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Discussion Starter #1
My 2003 dodge ram 2500 5.9 started up fine let warm up for 15 min pulled out of my drive way and died. Won't start still rolls over have no fuel rail pressure. I unhooked the line at bottom of rail and rolled it over fuel just dribbles out the line. Bad cp3?
 

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What kind of pressure do you have pre cp3?

Is there fuel pressure before and after the fuel filter?

Can you hear the lift pump when you first turn the key on?
 

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CP3s in these are extremely reliable.
Just like the older Gen2s, it's the cheap POS lift pump in the early Gen3s that failed early and often.
Start by measuring the output pressure and volume from the lift pump.
Is it even running?
You have intank update conversion or the OEM out of factory POS lift pump?
 

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Discussion Starter #4
I have like 29 psi rail pressure when truck is off when I roll it over it goes up to like 89psi and have not check pre cp3 but cracked feed line on the cp3 and had good pressure.
 

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any smoke??
Any codes ?? ecm controls fueling
fuel in oil??

briefly remove fca electrical connector on cp3, not too long can damage RPS, should get max rail psi.
 

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Discussion Starter #7
No codes no fuel in oil did disconnected that plug and did get maX rail pressure. Someone said something about maybe a key inside the pump broke?
 

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Discussion Starter #8
No codes no fuel in oil did disconnected that plug and did get maX rail pressure. Someone said something about maybe a key inside the pump broke?
Nvm when we unplugged the fca we didnt get max rail pressure didnt give us anymore pressure
 

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Not common for key to break also gear is press fit, any strange noises??
Most common cause is bad fuel , If there has been a major contamination issue with dirt and or water then it is very likely that the high pressure pump will need to be replaced, some cases where cascade overflow goes bad can try measure return flow on CP3 . Test and tool info here '03-'07, 5.9L Dodge Diesel HPCR Fuel Pump Return Flow Test Kit
 

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If you are reading 89 psi RP, at least 2 stages of CP3 pump are working, have to figure out why third stage is not.
If possible monitor demanded vs actual RP
Double check lift pump (engine not running) lift pump fuel flow rate should be
greater than 300 ml in 30 seconds.

To test FCA
Measure the resistance of the electronic fuel control
actuator valve. The maximum resistance is 5 ohms.
Install the electrical connection after measurement.
To test CP3
Disconnect the high pressure fuel line to the fuel rail
from the high pressure injection pump.
Connect a clear hose to the outlet of the high
pressure injection pump.
Run the high pressure fuel line into an empty bucket.
Crank the engine for 30 seconds and measure the
fuel pump flow.
Minimum fuel pump flow is 75 ml [2.5 oz] in 30
seconds at 125 rpm or 90 ml [3.04 oz] in 30 seconds
at 150 rpm for 4-cylinder and 6-cylinder engines.
If the minimum fuel flow is achieved, the electronic
fuel control (EFC) actuator is defective. on our trucks called , FCA.
If the minimum fuel flow is not achieved, the high pressure
injection pump is defective and needs to be
replaced.
 

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Discussion Starter #12
Lift pump is working as it should. Took the fca out was told if it don't rattel inside it's junk mine didn't rattel. So replaced it with a spare one that ratteled and didn't work not sure if I should buy a new one and try it
 

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TY for posting the outcome of your diagnosis.
 
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