Cp3 replacement, other mods...PITA!!

[juddski88]

a little help with big project??

I am currently tearing the truck apart to install a lbz cp3, remove the EGR system completely, and add a little extra airflow:cool2: there are a bunch of little fuel lines on top of the cp3 that are really hard to work with without just totally removing them...is it OK to reuse the copper washers? also, how the hell am i supposed to access the intake bridge bolts under the stock turbo mouthpiece? I cant take the mouthpiece off because one bolt can't come out without the intake bridge out?seems pretty f-ed up to me. i found that my thermostats were deteriorating, the inside of my upper coolant tube was flaking this hard black sh*t, it's nasty, and that wiring harness that goes across the top off the motor is hard to work around...looks a lot easier in the manuals (because it's not even mentioned). all in all, this motor is a PITA to work on, i can't wait to do it all again this winter. sorry for the venting, but this is supposed to be a 4-6 hr job (cp3) that has taken me 7 already and the old one ain't even out yet.

maybe this winter I'll have a friend of mine just re-machine the intake components to try to make tear down easier because this is rediculous.

 

[sweetdiesel]

If the wire harnees is somewhat removed It makes these motors so nice to work on IMO
if you are trying to get the intake runners off you need to pull the turbo
what brass washers are you talking about? Crush washers?

 

[2500HeavyDuty]

turbo mouthpirce can be removed, get the wire harness out the way and try using a wrench from the side or long extensions from the front, the bottom one can be a PITA

 

[juddski88]

well we got the CP3 in last night and worked on the turbo all day today.....such a biatch!!!! after hours of moving the tranny up and down, 2 bottles of gas, 400 bucks at sears, 8 busted knuckles, 3 broken sockets, we are still one up-pipe bolt away from getting her out!! it's the lower one of the three that go into the turbo housing on the driver's side...being right between the flywheel housing and the up-pipe makes it very awkward to get at with anything...

 

[juddski88]

well, we finally got the turbo out!!! sprayed it again with PB blaster and went to town....tried running extensions all the way back to transfer case and tried my trusty 231 and it didn't budge. tried a breaker bar and cheater pipe from back there and that just wanted to snap everything..so we tried it from the pass. side wheel well again and pop she went!! had to cut off the EGR butterfly valve and its workings inside the upper intake manifold in order to get the HUGE compressor housing to fit. I will have pictures up soon. our next challenge is hooking that compressor housing up to the Banks intercooler pipe at such and high angle and rerouting all the coolant lines we won't need!

 

[2500HeavyDuty]

good to hear

 

[juddski88]

update:::: PPE GT42 mounting kit is not fully functional...oil feed line doesn't work with the elbow supplied and only one T4 gasket was given, there should have been two. also, I have o clue how i should make an intake with such a big housing...i have a 5" fernco that i can use with sched 40 pvc and the K&N FIPK to not have to create my own MAF sensor mount. i could not find flex pipe anywhere this size. also having issues rerouting coolant lines and such with stock hoses since ripping EGR out...might need to make a trip to the store....also need that T4 gasket and oil feed elbow in the right size in order to get her up and running....i was hoping to have time to mod the motor mount to add insurance but it doesn't look like that will happen now.

 

[GMC_2002_Dmax]

Call either Tony Burhardt or Eric Merchant for non EGR stuff.

Remove the emmisions crap and replace with non-egr stuff.

The metal crossover may need the turbo cooling line removed and relocated away from the turbo mouth.

​

 

[juddski88]

as long as I can work out the turbo mounting issues, i think i can fudge everything else, i just can't believe an off the shelf kit didn't come with working parts..but it did come with plenty of different oil return pipe gaskets instead

 

[1lowdiesel]

if you got the kit new from PPE i'd say give them a call and let em know it was missing parts, they should be able to get you replacements.

 

[sweetdiesel]

update:::: PPE GT42 mounting kit is not fully functional...oil feed line doesn't work with the elbow supplied and only one T4 gasket was given, there should have been two. also, I have o clue how i should make an intake with such a big housing...i have a 5" fernco that i can use with sched 40 pvc and the K&N FIPK to not have to create my own MAF sensor mount. i could not find flex pipe anywhere this size. also having issues rerouting coolant lines and such with stock hoses since ripping EGR out...might need to make a trip to the store....also need that T4 gasket and oil feed elbow in the right size in order to get her up and running....i was hoping to have time to mod the motor mount to add insurance but it doesn't look like that will happen now.

