Hey guys I need some help. I've got a 2006 cummins and I had an electrical fire under the hood about 2 months ago. The dealer replaced the wiring harness and batts alternator and other plastic parts. I picked the truck up to take it to my snowplow shop so they could check and see if anything was damaged. The truck ran great going to and coming back from plow shop. The next day I went to take the truck to work so I could drop it back off at the dealer due to my running lights turning off when the right blinker was turned on. But I never made it to work. Truck got about a mile from hOme in the rain and just died. Now the dealer says it needs a new cp3 injection pump. At about 2900 bucks. The truck only has 48000 miles on it. The dealer said it has fuel up to the cp3 but none coming out of it so it has to be the cp3. Any help I would love to have. Ive been told that the fca could cause this problem also

 

Cascade overflow valve possible. Also check for contamination. Pull FCA check for any rust on valve. Fuel flow and pressure from transfer pump??

Verify high pressure pump output volume: Remove the high pressure fuel line from
the high pressure pump outlet port to the fuel rail. Connect a suitable hose to the high
pressure outlet port of the high pressure pump and route it to a graduated container.
Disconnect the Electronic Fuel Control Actuator. Crank the engine until fuel exits the
hose. NOTE: With the discharge line routed to atmosphere, fuel will discharge at
0 PSI. Crank the engine for three 10 second intervals, pausing to allow the starter to
cool between each crank event. High pressure pump output volume must be greater
than 70 mL in 30 seconds. Is the high pressure pump output flow sufficient?
a. Yes >> Go to Step #13.
b. No >> Replace the high pressure pump. Refer to the detailed service information
available in TechCONNECT under: Service Info tab > 14 - Fuel System > Fuel
Injection > Fuel Injection Pump. >> Go to Step #17.


http://www.genosgarage.com/BOSCH-CAS...F-00N-200-798/

 

I don't no about the amount of flow and pressure other then the dealer said it was good. All of this work so far has been done through my insurance and there was a misunderstanding about the work and I believe the dealer had to end up paying for some of the work/parts. I could be wrong but thinking that there trying to make there money back by telling me it's the pump when it's really a cheaper/easier part.

 

What was the cause of the electrical fire? I would be leaning toward an electrical issue causing the no start problem. All kids of shorts could have occurred once the insulation melted off the wiring back feeding and wiping out other components. You can buy a completely remanned CP3 for around $1000.00 and change it yourself in about 2 hours.

 

They said it was a diode shorted out in the alternator that started it. I agree with you but yet the dealer said they can't say for sure it was caused by the fire so the insurance company will not cover the part now. That's why I was wondering if the fca(the only electrical part on the cp3) could have went bad. The truck ran fine but then just died in route to work. Never stalled or ran bad or hard to start. I just find it hard that the cp3 just crapped out all of a sudden. Filter has been changed every oil change(6k)

 

CP3 is bullet proof contaminated fuel is the only thing that takes them out. FCA do go bad but usually give you idle problem and fuel pressure fluxtuation. That's why I asked about low side fuel flow and pressure. Ground wire from ECM if loose or corroded will give you no start condition. I've never seen a diode cause electrical fire and I've been working on Dodge trucks 28 years. Battery connections can cause all kinds of electrical problems. Most likely the alt was over charging and overcharged the batteries. Common problem since charge rate is determined by the drivers side battery, if high resistance in battery cables then alt will over charge battery. I have seen battery explode more then once because of that.

 

Do you know where the ground wire to the ECM is located? We have found a few grounds and all test good so far. When we gave the fca power we can here it kick on so we think that part is ok.

 

There is a 12 gauge black wire running from the ECM (left side mounted to engine block) to the negative terminal on the drivers side battery. This ground must be connected or truck will not start.

 

bigiron thank you for all your info so far! we checked this wire and it does test ok with a test light on motor side. since the dealer says cp3 all the way do you know how the iners of this pump is set up? could it be possible that a shaft or valve or oring just snapped or wiped out? i and my boss(automotive tech for 30 plus years) dont by that its all of a sudden went bad with the wiring problem that just occurred to the truck. but we also have no problem admitting that we dont know these motors inside and out. if the pump truly needs to be replaced i have no problem doing it but i dont want to do it and have it not be the true issue. once again thanks for all your info so far