twin cp3 install 1.1 - ats diesel · pdf filecp3-gm-twin-lb7-inst 1 installation manual v1.1:...

CP3-GM-TWIN-LB7-INST

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Installation Manual V1.1: ATS Twin CP3 Kit

2001-2004 GM LB7 Duramax

Please read all instructions before the installation of the ATS Twin CP3 Kit

Thank you for purchasing the ATS Twin CP3 Kit. This manual is to assist you with your installation and operation of the kit. If you are installing the unit for a customer, please pass this manual on to your customer for future reference. This kit will enable you to maintain desired Fuel Rail Pressure with large injectors and/or hot programming. For high horsepower applications we recommend custom tuning that is adjusted to compensate for increased horsepower, such as the ATS E-Power Tuner. This kit also assumes that you have a fuel supply pump other than the stock pump. If you expect to make more than 700hp then we recommend our Auxiliary Fuel Supply Kit, which when combined with your existing supply pump will supply enough volume to maintain pressure to both pumps.

We strongly recommend ATS E-Power Tuning to properly utilize the twin CP3 pumps. Using tuning that was not designed with twin CP3 pumps in mind can result in dangerous cylinder pressures, very high EGT’s, poor drivability and lackluster power levels.

We recommend the following injectors to achieve your desired power levels:

650 hp : ATS Stage 3 Injectors

650-800 hp: ATS Stage 4 Injectors

800+ hp: ATS Stage 5 Injectors


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Included in this kit are the following pieces: 1. Secondary CP3 Fuel Pump 2. CP3 Pump mount 3. 10mm x 1.5 x 65mm bolt (2) 4. 10mm x 1.5 x 80mm bolt 5. CP3 Pump Pulley 6. CP3 Pulley Nut 7. 8mm x 1.25 x 50mm (3) 8. 8mm Hex Nut (3) 9. 8mm Lock washer (3) 10. 8mm Flat washer (3) 11. Pump -8 Feed line fitting (2) 12. Pump -6 Return line fitting 13. -8 Tee

14. -8 PushLok® fitting (2) 15. 2’ -8 Fuel Hose 16. High Pressure Fuel Line 17. Fuel Rail End fitting 18. Banjo Bolt with -6 end fitting 19. Banjo Washer 20. 20” -8 Braided Steel Feed Line (2nd CP3) 21. 6” –8 Braided Steel Feed Line (1st CP3) 22. 24” -6 Braided Return Line 23. 10mm x 1.5 x 80mm bolt with modified

head 24. Serpentine Belt 25. Electrical harness assembly


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Installation 1. Disconnect negative terminals from both batteries. 2. Remove the serpentine belt 3. Remove the idler pulley in figure 1.

Figure 1

4. Reinstall the idler pulley in the new location shown in figure 2.

Figure 2


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5. Install CP3 Pump to the mount using (3) 8mm x 1.25 x 50mm bolts, flat and lock washers, and nuts.

Figure 3

6. Install CP3 pump with mount onto engine using (2) 10mm x 1.5 x 65mm bolts

and 10mm x 1.5 x 80mm bolt (do not use the modified bolt).

Figure 4


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7. Install CP3 Pulley and nut. Torque pulley nut to 52 ft-lbs.

Figure 5

8. Remove Fuel Rail Fitting at Left Front of Engine. Note: If truck is a 2001-2002 model year then you will need to use a magnet to remove the plug located behind fitting in the fuel rail.

Figure 6

9. Install the supplied Fuel Rail fitting into the fuel rail.

Figure 8


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10. Install -8 feed fitting into secondary CP3 pump. Install -6 return line fitting into secondary CP3 pump.

RETURNFEED

Figure 9

11. Remove Air intake tube from air filter to turbocharger.

12. Remove fuel line attached to fuel filter housing outlet.

Figure 10

Note: Supplied with the kit is a feed line and a fitting to run to the primary CP3 pump. This is not required but does allow for equal fuel flow to both pumps and does clean up engine compartment. If you would rather not install the extra feed line please skip to step #18.


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13. Drain engine coolant. 14. Remove thermostat housing.

Figure 11

15. Remove fuel feed line from CP3 Pump. Remove attaching bolts and completely remove hard feed line from engine.

REMOVE

Figure 12


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16. Remove CP3 feed fitting.

Figure 13

17. Install -8 feed fitting into primary CP3 pump.

Figure 14


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18. If you did not install primary CP3 pump feed line, then you must cut the feed line from fuel filter housing to CP3 Pump (Figure 16). Install -8 PushLok® into hose coming from CP3 pump.

CUT

Figure 15

19. Route supplied -8 hose from fuel filter housing to the supplied -8 tee. Attach

hose to fuel filter with existing fuel line clamp.

Figure 16


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20. Route feed line from tee fitting to primary CP3 pump.

Figure 17

21. Route feed line from tee fitting to secondary CP3 pump.

Figure 18


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22. Remove Fuel return banjo bolt (Figure 20) and install the supplied banjo bolt

with new washer.

Figure 19

23. Attach return line from 2nd CP3 to Banjo bolt.

Figure 20


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24. Install High Pressure line from 2nd CP3 to Fuel Rail. Fig #25.

Figure 21

25. Unplug Fuel Pressure Regulator connector on 1st CP3 Pump. Plug connector into female end of supplied electrical harness. Next plug male harness into 1st CP3 pump. Plug remaining male harness into 2nd CP3 pump. Mount electronics box using supplied Velcro.

Figure 22


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26. If previously removed, install the thermostat housing and refill cooling

system. 27. Remove alternator bracket bolt shown in figure 23 and install the modified

10mm x 1.5 x 80mm hex head bolt into alternator bracket.

Figure 23

28. Install Serpentine Belt.

Figure 24

29. Double check that all fittings and bolts are tight. 30. Reconnect negative battery cables. 31. Turn ignition on to check for any fuel leaks. 32. Start engine and verify that no fuel leaks are present and that serpentine belt

is tracking straight.


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Have Any Questions?

Thank you for purchasing the ATS Twin CP3 Kit. Please call or check our website at http://www.atsdiesel.com for technical support and other performance products such as the Five Star™ torque converter, ATS Co-Pilot, ATS High Performance Transmission along with our full line of power enhancers that include Tuning, Aurora Turbochargers, Fuel Injectors, Water Injection, Propane Injection, and more. Please call or e-mail our Technical Service Department, 8:00am to 5:30pm Mountain Standard Time, Monday through Friday.

Contact Information

Toll Free: 800-949-6002

Local: 303-431-7973 Fax: 303-431-0135

Website: www.ATSDiesel.com Email: [email protected]

twin cp3 install 1.1 - ats diesel · pdf filecp3-gm-twin-lb7-inst 1 installation manual v1.1:...

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