Replacing your CP3 - DIY

cumminalong · 09-05-2009, 03:12 PM

This DIY pertains to replacing the CP3 injection pump on a Common Rail 5.9. It's a fairly simple process, but some folks think it's a bigger deal than it really is.

Early CR's (03-04) will have an aditional step of removing the kickdown bracket for the TV cable going to the transmission as it interferes with removing the CP3.

WARNING! Cleanliness CAN NOT be over-emphasized when installing your new pump. Leave all fuel port covers in place until ready to connect lines.

WARNING! Whenever dealing with high pressure fuel from the CP3, use caution. At idle, the CP3 is making approx 6800 psi of fuel pressure. This is MORE than enough to cause severe injury or death.

YouTube - Resurrection II

__________________
'06 Ram 2500 CTD - 742 HP / 1456 TQ
Powered by: Doghouse Diesel Performance

BBRam · 09-05-2009, 03:19 PM

Very nice, Thank you !!!!!!!!!!

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03-3500, DRW, QC, 4x4, R850 BD Twins, BD IC Boots, BD Billet Flexplate, Full Billet DTT Trans, Lockup Switch, SMARTY TNT-R / TS MP-8, Wicked Diesels Eliminator Fuel System & Coolant Bypass, Floor It Stage 3 CP3 & Rail Cap, BIG Stix's by FTE, ARP Head Stud's, Springs, Fluidampr, ATS ARC-FLOW, Mag-Hytec, AFE, Boost, Drive Pressure, Pyro, Fuel Pressure, Tran's Temp, Rail Pressure Gauge, GDP Ladder Bars, GrandRock 7" Miters. (R/T .021, 60' 1.76, 1/4 ET 13.03 @ 102.05 mph)

July 2009 Cummins Forum ROTM Winner

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dillonjm · 09-05-2009, 03:20 PM

Good write-up

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03 Silver Quad Cab/Short Box 2500 305/555 4x4 - 4040XL - 2" Lift - 285 75R17 Dura Grapplers

***ilovemydiesel04.5*** · 09-05-2009, 03:26 PM

nice photos, a good read and i thought it was going to be harder when the time came.

__________________

2004.5 2500 Long bed Reg Cab
A/R Teflon Coated Rims,Wrapped in 33" Hankook M/T's,BHAF,smarty,Ts Performance Ramifier 100hp Pressure Box.4 inch exhaust Rat Rod style. Autometer boost,egt,tranny.Isspro fuel pressure.w6. Valve body,input shaft,T/C stb.

cumminalong · 09-05-2009, 06:01 PM

The worst part is getting the pump back in the pilot bore of the gear housing, everything else is cake.

Put some clean oil on the o-ring and lube the pilot bore of the gear housing and it's much easier.

Once your get the o-ring past the bevel on the pilot bore, the pump will slide right in.

Make sure you don't have any oil on the pump shaft and get as much oil off the shaft bore in the pump gear as possible.

__________________
'06 Ram 2500 CTD - 742 HP / 1456 TQ
Powered by: Doghouse Diesel Performance

Last edited by cumminalong : 09-05-2009 at 06:11 PM.

***NavyGuy2007*** · 09-05-2009, 06:09 PM

Wow, Nice write up, deffinatly easier then it looks.

__________________
'06 Inferno Red 2500 MegaCab SLT 4x4 CTD Automagic

'84 Ford Mustang SVO 2.3T

***ruidosododge*** · 09-05-2009, 06:12 PM

very nice write up sir...

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01 Red Sport X-cab SB 4.10's 6spd 4x4, Drag Comp, 62/71/14, 125hp stix, luk clutch, Raptor 150,boost & EGT gauges, intake, 4" exhaust, new brakes and front end

BBRam · 09-05-2009, 10:41 PM

Moved to the 3rd gen Tech Articles forum.

__________________

03-3500, DRW, QC, 4x4, R850 BD Twins, BD IC Boots, BD Billet Flexplate, Full Billet DTT Trans, Lockup Switch, SMARTY TNT-R / TS MP-8, Wicked Diesels Eliminator Fuel System & Coolant Bypass, Floor It Stage 3 CP3 & Rail Cap, BIG Stix's by FTE, ARP Head Stud's, Springs, Fluidampr, ATS ARC-FLOW, Mag-Hytec, AFE, Boost, Drive Pressure, Pyro, Fuel Pressure, Tran's Temp, Rail Pressure Gauge, GDP Ladder Bars, GrandRock 7" Miters. (R/T .021, 60' 1.76, 1/4 ET 13.03 @ 102.05 mph)

July 2009 Cummins Forum ROTM Winner

95 1500 Sport 2wd Cummins Drag Truck under construction.

"In search of the Magic Dyno"

09-05-2009, 03:12 PM	#1 (permalink)
cumminalong TECH SPECIALIST Join Date: Oct 2006 Location: East Alabama Posts: 493 Thanks: 1 Thanked 33 Times in 9 Posts cumminalong's Truck Pics	Replacing your CP3 - DIY This DIY pertains to replacing the CP3 injection pump on a Common Rail 5.9. It's a fairly simple process, but some folks think it's a bigger deal than it really is. Early CR's (03-04) will have an aditional step of removing the kickdown bracket for the TV cable going to the transmission as it interferes with removing the CP3. WARNING! Cleanliness CAN NOT be over-emphasized when installing your new pump. Leave all fuel port covers in place until ready to connect lines. WARNING! Whenever dealing with high pressure fuel from the CP3, use caution. At idle, the CP3 is making approx 6800 psi of fuel pressure. This is MORE than enough to cause severe injury or death. YouTube - Resurrection II __________________ '06 Ram 2500 CTD - 742 HP / 1456 TQ Powered by: Doghouse Diesel Performance

