CP3 fuel pump upgrade thread

Tuheeden

Veteran Member
Joined
Sep 18, 2022
Location
North Carolina
TDI
2013 & 2014 Jetta sportwagon
Hello! I need some help with my cp3 conversion...
So, yesterday I finished my cp3 conversion to a vw passat 2.0, i primed the fuel system and the car started right away, built the needed pressure but after 20 seconds of running stalled and i cant figure out what just happened. I removed the fca, the ramp pressure control valve and the pump builds only 8 bar of pressure wich i suppose is made by the tank pump
Did you get any codes? That sounds like a fuel input issue since the car started. Double check the feed and return hoses as I have seen these get reversed. Then of course check for leaks on the high pressure side. Since it started you must be pretty close!
 

ukf44

Member
Joined
May 26, 2023
Location
Romania
TDI
VW Passat 2.0
I did prime again the system very well and let it crank for like 30 and it started but guess what now i get a faulty code - pressure too high.
The engine starts now imediatly but the fuel pressure spikes to 1200 bars and the engine shuts down.
 

Tuheeden

Veteran Member
Joined
Sep 18, 2022
Location
North Carolina
TDI
2013 & 2014 Jetta sportwagon
I did prime again the system very well and let it crank for like 30 and it started but guess what now i get a faulty code - pressure too high.
The engine starts now imediatly but the fuel pressure spikes to 1200 bars and the engine shuts down.
You must remove the intermediate fuel pump. It's the one between the tank and the fuel filter. The CP3 has its own lift built in. You can't just unplug it, you have to have the hose from the tank go straight to the filter
 

ukf44

Member
Joined
May 26, 2023
Location
Romania
TDI
VW Passat 2.0
I did remove the intermediate fuel pump … I’m thinking that the metering valve it’s not working as it should or it’s inappropriate.
 

Tuheeden

Veteran Member
Joined
Sep 18, 2022
Location
North Carolina
TDI
2013 & 2014 Jetta sportwagon
I did remove the intermediate fuel pump … I’m thinking that the metering valve it’s not working as it should or it’s inappropriate.
You can unplug the electric connection on the CP3 and it will start and run in limp mode. Who did you buy the pump from? I would contact them next as what you are describing is very common
 

ukf44

Member
Joined
May 26, 2023
Location
Romania
TDI
VW Passat 2.0
I bought like 4 of them from a scrapyard with different serial numbers and fittings … and made by myself the plate and so on. Also I did remove the connection on the metering valve and acts the same builds too much fuel pressure.
 

Mrrogers1

Veteran Member
Joined
Jun 25, 2006
Location
Omaha NEEEBRASKA
TDI
2011 Golf TDI 6MT, 2011 Jetta TDI DSG, 2015 Golf Sportwagen S TDI DSG

T1MMBOJONES

Veteran Member
Joined
Nov 10, 2020
Location
Milwaukee
TDI
03 ALH 01M wagon
Hello! I need some help with my cp3 conversion...
So, yesterday I finished my cp3 conversion to a vw passat 2.0, i primed the fuel system and the car started right away, built the needed pressure but after 20 seconds of running stalled and i cant figure out what just happened. I removed the fca, the ramp pressure control valve and the pump builds only 8 bar of pressure wich i suppose is made by the tank pump
are you positive it doesnt just need a re priming?
 

smelly621

Veteran Member
Joined
Nov 13, 2008
Location
Sonoma County, CA
TDI
2001 Golf, 2003 Tacoma
Starts quicker with the cp3 for me, definitely shouldn't require extra cranking if things are working correctly. The target duty cycle for the fmv is set in the tune, resistance on the bench shouldn't matter it's the physical size of the holes on the piston inside the fmv that varies
 

coolusername

Veteran Member
Joined
May 4, 2022
Location
Orange, CA
TDI
2012 Jetta Sportwagen TDI
Solved that problem. Cp3s needs longer craking before starting.
Now I’m trying to figure it out how to manage the high fuel pressure cp3 is making.
That's not true, my CP3 starts about a quarter second quicker than my old CP4 ever did.
 

ukf44

Member
Joined
May 26, 2023
Location
Romania
TDI
VW Passat 2.0
You guys got me wrong. What I was trying to say is after you first install and prime the fuel system the cp3 pump need a longer crank before build pressure and start the engine ...
Starts quicker with the cp3 for me, definitely shouldn't require extra cranking if things are working correctly. The target duty cycle for the fmv is set in the tune, resistance on the bench shouldn't matter it's the physical size of the holes on the piston inside the fmv that varies
Great info! I looked over some video on how people modify their cp3 pumps and they are doing that by mounting different pin inside the valve.
 
