03-07 Cummins CR 24V 5.9L Tech Talk Tech articles for the 03-07 Cummins Common Rail 5.9L Engines.

Remove and Install CP3

 
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Old 02-18-2009, 07:20 PM
Dragon Flow Diesel 128's Avatar
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Default Remove and Install CP3

Ok, this weekend I'm going to be putting a new injection pump on an
'03 dodge and I really need the torque specs for the nut that bolts the shaft to the gear.
Does anyone have those specs?
 
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Old 02-20-2009, 01:24 AM
cummins tech's Avatar
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INSTALLATION
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

Inspect pump mounting surfaces at pump and mounting flange for nicks, cuts or damage. Inspect o-ring surfaces for nicks, cuts or damage.
Clean injection pump mounting flange at gear housing. Also clean front of injection pump.
Install new rubber o-ring into machined groove (FUEL INJECTION PUMP REMOVAL/INSTALLATION) at pump mounting area.
Apply clean engine oil to injection pump o-ring only.
The machined tapers on both injection pump shaft and injection pump gear must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening.

Clean pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.
Position injection pump to mounting flange on gear housing while aligning injection pump shaft through back of injection pump gear.
After pump is positioned flat to mounting flange, install 3 pump mounting nuts and tighten finger tight only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) pump to gear housing using mounting nuts. Damage to pump or gear cover may occur. The pump must be positioned flat to its mounting flange before attempting to tighten 3 mounting nuts.
To prevent damage or cracking of components, install and tighten nuts in the following sequence:
Install injection pump shaft washer and nut to pump shaft. Tighten nut finger tight only.
Do preliminary (light) tightening of injection pump shaft nut.
Tighten 3 injection pump mounting nuts to 24 N·m (212 in. lbs.).
Do a final tightening of pump shaft nut to 105 N·m (77 ft. lbs.).
Install drive gear access cover (plate) using a 3/8” or 1/2“drive ratchet. Plate is threaded to timing gear cover. Tighten to 8 N·m (71 in. lbs.) torque.
Install Engine Control Module (ECM) to left side of engine.
Install fuel line (injection pump-to-overflow valve). Tighten bolts to 24 N·m (18 ft. lbs.) torque.
Install fuel line (injection pump-to-fuel rail). Tighten to 36 N·m (27 ft. lbs.) torque. Use a back-up wrench.
Install fuel line (injection pump-to-fuel filter housing). Tighten to 24 N·m (17 ft. lbs.) torque.
Connect Fuel Control Actuator (FCA) electrical connector to rear of injection pump.
Install intake manifold air intake tube (above injection pump). Tighten clamps.
Install accessory drive belt.
Install cooling fan shroud.
Install cooling fan assembly.
Connect both negative battery cables to both batteries.
Check system for fuel or engine oil leaks
 
The following 3 users liked this post by cummins tech:
Bigg Redd (07-06-2022), Dragon Flow Diesel 128 (02-20-2009), nmlakerat (02-24-2009)
 
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