！Before installation, confirm that：
This product is designed for competition or off-road use only and may not be legal for use on public roads under EPA or local emissions regulations. Installation should be performed by a professional technician; the user assumes all risks for any mechanical damage or legal consequences resulting from the use of this product.
This is the installation process for the ER-0331: 2011-2016 6.6L GM Duramax LML CP3 Injection Pump Conversion Kit,provided for your reference during installation.
Important Note: We recommend removing and inspecting the high-pressure regulator, checking for debris inside.
If debris is found inside the high-pressure regulator, we recommend replacing the regulator, injector return lines, and check valve assembly.
Step 1:
Remove the right front wheel inner fender and drain the coolant from the engine cooling system through the lower radiator hose connection.
Step 2:
Disconnect both batteries and remove the plastic intake manifold cap, air filter hose, and the hose between the throttle body and the turbocharger air cooler (CAC). Gently turn the locking ring counterclockwise to disconnect the CAC hose.
Step 3:
Remove the aluminum intake manifold with the throttle body and its support bracket.
Step 4:
Remove the plastic intake bend from the turbocharger intake.
Step 5:
Disconnect the exhaust gas recirculation (EGR) system, including the cooler, bypass hose, valves, and coolant hoses.
Step 6:
Remove the intake manifold "Y" bridge.
Step 7:
Disconnect the water inlet hose, serpentine belt, and alternator. Use the 1/2-inch ratchet wrench located under the alternator to loosen the belt tensioner.
Step 8:
Remove the air conditioning compressor and carefully move it aside; refrigerant recovery is not required.
Step 9:
Unscrew the bolts on the cooling fan housing and slide it forward toward the radiator. The fan does not need to be removed or repositioned.
Step 10:
Remove the alternator mounting bracket. The belt tensioner and idler pulley can remain mounted on the bracket.
Step 11:
Move the air conditioning compressor/power steering pump mounting bracket aside. After removing the nuts and bolts, remove the two mounting studs to reposition the bracket.
Step 12:
Disconnect the oil filler hose, and then remove the thermostat housing with the crossover and bypass pipes. Plug the oil filler hose opening to prevent debris from entering.
Step 13:
Disconnect all fuel lines and hoses connected to the fuel injection pump. Set the rubber hoses aside, as some hoses will be reused during installation. Note that the 9th injector supply hose can be loosened and folded upwards; do not bend it sharply, as this can damage the internal components and cause poor fuel supply or breakage. Make sure to cover the ports on the fuel rail to prevent debris from entering!
Step 14:
Carefully bend the return hose to a position parallel to the machined surface of the left intake manifold. Further adjustments may be needed after installing the new pump.
Step 15:
Remove CP4 from the cylinder block and polish the mounting holes to facilitate CP3 installation.
Step 16:
Remove and save the drive gear, nut, and temperature sensor for reuse.
Step 17:
Lubricate the O-ring at the pump tip.
Step 18:
Install the pump mounting adapter onto the pump and tighten the three mounting bolts to 18 ft-lbs.Lubricate and install the included O-ring onto the pump mounting adapter.
Step 19:
Remove the barbed water supply and return connectors from the pump. Install using the included barbed fitting and lubricating sealing washer, as shown, and tighten to 20 ft-lbs. Use a 1/2-inch barbed fitting horizontally and a 3/8-inch barbed fitting vertically.
Step 20:
Install the drive gear and tighten the nut to 75 ft-lbs. Note that the CP4 nut cannot be fully screwed into the pump shaft; this is not a problem. It is higher than the CP3 nut. Thread engagement remains unchanged.
Step 21:
Remove the two 6 mm studs from the intake manifold.
Step 22:
Move the CP3 water pump to the appropriate position. Tighten the four original CP3 mounting bolts to 20 ft-lbs. Important! Tighten the bolts evenly as you move the water pump to the appropriate position to prevent damage to the water pump mounting adapter.
Step 23:
Using a pry bar and adjustable pliers, remove the support bracket from the jumper. Be careful not to bend or damage the fuel line.
Step 24:
If necessary, adjust the crossover and return lines to prevent them from contacting CP3.
Step 25:
Replace the low-pressure fuel supply line with a new extension hose and install it onto the engine. Tighten the compression fitting to 35 Nm (26 lb-ft).
Tip: Clean and lightly lubricate the low-pressure fuel supply line compression fitting for easy installation in the engine compartment.
Line A should be used with the original factory fuel filter housing.
