INDUSTRIAL CP Series Conversion Kit Instruction Manual

INDUSTRIAL CP Series Conversion Kit

Product Information

• This user manual provides instructions for the CP4 to CP3 Conversion for the 2019+ RAM Cummins.
• The conversion involves replacing the CP4 injection pump with the CP3 injection pump.
• The manual provides step-by-step instructions along with figures to guide the conversion process.

Product Usage Instructions

1. Step 1: Disconnect and isolate the negative battery cables. Remove the engine cover.
2. Step 2: No specific instructions provided in this step.
3. Step 3: Loosen the left charge air cooler clamp and remove the air intake elbow.
4. Step 4: Remove the fuel rail noise isolator.
5. Step 5: Clean the fuel rail and fuel injection pump using brake clean and shop air. Remove the high pressure and low-pressure fuel connections.
6. Step 6: Disconnect the low-pressure feed and return lines from the CP4 injection pump.
7. Step 7: Remove the rear high-pressure fuel line hold down bolt from the cylinder head and hold down nut from the side of the cylinder block. Remove both high-pressure fuel lines from the fuel rail and injection pump.
8. Step 8: Install FX-1057 to block off the rear high-pressure inlet on the fuel rail. This kit uses a single high-pressure line to feed the fuel rail from the CP3.
9. Step 9: Disconnect the fuel quantity solenoid electrical connector.
10. Step 10: Remove the nut holding the engine harness to the injection pump support bracket. Remove the fuel pump support bracket mounting bolts and bracket.
11. Step 11: Remove the engine harness holder that is attached to the engine harness.
12. Step 12: Remove the three injection pump mounting nuts and remove the injection pump by pulling straight backwards from the gear housing. The pump, pilot adapter, and gear will come out as one unit.
13. Step 13: Remove the nut, washer, and gear from the injection pump as these will be reused.
14. Step 14: Remove the mounting studs from the front cover.
15. Step 15: Disconnect the ECM connectors by pushing in tabs under latches and pulling the latch upwards.
16. Step 16: Remove the four bolts attaching the ECM to the mounting plate and remove the ECM.
17. Step 17: Remove the ECM mounting plate bolts and remove the mounting plate from the engine block.
18. Step 18: Re-install the ECM mounting plate with new supplied bolts and spacers. Use two short spacers for the lower two mounting holes and longer spacers for the upper two mounting holes. Secure the spacers and bolts to the ECU mounting plate using the supplied retaining clips.
19. Step 19: Re-install the rear ECM connector only, taking caution not to bend ECM pins as it is a tight fit. Step 20: Re-install the ECM to the mounting plate using the factory hardware. You may need to slightly bend the power steering line towards the driver’s fender.
20. Step 21: Install the supplied black O-ring onto the CP3 hub.
21. Step 22: The new pilot adapter will come with O-rings installed. Install the pilot adapter onto the CP3, followed by the gear, lock washer, and nut. Torque to 85 ft lbs.
22. Step 23: Install the front cover adapter to the front cover using the supplied M8x1.25X30 cap head bolts.

Use a small amount of Loctite and torque to 15 lbft.

Installation Instructions

1. STEP 1 Disconnect and isolate negative battery cables.

2. STEP 2 Remove engine cover.

3. STEP 3 Loosen left charge air cooler clamp and remove air intake elbow.

4. STEP 4 Remove fuel rail noise isolator.

5. STEP 5 Using brake clean and shop air, clean fuel rail and fuel injection pump. Then remove high pressure and low pressure fuel connections.

6. STEP 6 Disconnect low pressure feed and return lines from cp4 injection pump. #2 and #3 in Figure 1 (next page).

7. STEP 7 Remove rear high pressure fuel line hold down bolt #7 from cylinder head and hold down nut#1 from side of cylinder block. Remove both high pres-sure fuel lines from fuel rail and injection pump. #16 and #17 in Figure 2 (next page).

8. STEP 8 Install FX-1057 to block off the rear high-pressure inlet on the fuel rail. This kit uses a single high-pressure line to feed the fuel rail from the CP3. Figure 2 (next page).

9. STEP 9 Disconnect fuel quantity solenoid electrical connector. #1 in Figure 1 (page 3).

10. STEP 10 Remove nut holding engine harness to the injection pump support brack-et. And remove fuel pump support bracket mounting bolts and bracket. Figure 3.

11. STEP 11 Remove engine harness holder that is attached to the engine harness.

12. STEP 12 Remove 3 injection pump mounting nuts and remove injection pump by pulling straight backwards from the gear housing. Pump, pilot adapter, and gear will come out as one unit.

13. STEP 13 Remove nut, washer, and gear from injection pump as these will be re-used.

14. STEP 14 Remove mounting studs from front cover at this time. (Mounting nuts can be used to double nut and re-move studs)

15. STEP 15 Disconnect ECM connectors by pushing in tabs under latches and pulling latch upwards.

16. STEP 16 Remove 4 bolts attaching ECM to mounting plate and remove ECM.

17. STEP 17 Remove ECM mounting plate bolts and remove mounting plate from engine block.

18. STEP 18 Re-install ECM mounting plate with new supplied bolts and spacers. 2 short spacers for lower 2 mounting holes and longer spacers for the upper 2 mounting holes. Using the supplied retaining clips, secure the spacers and bolts to the ECU mount-ing plate for an easy installation

19. STEP 19 Re-install the rear ECM connector only using caution to not bend ECM pins as this is a tight fit.

20. STEP 20 Re-install ECM to mounting plate with the factory hardware. You may need to slightly bend power steering line towards the drivers fender.

21. STEP 21 Install supplied black O-ring onto CP3 hub.

22. STEP 22 The new pilot adapter will come with o-rings installed. Install the pilot adapter onto the CP3 followed by the gear, lock washer, and nut. Torque to 85 ft lbs.

23. STEP 23 Install front cover adapter to front cover as shown us-ing supplied M8x1.25X30 cap head bolts. Use a small amount of Loctite and torque to 15lbft.

24. STEP 24 Install CP3 injection pump through the front cover adapter. Pump will need to be rotated towards the driver’s fender and then rotated towards the engine block to clear the boss on the block and align the pump mounting holes. Install sup-plied m8x1.25×40 cap head bolts, lock washers, and flat washers. Hand tighten them in a star pat-tern until snug, then torque them 33 lb ft.

25. STEP 25 Plug in front ECM connector. Then install FCA extension harness between factory harness and actuator on the pump.

26. STEP 26 Install high pressure fuel lines. The line will route from the high pressure outlet next to the return fitting to the front port on the fuel rail.
    Connect fuel feed and return lines onto the pump. Be sure the lines are not bent or pinched.

27. STEP 27 Reinstall noise isolator over fuel rail and install intake air horn. Be sure to plug in all sensors that were disconnected when removing.

28. Be sure to replace both fuel filters before starting truck with the new fuel pump.

29. STEP 28 Turn truck to the run position for 3 cycles – 15 sec each while keeping your foot off the brake, in order to prime the low pressure system. Start truck and check for fuel leaks and codes.

30. Truck may have a little extended crank on first fire up after a few minutes of driving it will be back to normal.

DO NOT ATTEMPT TO BLEED HIGH PRESSURE FUEL SYSTEM SERIOUS INJURY MAY OCCUR.

800-955-0476 2858
South 300 West Salt Lake City, Utah 841 1 5
www.industrialinjection.com

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>