High-pressure common-rail bang technology has revolutionized the agent industry. Over the aftermost decade, it has accustomed agent builders to run college bang pressures (as abundant as 29,000 psi in the new LML Duramax and 6.7L Ability Stroke) in adjustment to access efficiency, while abundantly abbreviation emissions. Use of the common-rail arrangement has additionally facilitated assorted bang contest (making diesels quieter). The icing on the block is that these cleaner-burning engines accomplish abundant added ability than their predecessors.
In the case of the ’01-to-’10 Duramax and ’03-to-present Cummins, the affection of the common-rail arrangement has been the Bosch CP3. Unlike antecedent (pre-common-rail) bang pumps, it has beneath tasks to perform. The CP3 bang pump’s sole job is to actualize and adapt high-pressure ammunition (it’s not timed with the engine’s crankshaft and camshaft). The actuality that the CP3 came from Bosch’s able band of bang pumps additionally speaks to its abundant reliability, as it was advised to comedy a basic role in million-mile engines.
Through the years, we’ve talked about how these adorable agent pumps assignment and acicular out aback you charge to accede upgrading. Now, for the aboriginal time, and with advice from the experts at Bosch Motorsport and Motorsport Diesel, we’re able to booty you central the CP3 bang pump, explain its functionality, and appearance you what needs to be upgraded. With a assemblage from an LBZ Duramax disassembled, you’ll see which centralized apparatus about get adapted to abutment high-horsepower applications.
Low-Pressure CircuitIn adjustment to allocution about the adapted bang pumps accessible in the aftermarket, which affection added displacement (i.e. stroker pumps), we aboriginal accept to accept the CP3 pump’s functionality. This diagram (which shows the airy ammunition ambit on the appropriate ancillary of the pump) is agnate to what you’d see in a Bosch CP3.3 NH pump, which is the archetypal acclimated on an LBZ Duramax. First, airy ammunition enters the accessory pump (A). The accessory pump’s purpose is to augment the high-pressure pump. The best breeze amount of the accessory pump is bound by the calibrated assimilation burke (B) to abstain an afflict book at the overflow valve (C). The overflow valve allotment ammunition to the accessory pump inlet, provides lubrication for the pump, and keeps burden in advanced of the metering assemblage (D) constant. The metering unit, additionally accepted as the MPROP, FCA, or ammunition burden regulator, regulates the best breeze amount the CP3 delivers to the rail. The aught commitment burke (E) exists for instances in which no added ammunition is appropriate in the rail. It routes agent that is advised to aperture out of the metering assemblage (when it’s in the bankrupt position) abroad from the plungers in the pump and aback to the accessory pump inlet.
*The aught commitment throttle’s acknowledgment avenue is the capital aberration aback comparing a CP3 from a Duramax to a assemblage begin on the 5.9L and 6.7L Cummins. On a Cummins CP3, the aught commitment breach routes the leaked ammunition aback to the return, instead of the accessory pump inlet.
High-Pressure CircuitIn this diagram, you can see the breeze of the high-pressure ammunition circuit. Once through the metering unit, ammunition makes its way to the assimilation valves (A). The assimilation valves are amid at the top of the plungers (B) and acquiesce ammunition to access anniversary of the pump’s three cylinders. Finally, the high-pressure valves (C) accelerate pressurized ammunition out to the rail.
Vital apparatus on the CP31. Flange2. Shaft3. Polygonal ring4. Housing5. Accessory pump6. Overflow valve7. Airy inlet8. Metering unit9. Backflow connector10. High-pressure connector11. Plunger12. Bucket13. Assimilation valve14. High-pressure valve (out to rail)
Stroker Pump Ingredient 1: Added Achievement Increasing displacement in any pump, engine, or injector comes bottomward to two things: bore and stroke. The best accepted adjustment for abacus displacement to a CP3 is to access its achievement from 8.2 mm to 10 mm. Aftermarket companies about draw the band actuality because it’s aloof about as far as you can go and still be able to use 18-carat Bosch parts. Abundant accomplished 10 mm of achievement and the OE polygonal arena will no best fit.
Stroker Pump Ingredient 2: Machined BucketsBecause the plunger is now traveling added (thanks to added stroke), the buckets crave some machining. It may be adamantine to see here, but the basal of the brazier on the larboard has been machined and is beneath than the banal one on the right. The advantage to abbreviate the plunger is on the table for pump builders, but according to Bosch, a lot of ability can be absent by accomplishing it.
Stroker Pump Ingredient 3: Assimilation ValvesOne basic that essentially banned ammunition breeze in banal anatomy is the assimilation valve. Fortunately, it’s addition breadth area added achievement helps out greatly. Aback you analyze the assimilation valve in both of these photos, you can see the one on the appropriate sits added abroad from its seat. Because the assimilation valves are amenable for acceptance ammunition into the cylinders, acclamation them provides abundant added flow. One of the drawbacks actuality is that the valve bank abrasion increases (causing the assimilation valve to abrasion out sooner)—and while the pump will still aftermost a while, constancy is sacrificed.
Stroker Pump Ingredient 4: Metering UnitModifying the metering assemblage (also accepted as the MPROP, FCA, or ammunition burden regulator) is actual accepted because it’s amenable for the abundance of agent that feeds the high-pressure ancillary of the pump. It regulates the breeze to the high-pressure pump, and ultimately the injectors. Porting the valve agent on the metering valve is a archetypal agency of modifying it, but added proprietary modifications may additionally exist. The end ambition is to accumulate the plungers as abounding of ammunition as possible, yet still be able to adapt it.
*Other airy modifications include: accretion the ports on the accessory pump and modifying the overflow valve to access centralized pressure.
Displacement, Flow, and Pump Differences All branch CP3s allotment the aforementioned displacement. However, due to hardly college ability appropriate out of the box, the Duramax pump will breeze 195 to 200 lph on a breeze bench, while a Cummins pump will put out 180 to 185 lph.
A stroker CP3 can breeze as abundant as 260 to 270 lph. So your boilerplate aftermarket pump can crop 30 to 35 percent added breeze than a banal pump, and as abundant as a 22 percent displacement increase. While that access may not complete like a lot, in absoluteness it is absolutely substantial, accustomed that actual little believability is sacrificed.
It has to be acclaimed that CP3s can’t be rebuilt. Only aboriginal pumps or acceptable acclimated cores can be adapted into stroker pumps.
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