay issue
We wanted to work on the boost pressure sensor code first. Unfortunately, it is impossible to access it from behind or side of the engine. We had to cut a hole in the bench. Always nice to do something like that AFTER having insulated and covered it with plywood…
Not an easy fix
Cutting the hole was not as easy as it sounds and due to limited time availability, it took about three weeks to have the individual cuts complete without destroying anything below the bench. Then we pulled out the sensor from the top of the engine and discovered that the replacement we had purchased was not the same as the sensor we had on the engine. It took two weeks to get the correct part. After that the engine still did not turn over so we proceeded to work on flash code 63.
Next code – fuel pressure regulator
This code can normally be resolved by replacing the fuel pressure regulator. This regulator is placed in another very convenient location: at the back of the engine. Hoping not to have to cut another hole in the bench, we decided to move the air intake line. This was much easier than expected. Even though access was difficult, we could see the front side of the engine clearly. The front of the engine was so caked in dirt and grime that it took us a while to find the regulator. It involved a few more days of research to make sure we would pull off the correct part.
With help from Oma, who had arrived for a two-week visit, we managed to get the grime off and find the problem location.
Ecstatic to be making some headway, we started to undo it (two more trips home for the correct tools). Lo and behold, the part came loose…. after breaking off the attached fuel pressure sensor… AAARGH!! Fortunately, Oma was sitting beside me to hold open the access hatch, which prevented the explicits from coming out of my mouth.
Perseverance pays off
A few frustrated deep breaths and onward we went, unbolting the entire system. After blocking off and covering the now open fuel line, we took the section home. A little cleanup and reassembly, then back online to order a new fuel sensor. These have changed since this Cat was built so we hope the new version works the same way.
We did spot fuel in the electronic part of the sensor, a common issue with the Cat C7, so a replacement was due but still more money and time spent. We remounted the assembly and put back the air intake line. Re-strapped all the electronic cables and re-tightened all the bolts we had loosened for the easy access.
More delays
We spent a day replacing the batteries in the bus with fully charged ones. Then a day to figure out how to reset engine error codes. And of course, the latter did not work. Meaning we now have run all electrical possibilities and replaced:
- Batteries
- Starter
- Boost pressure sensor
- Fuel sensor
- Fuel regulator
All of this, plus a lot of prayers and we are still stopped dead in our tracks. And we have not made one step of progress since May. We now officially have reached the point where we need to call in assistance. Frustrating, but we look forward to the moment where we have a purring engine again…