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Author Topic: Removal and Installation of a CP3 on a CR Cummins  (Read 11105 times)

Offline Cumminalong

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Removal and Installation of a CP3 on a CR Cummins
« on: September 05, 2009, 02:21:56 pm »
This DIY pertains to replacing the CP3 injection pump on a Common Rail 5.9

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.































« Last Edit: September 05, 2009, 02:24:42 pm by Cumminalong »

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #1 on: September 05, 2009, 03:38:27 pm »
Nice. Looks pretty easy compared to some work on the engine.
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Offline Cumminalong

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #2 on: September 05, 2009, 03:51:43 pm »
It's not bad at all.

The hardest part is getting the new pump lined back up in the bore.

You don't need any real special tools, other than the gear puller, which is about $20 at AutoZone.

Everything else is hand tools. 10, 13, 17, 19 and 24mm wrenches, a 13 & 27 mm socket, 1/2" and 3/8" ratchet with extensions and u-joint, and a torque wrench.

Offline BigRiver

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #3 on: September 05, 2009, 03:57:36 pm »
Very concise explanation.......

When is your DIY Journal due out? ;D

Good job Rich.....your write ups are extremely helpful!

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #4 on: September 06, 2009, 03:37:36 am »
Great write-up, very detailed & understandable!

Takes the worry away for someone who never did it before :up:
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Offline NickBeek

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #5 on: September 09, 2009, 03:46:42 am »
Nice write up Rich. Question, how exactly did you get the fan shroud out without messing with the fan? It doesn't appear that there is enough room in there to simply pull it up and out.

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Offline Cumminalong

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #6 on: September 09, 2009, 10:19:09 am »
The fan shroud collapses.

Once you remove the 4 nuts and the wiring harness bolt, you can compress it down pretty flat and push it up.

As you push it up, rotate the fan to keep it from snagging and the shroud comes right out.

Same thing going back in.

Offline NickBeek

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Re: Removal and Installation of a CP3 on a CR Cummins
« Reply #7 on: September 13, 2009, 11:47:22 pm »
Cool, I may need to remove the shroud soon for a project I am thinking about.  :wait:

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