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09-05-2009, 03:19 PM	#2 (permalink)
BBRam Super Administrator Join Date: Jan 2006 Location: Chelsea MI Posts: 23,419 Thanks: 173 Thanked 248 Times in 162 Posts BBRam's Truck Pics	Very nice, Thank you !!!!!!!!!! __________________ 03-3500, DRW, QC, 4x4, R850 BD Twins, BD IC Boots, BD Billet Flexplate, Full Billet DTT Trans, Lockup Switch, SMARTY TNT-R / TS MP-8, Wicked Diesels Eliminator Fuel System & Coolant Bypass, Floor It Stage 3 CP3 & Rail Cap, BIG Stix's by FTE, ARP Head Stud's, Springs, Fluidampr, ATS ARC-FLOW, Mag-Hytec, AFE, Boost, Drive Pressure, Pyro, Fuel Pressure, Tran's Temp, Rail Pressure Gauge, GDP Ladder Bars, GrandRock 7" Miters. (R/T .021, 60' 1.76, 1/4 ET 13.03 @ 102.05 mph) July 2009 Cummins Forum ROTM Winner 95 1500 Sport 2wd Cummins Drag Truck under construction. "In search of the Magic Dyno"

09-05-2009, 03:20 PM	#3 (permalink)
dillonjm Cummins Nut Join Date: Jun 2009 Location: AF OTS : 3 NOV - 18 FEB Posts: 428 Thanks: 1 Thanked 31 Times in 25 Posts dillonjm's Truck Pics	Good write-up __________________ 03 Silver Quad Cab/Short Box 2500 305/555 4x4 - 4040XL - 2" Lift - 285 75R17 Dura Grapplers

09-05-2009, 03:26 PM	#4 (permalink)
*ilovemydiesel04.5* Cummins Nut Join Date: Oct 2008 Location: Northern NJ Posts: 1,387 Thanks: 35 Thanked 24 Times in 22 Posts ilovemydiesel04.5's Truck Pics	nice photos, a good read and i thought it was going to be harder when the time came. __________________ 2004.5 2500 Long bed Reg Cab A/R Teflon Coated Rims,Wrapped in 33" Hankook M/T's,BHAF,smarty,Ts Performance Ramifier 100hp Pressure Box.4 inch exhaust Rat Rod style. Autometer boost,egt,tranny.Isspro fuel pressure.w6. Valve body,input shaft,T/C stb.

09-05-2009, 06:01 PM	#5 (permalink)
cumminalong TECH SPECIALIST Join Date: Oct 2006 Location: East Alabama Posts: 493 Thanks: 1 Thanked 33 Times in 9 Posts cumminalong's Truck Pics	The worst part is getting the pump back in the pilot bore of the gear housing, everything else is cake. Put some clean oil on the o-ring and lube the pilot bore of the gear housing and it's much easier. Once your get the o-ring past the bevel on the pilot bore, the pump will slide right in. Make sure you don't have any oil on the pump shaft and get as much oil off the shaft bore in the pump gear as possible. __________________ '06 Ram 2500 CTD - 742 HP / 1456 TQ Powered by: Doghouse Diesel Performance Last edited by cumminalong : 09-05-2009 at 06:11 PM.

09-05-2009, 06:09 PM	#6 (permalink)
*NavyGuy2007* Cummins Fan Join Date: May 2009 Location: Whidbey Island WA Posts: 84 Thanks: 0 Thanked 1 Time in 1 Post NavyGuy2007's Truck Pics	Wow, Nice write up, deffinatly easier then it looks. __________________ '06 Inferno Red 2500 MegaCab SLT 4x4 CTD Automagic '84 Ford Mustang SVO 2.3T

09-05-2009, 06:12 PM	#7 (permalink)
*ruidosododge* SCRRRP Join Date: Dec 2007 Location: New Mexico Posts: 3,170 Thanks: 0 Thanked 63 Times in 62 Posts ruidosododge's Truck Pics	very nice write up sir... __________________ 01 Red Sport X-cab SB 4.10's 6spd 4x4, Drag Comp, 62/71/14, 125hp stix, luk clutch, Raptor 150,boost & EGT gauges, intake, 4" exhaust, new brakes and front end

09-05-2009, 10:41 PM	#8 (permalink)
BBRam Super Administrator Join Date: Jan 2006 Location: Chelsea MI Posts: 23,419 Thanks: 173 Thanked 248 Times in 162 Posts BBRam's Truck Pics	Moved to the 3rd gen Tech Articles forum. __________________ 03-3500, DRW, QC, 4x4, R850 BD Twins, BD IC Boots, BD Billet Flexplate, Full Billet DTT Trans, Lockup Switch, SMARTY TNT-R / TS MP-8, Wicked Diesels Eliminator Fuel System & Coolant Bypass, Floor It Stage 3 CP3 & Rail Cap, BIG Stix's by FTE, ARP Head Stud's, Springs, Fluidampr, ATS ARC-FLOW, Mag-Hytec, AFE, Boost, Drive Pressure, Pyro, Fuel Pressure, Tran's Temp, Rail Pressure Gauge, GDP Ladder Bars, GrandRock 7" Miters. (R/T .021, 60' 1.76, 1/4 ET 13.03 @ 102.05 mph) July 2009 Cummins Forum ROTM Winner 95 1500 Sport 2wd Cummins Drag Truck under construction. "In search of the Magic Dyno"