I'm doing the dance with DC to get a second CP3 now. I know the dance from getting the first one... First day bring it in (this time I attached a picture of where the leak was...) and the dealer calls back at close-of-business to tell me he sees the leak but can't contact STAR today. Second day, confirm that they should replace a pump that leaks. Wait a day for the pump to arrive... Final day they install the pump. I can't give them the truck for the whole week so this dance takes me three trips

But anyway, my question is this... My first pump went at 21,000 miles during the winter. Now, at 36,000 during the next winter the new pump is leaking. If this is an annual thing it will get old fast. I remember hearing there's a new code for the pump? I searched but couldn't find where I read that. Are there any advisories out on it yet? Should I ask about the lift pump? What ammo can anyone provide?
I'm dropping the truck again tonight for them to get permission to order the part. I'd like to give them info if any exists.

 

Dave,

Once you get your new CP3, you might consider getting an aftermarket lift pump. There have been some threads on here by Superduty and others who speak of starving the CP3 of fuel. Our stock lift pumps barely supply enough fuel pressure to keep them running, and that is aggravated by colder weather.

I have already ordered a Fuel Pressure gauge and I am making some final decisions nows on which aftermarket pump to use (fass, rasp, wallbro etc.).

 

I'm curious about alternatives to the stock lift pump.
But... my fuel system is completely stock, am I really running the CP3 in a way that could damage it (eg in a stock config).

The other dilemma is that I've got 2 more years on the warranty. If I mod the fuel system and another CP3 starts leaking couldn't DC use the fuel system mods to deny the claim?

 

My CP3 went out at 28K miles. I installed a fuel pressure alarm kit for $55 from BD which tells you when you fuel pressure drops below 5 psi. With a stock lift pump and temps below 10 F I have to add a 50% number 1 and 50% winterized number 2 blend to keep the fuel pressure about 5 psi, and I still have to take it easy. I am going to install a BD OEM Bypass lift pump kit to fix the factory low fuel pressure problem. I would not run one of these trucks with a CP3 without some sort of fuel pressure gauge.

 

crud... that's not encouraging.

I'd read that the VP44's failed if the lift pump failed. I didn't know if the CP3's had the same problems. Do they really need the inlet pressurized to work? Can this be a problem w/o a box modding the fuel system?

I'd remembered that Bosch had a run of bad pumps and I was hoping there was a way to know if you got a better CP3... We will see.

 

The CP3 works the same way a VP44 does. Excess fuel is used to lube and cool. No excess fuel and the FCA will route all the fuel flow to injection events and none elsewhere.

The HPCR is even more intolerant of bad fuel than all the previous ones. Bad fuel will cuase issues with the FCA, return valves, and the high pressure relief valves. In severe case it causes major damage in the CP3 itself due to the close tolerances. The colder it gets the harder the fuel is to pump and it is possible to get into negative pressure on the CP3 inlet if the LP is not up to par and that is just asking for problems.

Where is the leak on your pump? Bosch was having problems with a couple of the valves not seating and causing leaks.

 

Good question. Anyone had a warranty denial because they upgraded to FASS or some other system?

 

ok I have been reading alot of us having problems with the lift pumps.... I would like to do something about it since I just got my first cp3 replaced a few weeks back.. I don't want to do this again out of my pocket! Where can I get a fass,walboro, or whatever. and how much do they cost? Are we talking $50.00 or $500.00 here. Either way it is still cheaper than 2k for a cp3.

 

On my first CP3 I found fuel on the grounding lug well below the pump, dripping off. I never did see exactly where on the pump it came from. On my second I found a little fuel collecting on the bottom of the pump. I just posted a pic in my gallery. Since it was replaced last year I've been inspecting it at oil changes.

In the past I thought the situation was... lift pump quits, truck won't run, VP44 dies a little while later. On the CP3 I thought it was... lift pump quits, truck won't run, CP3 survives. So... it's possible that lift pump is dying, truck runs fine, CP3 wears out prematurely??

I'm sure glad this is on DC nickel for another 2 years!

Is the feeling here that even without fuel system mods a fuel pressure gauge is important?

 

Tell ya what I did to fix my leaking CP3...sold it and bought a P7100 12V and couldn't be happier I was like you davelinde, I was tired of fighting Dodge. If they won't work with you tell them you want to meet with the area rep, it always worked for me, just got tired of asking everytime I took it in.

 

Might be a good ideal to have them replace the lift pump. I think ther was another post on here about the same thing 2nd & 3rd pump replacement and they finaly replaced both and now its all good. I might be wrong but Im sure I read that on here somewhere.

 

Dave,

I think that DC is also moving the lift pumps to the fuel tank on 05 and up trucks. Also, if you have to have your stock lift pump replaced under warranty..........I believe they are putting it there now for 03 through 04.5 trucks. It is my understanding that the stock lift pumps work better pushing the fuel rather than sucking it to the pump.

I don't care whether it does or not though..........im going to put another pump on it. I am putting a Dipricol FP gauge in as soon as I can get it in and see where my stock FP is. Then make a final decision on the aftermarket pump. Mine is not really an emergency though since im basically still stock, my cp3 is fine, I don't pull heavy and/or live in a cold climate. But I do plan to Bomb someday and I don't want to have any problems now or in the future with fuel supply.

I believe Gypsyman is supposed to be putting together a kit with fuel lines etc. to use with a Wallbro pump. It would be nice to know somemore about that if anybody knows. If that one doesn't become available soon, I make be looking at a FASS system.

 

You would be surprised at the amount of bone stock trucks that are pulling the FP to 0 psi. Yeah, a FP gauge is really good insurance.

Since you have lost 2 CP3's I would take a hard look at your fuel source and filtering capapbility. The stock 10 micron filter is not enough to stop pump damage and low quality fuel doesn't help a lot either.

My .02

 

Mr. Jimmy:

Good point on the old 12 valve Dodge's with the P-7100 Pumps!

I have said before that it is really funny that the aftermarket diesel guys are coming up with new designed cams to run a mechanical pump similar to what was on the 94-98.5 12 valve Dodges for the newer 24 valve trucks (99-02').
I understand that the big three and the engine builders (Cummins, Isuzu and Navistar) went to the electronics on the timing and fuel for emissions reasons, but you can't argue with how well those old 12 valve fuel systems (P-7100 and mechanical pumps) held up! I know that my 96' Dodge CTD 12 valve had 218,000 miles at the time I did my initial rebuild and everything in that system was original!

Defintiely something to think about.

--------
John_P

 

Second step in the dance done. STARS ok'd the new pump, they will install it next week sometime.

more questions... if this was on my tab I'd be waiting for the leak to get worse. Any ideas how long a pump can weep fuel before it turns into a full out leak? or from a full out leak to stuck on the road?

next... a quick google for gauges didn't turn up any budget solutions - they were all $200+? I'd like something small, mounted off the pillar - maybe even with an integrated idiot light or buzzer so I think to look at it.

What does a better fuel delivery system go for? Unless we upgrade the FW and I need a dually I plan to keep this truck a very long time... I'll talk to the Service Writer about warranty and lift pump mods...