Joined
Mar 10, 2023
Location
Ireland
TDI
2.0 Tdi CR136
Hi Lads, I have a CP3 and Fuel Metering Valve and Fitting Kit for Sale.

90,000km on Pump
Fitting kit never fitted (XMAN - Brand New )
Brand New fuel Metering Valve (Bosch 928 400 643)
 

MartyPongo

Member
Joined
Aug 3, 2018
Location
Costa Mesa, CA
TDI
13 JSW GTD 06 Jetta GTD Sedan and 11 JSW
Hi all,
I installed a CP3 on a 2011 Golf. Unfortunately, the injectors were all leaking due to the metal bits so they had to be replaced too. The car ran well until it threw a code, apparently too much soot in the DPF and/or filter. Working on that soon.
 

mikerob97

Veteran Member
Joined
Feb 17, 2002
Location
Cary, NC
TDI
2014 Jetta Sportwagen
Is the Whitbread Performance Innovations generally considered one of the better kits and suppliers of remanufactured pumps? I am looking at the CP4 CP3 upgrade this fall when I do my timing belt change. Are there other kits / reman pump companies that I should be considering?

Thanks,
Mike
 
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T1MMBOJONES

Veteran Member
Joined
Nov 10, 2020
Location
Milwaukee
TDI
03 ALH 01M wagon
Is the Whitbread Performance Innovations generally considered one of the better kits and suppliers of remanufactured pumps? I am looking at the CP4 upgrade this fall when I do my timing belt change. Are there other kits / reman pump companies that I should be considering?

Thanks,
Mike
for the record its a cp3 upgrade you already have a cp4, i assume you meant that however. i think whitbread is about the only one still selling kits. overall i am happy with mine. i cannot stress enough though while installing make sure if you are following 2Microns instructions found on whitbreads page DO NOT follow his torque specs for the adaptor plate studs! Whitbread has the proper specs on his page under the link, i overlooked this initially and snapped a stud off. overall its a very easy diy project but make sure you have all the required tools and some.
 

curty1500

New member
Joined
Jun 12, 2023
Location
Western ny
TDI
Ckra passat
Can someone post how the fuel lines are ran on a ckra passat with three hoses coming off the top of the fuel filter to the r90 cp3 pump and show how to bend the fuel line to fit
 

CrustyOreo

Veteran Member
Joined
Nov 19, 2011
Location
Hanover, Mass
TDI
2011 Golf 2 Door 6MT
Is a CP3 pump a CP3 a CP3 pump ? I see used ones on eBay off various other diesels (Duramax and Cummins mostly) for decent prices with warranties. Does it matter what the CP3 came from for a retrofit ?
 

T1MMBOJONES

Veteran Member
Joined
Nov 10, 2020
Location
Milwaukee
TDI
03 ALH 01M wagon
Is a CP3 pump a CP3 a CP3 pump ? I see used ones on eBay off various other diesels (Duramax and Cummins mostly) for decent prices with warranties. Does it matter what the CP3 came from for a retrofit ?
no, i have a duramax cp3 in my garage which is quite a bit larger than my united diesel rebuilt cp3 in the tdi. ive read cr jeep liberties used them as well as certain citroens and peugots i believe but thats still pretty unclear. also you can have the right pump but the wrong metering valve. i ordered mine through whitbread but you likely could source it directly from united diesel, however you would still need to source the rest of the needed parts. i do know tunzilla/malone has a list of metering valves when they write a tune for a cp3 so looking at their page may get you off to the right start if you insist on sourcing your own...


 

T1MMBOJONES

Veteran Member
Joined
Nov 10, 2020
Location
Milwaukee
TDI
03 ALH 01M wagon
Can someone post how the fuel lines are ran on a ckra passat with three hoses coming off the top of the fuel filter to the r90 cp3 pump and show how to bend the fuel line to fit
i cant help you with pics here but as far as bending the lines its kinda just up to you how you route and bend it. expect to take it on and off several time and making slight tweaks til it fits. i plumbed mine to an alternative fuel port thats "behind the egr" as opposed to "in front" but i have a cjaa... also try to reuse as many fuel line hold downs as possible and not let it rub on anything.

first photo shows the locations after i switched them, initially the threaded fitting was where my middle finger points and the plug where my pointer finger is.
if you chose to swap/alternate these ports be aware that there is a spring loaded ball valve of sorts that can fly away.... here is how my cjaa looks using said port.
 
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scottdi90

Active member
Joined
Dec 31, 2009
Location
UK, west wales
TDI
11' cr170 a4 allroad
DIY converted an Audi A4 170hp 2.0 tdi CAHA with cp3.