Line B should be used after removing the original factory fuel filter housing (CP3 fuel supply hose is not included).
Step 26:
Connect the provided fuel hose to the original fuel pump supply line and secure it with a constant tension clamp. Install the new fuel return hose. Ensure the return hose does not contact the high-pressure fuel line. New low-pressure fuel supply “L” hose, new low-pressure fuel return “U” hose.
Step 27:
Install the new high-pressure fuel line from the fuel pump outlet to the right-side fuel rail. Tighten the fuel pump connector to 38 Nm and the fuel rail connector to 30 Nm. Tighten the passenger-side fuel rail opening with the provided plug and cap.
Step 28:
Install thermostat housing with crossover and bypass pipe.
Step 29:
Install the air conditioning compressor/power steering pump bracket.
Step 30:
Install the alternator mounting bracket.
Step 31:
Install the oil filler hose and alternator. Carefully check that there is sufficient clearance between the fuel line and the rear of the alternator.
Step 32:
Reinstall the air conditioning compressor and the serpentine belt.
Step 33:
Move the inner fan shroud forward and reinstall it. A 90-degree elbow may be needed to readjust the position of the rubber seals around the fan shroud. Do not damage the radiator when using the elbow!
Step 34:
Install upper rad hose.
Step 35:
Reinstall the two previously removed intake manifold studs. Install the intake manifold "Y" connector and tighten the nuts and bolts to 89 inch-pounds.
Step 36:
Install the EGR system, including the cooler, bypass hose, valves, and coolant hoses. Ensure there is clearance between the precooler and the new high-pressure line, directly above the CP3 connection.
Step 37:
Install the plastic intake elbow onto the turbocharger intake.
Step 38:
Install the aluminum intake manifold with throttle body and support bracket. Tighten the bolts to 18 ft-lbs.
Step 39:
Install the intercooler hoses between the throttle body and the intercooler, air filter hoses, and plastic intake manifold cap. A click should be heard at the intercooler hose connections.
Step 40:
Install the inner fenders and add coolant.
Step 41:
Connect both batteries and start the fuel system.
1. Press the starter pump repeatedly until it hardens.
2. Loosen the bleed screw until fuel flows freely without air.
3. Check the fuel system for leaks.
4. Start the engine for 10 seconds or until it ignites.
5. If the engine fails to start and no leaks are found, press the starter pump repeatedly until it hardens again. Restart the engine for 10 seconds each time until it starts. It may take 3-4 attempts to start the engine. Confirm that the vehicle's engine malfunction indicator light is not illuminated and that there are no issues with its driving performance.
This product is designed for competition or off-road use only and may not be legal for use on public roads under EPA or local emissions regulations. Installation should be performed by a professional technician; the user assumes all risks for any mechanical damage or legal consequences resulting from the use of this product.
This is the installation process for the ER-0331: 2011-2016 6.6L GM Duramax LML CP3 Injection Pump Conversion Kit,provided for your reference during installation.
If debris is found inside the high-pressure regulator, we recommend replacing the regulator, injector return lines, and check valve assembly.
Step 1:
Remove the right front wheel inner fender and drain the coolant from the engine cooling system through the lower radiator hose connection.
Disconnect both batteries and remove the plastic intake manifold cap, air filter hose, and the hose between the throttle body and the turbocharger air cooler (CAC). Gently turn the locking ring counterclockwise to disconnect the CAC hose.
Remove the aluminum intake manifold with the throttle body and its support bracket.
Remove the plastic intake bend from the turbocharger intake.
Disconnect the exhaust gas recirculation (EGR) system, including the cooler, bypass hose, valves, and coolant hoses.
Remove the intake manifold "Y" bridge.
Disconnect the water inlet hose, serpentine belt, and alternator. Use the 1/2-inch ratchet wrench located under the alternator to loosen the belt tensioner.
Remove the air conditioning compressor and carefully move it aside; refrigerant recovery is not required.
Unscrew the bolts on the cooling fan housing and slide it forward toward the radiator. The fan does not need to be removed or repositioned.
Remove the alternator mounting bracket. The belt tensioner and idler pulley can remain mounted on the bracket.
Move the air conditioning compressor/power steering pump mounting bracket aside. After removing the nuts and bolts, remove the two mounting studs to reposition the bracket.
Disconnect the oil filler hose, and then remove the thermostat housing with the crossover and bypass pipes. Plug the oil filler hose opening to prevent debris from entering.
