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5.9 Liter CR Dodge Cummins 03-07 Discussion of 5.9 Liter Dodge Cummins Diesels with Common Rail Injection

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I have a 2003 3500 cummins for a repo truck and I am having a problem with it surging, and dying. It has 275000 miles on it and is bone stock, and I live in houston, texas so i dont think that it could be ... JOIN NOW TO REMOVE TRACER

Cummins Surging and dying

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Old 02-03-2010, 02:37 PM


Default Cummins Surging and dying

I have a 2003 3500 cummins for a repo truck and I am having a problem with it surging, and dying. It has 275000 miles on it and is bone stock, and I live in houston, texas so i dont think that it could be a gelling issue. This truck has done this for awhile but now it is getting worse. Any ideas? The mechanics i have taken it to cant figure it out
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Old 02-03-2010, 02:55 PM
Diesel Enthusiast



Check the lift pump. With that many miles there is a good chance it's finally died and your CP3 is having to pump its own fuel now.

10 to 12 psi at a minimum, and no less than 10psi at WOT.

MarineOne's Sig:2008 Dodge Ram 3500 QCLB SRW 6.7L - Titan 50 gallon fuel tank, Aero Muffler 4040XL, Firestone Air Springs, Nathan AirChime K3LA

2006 Dodge Ram 2500 QCSB 5.9L - Wife's truck - totally stock
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Old 02-03-2010, 04:53 PM
cerberus60's Avatar
Diesel Wrench



Have you checked lift pump pressure?

The symptoms are classic FCA issues also.

cerberus60's Sig:05 3500 QC SRW LWB 4x4, Smarty REVO, ISSPRO Gauges, 48RE, OPIE Inpu,t Billet Single Disk TC, Transgo Kit, other tweaks and parts

92 D250, 370 Marine Inj tips, Tweaked pump, HX35 60\16, 47RH, Billet TC, Transgo Kit
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Old 05-18-2010, 11:08 AM
Diesel Fan



This one's for all who fought (or are fighting) with choppy idle / fuel issues. there is a part on the cp3 called a "fuel control actuator". After being told (by cummins-certified mechanics) that I needed a:
1/ new set of injectors
2/ new lift pump
3/ new cp3, I ended up just replacing the fca. the part cost $105, took all of 5 minutes to change out, and fixed the problems I had been trying to diagnose for 30,000 mi.
hope this helps...
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Old 05-18-2010, 11:41 AM
dieseldude03's Avatar
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Start with the simple things first. Change the fuel filter. It's possible you got a bad tank of fuel and you may have to change it several times until you use up that tank or siphon the stuff out. Only buy fuel at reputable fuel stations with lots of diesel traffic... like truck stops. When fuel sits in the storage tanks too long, it can go "stale" and even grow algae! Then, like stated above, check the lift pump output pressure. A lot of the stock lift pumps die around 100,000 miles. If that checks out, change out the FCA on the injection pump.

dieseldude03's Sig:[SIGPIC][/SIGPIC]

2003 Ram 2500 Laramie 4x4, QC, long bed. Cummins H.O., 6-speed, 4.10 axle gearing, Jake Brake, AEM Brute Force HD cai, AFE Blade Runner intake horn, Summit Racing 4" SS Exhaust, Edge "HOT" Juice w/ Attitude, DDP 50hp Injectors, Air Dog-100, HTT HTB2 62/12/65, 33 x 12.50 ProComp Extreme All Terrains, South Bend Con OFE, various other gizmos.

"Some people are like Slinkys. Pretty much worthless, but they still bring a smile to your face when you push them down a flight of stairs!"
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Old 05-19-2010, 03:40 PM



FCA ... as the man said, I did mine on my 2003 after visiting a diesel injection shop, they said they really had no clue, had not seen the problem before, but that's what it was, simple fix, 20 minutes
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Old 05-06-2011, 03:58 PM
Diesel Fan



Mine is having hard start and now dying while stoped, lift pump already done.
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Old 05-06-2011, 10:11 PM
Diesel Fan



While the lift pump is generally considered the weak link in the fuel delivery system, I've found that the cp3 has some suspect components too. there is a part on the cp3 that (when on the fritz) displays the very symptoms you've described. It's called a fuel control actuator, and when it pukes, it doesn't throw a code. The engine will stutter and cough at idle, but once underway, it'll feel ok. Chrysler will fix it for about $600, but $500 of that is "labor". Try tapping the side of the cp3 with a hammer (just tap-don't whack) that might free it up. OR, go to cummins, and spend $110 on a new actuator. It's held in place by two allen or torx screws, and literally takes all of 5 minutes to change out. You'll need the engine id# to get the right one- It's located on the driver's side of the valve cover. Easy stuff! hope it works for you.
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