2005 RAM 3500 Injector pump R and R

LD1 · Jan 2, 2014

Any tips, tricks, or words of wisdom before I tear into it. Bout to browse the web and see what I can find. But it looks like a PITA.

Missing out on snowplowing as we speak:mur:

Drove the truck/plow to work, I get off at 2:30 and was ready to plow.Truck started fine and ran for ~10 minutes as I was cleaning the windows. Got in it, just as I pulled onto the road, she died and wouldnt restart.

Pulled it in the building and put a big torpedo heater on it thinking I may have a froze line. Nothing. So I cracked the inlet to the injector pump and cycled the key. Pleanty of flow there. Cracked the output of the pump (high pressure going to common rail, not the return), and nothing at all. Not even a drop.

So...i dont see how it can be anything but the injector pump, but its odd that it ran fine for 10 minutes and then died suddenly. And only 81k miles.:mur:

I see 3 bolts at the back holding the pump on, but its tight in there. Is there a hidded 4th bolt??? and does anything need to come off the front? That would involve pulling the fan and shroud and serpentine belt?? Or could this possibly be some other issue before I dig in? And what is the electric plug on the injector pump for?

Any advice appreciated? now to do some googling and see how many of these questions I can get answered.

DT86 · Jan 2, 2014

Try this link... http://www.dodgeownerforums.com/smf/index.php?topic=9087.0

But I'm not 100% sure the pump is bad. Suddenly stoping doesn't sound to me like the pump. The pumps I've dealt with slowly die over time, but on the other hand never have dealt with a bad CP3.

kenmac · Jan 2, 2014

Sorry to here about your troubles LD. I have a Cummins but, never had any troubles so, I'm sorry I can't help you... Here's http://www.cumminsforum.com/ where I go for questions. Some of these guys have a wealth of information Is yours a 12 valve or newer 24 valve ?? I've heard of some problems with the 12 valve injector pump. If it's the 24 v. I would look at the lift pump not supplying enough pressure

LD1 · Jan 2, 2014

Thanks, thats exactly what I needed.

I noticed with some other reading that this pump (cp3) also seems to have a lo pressure gear pump on the back??? and also that electric plug is the pressure control that limits amount of flow to high pressure side.

One thing I have NOT found though is how to go about diagnosing either??

Here is what I know:
Loosen banjo bolt going to front of pump (on the seemingly aluminum part), good flow.
Loosen the banjo bolt that seems to be a return from the cast iron part of the pump, good flow.

Both those with just turning the key on. SO I think this rules out filters, fuel pump, etc.

Crack open the high pressure line (even clear off at the moment), get NOTHING. Not even a drop.

Injector pump bad?? or am I missing something before I drop $1000?

DT86 · Jan 2, 2014

Have that pump bench tested before you replace it! Our local place waives the testing fee if you buy the replacement from them. Testing is cheap, no way I'd slap a new one in there before testing the old one!

Also read this!!! I borrowed it from the link above.

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.

LD1 · Jan 2, 2014

Anyone know anywhere in central ohio, from columbus-mansfield, that tests injector pumps??

kenmac · Jan 2, 2014

yes , an injection pump has enough to slice through human tissue with ease. Very dangerous pressures

kenmac · Jan 2, 2014

is this place Columbus Diesel Supply. Fuel Injection, Pumps and Injectors. close to you. I believe you have a bosch injector. I don't know anything about them. I just googled it

LD1 · Jan 3, 2014

Called them this morning. One more thing to check when I get home...

The electrical plug on the pump is the Fuel Control Actuator solenoid valve. They said they can sometimes fail, and to try unplugging it and see if I get fuel out of the high pressure side. If that don't work, its an injector at $750 with exchange:mur:

dodge man · Jan 3, 2014

I agree, test the FCA. I have good money your high pressure pump is fine (called a CP3). Its not common for them to fail at the low of mileage, but of course its always possible.

It sound like your lift pump is OK but a good way to check it is to crack open the drain valve on your fuel filter bowel, its a yellow lever on the front of it, and while cranking it make sure plenty of fuel comes out.

I will also sound the warning, you aren't suppose to crack open the high pressure side anywhere on a common rail.

This web site is a wealth of info. http://www.cumminsforum.com/forum/3rd-gen-dodge-cummins-03-07-common-rail-forums/