Disconnect all fuel lines and hoses connected to the fuel injection pump. Set the rubber hoses aside, as some hoses will be reused during installation. Note that the 9th injector supply hose can be loosened and folded upwards; do not bend it sharply, as this can damage the internal components and cause poor fuel supply or breakage. Make sure to cover the ports on the fuel rail to prevent debris from entering!
Carefully bend the return hose to a position parallel to the machined surface of the left intake manifold. Further adjustments may be needed after installing the new pump.
Remove CP4 from the cylinder block and polish the mounting holes to facilitate CP3 installation.
Remove and save the drive gear, nut, and temperature sensor for reuse.
Lubricate the O-ring at the pump tip.
Install the pump mounting adapter onto the pump and tighten the three mounting bolts to 18 ft-lbs.Lubricate and install the included O-ring onto the pump mounting adapter.
Remove the barbed water supply and return connectors from the pump. Install using the included barbed fitting and lubricating sealing washer, as shown, and tighten to 20 ft-lbs. Use a 1/2-inch barbed fitting horizontally and a 3/8-inch barbed fitting vertically.
Install the drive gear and tighten the nut to 75 ft-lbs. Note that the CP4 nut cannot be fully screwed into the pump shaft; this is not a problem. It is higher than the CP3 nut. Thread engagement remains unchanged.
Remove the two 6 mm studs from the intake manifold.
Move the CP3 water pump to the appropriate position. Tighten the four original CP3 mounting bolts to 20 ft-lbs. Important! Tighten the bolts evenly as you move the water pump to the appropriate position to prevent damage to the water pump mounting adapter.
Using a pry bar and adjustable pliers, remove the support bracket from the jumper. Be careful not to bend or damage the fuel line.
If necessary, adjust the crossover and return lines to prevent them from contacting CP3.
Replace the low-pressure fuel supply line with a new extension hose and install it onto the engine. Tighten the compression fitting to 35 Nm (26 lb-ft).
Tip: Clean and lightly lubricate the low-pressure fuel supply line compression fitting for easy installation in the engine compartment.
Line B should be used after removing the original factory fuel filter housing (CP3 fuel supply hose is not included).
Step 26:
Connect the provided fuel hose to the original fuel pump supply line and secure it with a constant tension clamp. Install the new fuel return hose. Ensure the return hose does not contact the high-pressure fuel line. New low-pressure fuel supply “L” hose, new low-pressure fuel return “U” hose.
Install the new high-pressure fuel line from the fuel pump outlet to the right-side fuel rail. Tighten the fuel pump connector to 38 Nm and the fuel rail connector to 30 Nm. Tighten the passenger-side fuel rail opening with the provided plug and cap.
Install thermostat housing with crossover and bypass pipe.
Install the air conditioning compressor/power steering pump bracket.
Install the alternator mounting bracket.
Install the oil filler hose and alternator. Carefully check that there is sufficient clearance between the fuel line and the rear of the alternator.
Reinstall the air conditioning compressor and the serpentine belt.
Move the inner fan shroud forward and reinstall it. A 90-degree elbow may be needed to readjust the position of the rubber seals around the fan shroud. Do not damage the radiator when using the elbow!
Install upper rad hose.
Reinstall the two previously removed intake manifold studs. Install the intake manifold "Y" connector and tighten the nuts and bolts to 89 inch-pounds.
Install the EGR system, including the cooler, bypass hose, valves, and coolant hoses. Ensure there is clearance between the precooler and the new high-pressure line, directly above the CP3 connection.
Install the plastic intake elbow onto the turbocharger intake.
Install the aluminum intake manifold with throttle body and support bracket. Tighten the bolts to 18 ft-lbs.
Install the intercooler hoses between the throttle body and the intercooler, air filter hoses, and plastic intake manifold cap. A click should be heard at the intercooler hose connections.
Install the inner fenders and add coolant.
Connect both batteries and start the fuel system.
1. Press the starter pump repeatedly until it hardens.
2. Loosen the bleed screw until fuel flows freely without air.
3. Check the fuel system for leaks.
4. Start the engine for 10 seconds or until it ignites.
5. If the engine fails to start and no leaks are found, press the starter pump repeatedly until it hardens again. Restart the engine for 10 seconds each time until it starts. It may take 3-4 attempts to start the engine. Confirm that the vehicle's engine malfunction indicator light is not illuminated and that there are no issues with its driving performance.
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