Bought the car with failed cp4 HPFP at 150k miles.

Fitted a used 1.4hdi cp3 pump
no# 0445010042 with stock metering valve no# 928400643.

Lathed the centre out of the 1.4hdi pulley and recessed it into the original cp4 pulley, then drilled and threaded the engine bracket to bolt the cp3 pump directly to the engine.
Made up an adapter for the hard fuel line and had to bend line a little.
Removed auxiliary pump, just unplugged wasn't enough it was restricting the fuel.

I would upload some photos if I could figure out how!

Going with the pump/meter valve info on here it was all straight forward and runs perfect, starts quickly and idles smooth.
Edit* should be link to photos here
 
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T1MMBOJONES

Veteran Member
Joined
Nov 10, 2020
Location
Milwaukee
TDI
03 ALH 01M wagon
so for the hell of it i mocked my cp3 up without the adapter plate and found it fits right in the cp4 "cradle" only problem was you would have to countersink your own bolt holes. i also convinced myself the plate might compensate for a different offset. but i honestly would like to elliminate it if possible next timing belt job maybe....
 

scottdi90

Active member
Joined
Dec 31, 2009
Location
UK, west wales
TDI
11' cr170 a4 allroad
so for the hell of it i mocked my cp3 up without the adapter plate and found it fits right in the cp4 "cradle" only problem was you would have to countersink your own bolt holes. i also convinced myself the plate might compensate for a different offset. but i honestly would like to elliminate it if possible next timing belt job maybe....
Yes I thought it was a stronger setup, especially when people were saying the adaptor plate studs are easily over torqued.
There is plenty of material to drill and tap new threads, at least 10mm depth.

 

austinroepke

Member
Joined
Nov 29, 2020
Location
Illinois, USA
TDI
2012 Sportwagen
Just installed a CP3 pump and adapter kit from Whitbread!
Everything went well on the installation, but the high pressure line sucked to bend. My harbor freight tube bender was not up for it, but the bench vise bending approach worked.

I recommend depinning the metering valve connector on the harness and reusing the terminals. I’m not sure I’d be able to route much sigh shorter wires, and I feel that splicing wires is more work than is necessary.

I replaced my thermostat and did a timing belt service all at the same time. I don’t think I’d recommend replacing the thermostat as preventative maintenance because it was probably worse than the fuel pump swap.
 

scottdi90

Active member
Joined
Dec 31, 2009
Location
UK, west wales
TDI
11' cr170 a4 allroad
and the timing belt is still properly alligned i assume?
Yes I made the sprocket on mine to suit the offset.
The pump sprocket in the kits would move the same distance as the thickness of adaptor plate. So you might need to remove that amount off the hub adaptor if it is offset too much by removing the plate.
 

Ds026

New member
Joined
Jun 29, 2023
Location
go2rm85123
TDI
2013 golf tdi cjaa
Got a issue with a 2013 tdi I just installed a cp3 fuel pump and I’m getting no start there’s a lot of fuel flowing back into the filter and out of the pump it seems to be flowing, I turned the pump a few times while it was uninstalled and it did flow fuel so it’s not bad, just no high presure output now? Does the connectors positive and negative matter for the metering valve… I tryed priming it 3 times 30 secconds each and cranking max 10 secconds after filled the high presure line and still no output from it… lost I did upload the tune from tune zilla with the correct metering valve the one ending in 493
 

Tuheeden

Veteran Member
Joined
Sep 18, 2022
Location
North Carolina
TDI
2013 & 2014 Jetta sportwagon
Got a issue with a 2013 tdi I just installed a cp3 fuel pump and I’m getting no start there’s a lot of fuel flowing back into the filter and out of the pump it seems to be flowing, I turned the pump a few times while it was uninstalled and it did flow fuel so it’s not bad, just no high presure output now? Does the connectors positive and negative matter for the metering valve… I tryed priming it 3 times 30 secconds each and cranking max 10 secconds after filled the high presure line and still no output from it… lost I did upload the tune from tune zilla with the correct metering valve the one ending in 493
Ok, the engine should start WITHOUT the electrical connector to the CP3 or a tune. I would check the fuel lines to make sure they are hooked up correctly (I have seen them hooked up wrong). You did remove the aux pump?? Check those hoses too. You can unhook the feed line from the rail and crank it to make sure you have positive flow from the pump. Other than that the next question is are you sure you locked the crank/cam when you put in the new pump? The belt can jump a tooth or two.
Normally a no start means air in the high pressure side. I have done many of these and they start in 15 to 30 seconds if they are primed.
Hope that helps
 
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