5 in SS flex pipe
http://store.airflo.com/ss5.html

T4 gaskets are common divided or undevided will both work

why doesnt the oil line work? Do you need seperate fittings?
http://store.summitracing.com/egnsearch.asp?N=115+400041

 

[juddski88]

well, i had Berry from www.customracinghose.com come over to the shop and make me a custom line...much better flow characteristics i might have a lead on the T4 gasket, if it doesn't work out ill get it from mass diesel performance. and I went with your SS flex idea and am building a 5" to 4" system to go into the K&N filter... the only thing i need to do is figure out the MAF mounting place. Can i run with out it???

 

[sweetdiesel]

well, i had Berry from www.customracinghose.com come over to the shop and make me a custom line...much better flow characteristics i might have a lead on the T4 gasket, if it doesn't work out ill get it from mass diesel performance. and I went with your SS flex idea and am building a 5" to 4" system to go into the K&N filter... the only thing i need to do is figure out the MAF mounting place. Can i run with out it???

You can run with out or build a flange to accept the maf sensor
5" to 4" how come? you will need some silicone hose or similar to connect each end im thinking

I wouldnt swedge down,just get a new filter

 

[bullfrogjohnson]

well, i had Berry from www.customracinghose.com come over to the shop and make me a custom line...much better flow characteristics i might have a lead on the T4 gasket, if it doesn't work out ill get it from mass diesel performance. and I went with your SS flex idea and am building a 5" to 4" system to go into the K&N filter... the only thing i need to do is figure out the MAF mounting place. Can i run with out it???

Judd,

I would run 5" mcmaster tubing ar what Simon posted, You can run without the MAF but you will need to change alot in your tuning. I personally dont run one so it can be done.

Godd Luck and PM me if you need any help

 

[sweetdiesel]

Judd,

I would run 5" mcmaster tubing ar what Simon posted, You can run without the MAF but you will need to change alot in your tuning. I personally dont run one so it can be done.

Godd Luck and PM me if you need any help

I run hose to

 

[juddski88]

Update::::: we still don't have a 2nd T4 gasket yet, hopefully tomorrow night or friday morning....the 5" flex pipe is too big so i took the 5" to 4" exhaust reducer and am going to clamp it to the turbo and run a 45* off it and then continue with 4" SS flex to the filter. the driver's side bolt to the oil return flange under the turbo is a biatch!!!!! we tried for over an hour but it's just so friggin tight in there....cant take the compressor cover off because it is touching the intake manifold and the intake manifold isn't coming out that's for sure. i am still not sure about the MAF, I can't delete it now i guess, I don't have time to get the tuning changed, maybe i can cut the K&N FIPK mount out and and clamp it between the flex and the filter.

 

[juddski88]

ok, well the turbo is finally on thanks to RCS Diesel for the gasket. i heard today that guys running bigger oil-cooled turbos are relocating their feed-lines to a port on the front of the motor in leu of the #4 camshaft bearing being starved using the stock port in the valley....anyone have any input on this?? also, FYI to anyone that tries to replicate this exact install, either get a taller riser made and put the turbo in in 3 pieces or have to do what i just did..put almost everything together and have to take it all apart again because it was so damn tight fitting i couldn't get to two of the nuts on the T4 flange to the riser, and put it in in three pieces

 

[bullfrogjohnson]

ok, well the turbo is finally on thanks to RCS Diesel for the gasket. i heard today that guys running bigger oil-cooled turbos are relocating their feed-lines to a port on the front of the motor in leu of the #4 camshaft bearing being starved using the stock port in the valley....anyone have any input on this?? also, FYI to anyone that tries to replicate this exact install, either get a taller riser made and put the turbo in in 3 pieces or have to do what i just did..put almost everything together and have to take it all apart again because it was so damn tight fitting i couldn't get to two of the nuts on the T4 flange to the riser, and put it in in three pieces

Yes the big turbos have to go in 3 pieces, at least mine did. As for the oil line I got a kit from ATS but you could easily do it if you had some time. All you will need are some AN fittings and a piece of braided line about 4ft long.

 

[juddski88]

where does the oil line mount to in the ATS kit? line and fittings are no problem anymore.....guy comes right to the shop and does it

 

[juddski88]

what type of McMaster tubing? i see they offer a few different kinds....my guess would be the vacuum stuff....thanks guys for all your help....i jumped in over my head on this one but we just had to do it to go out and prove ourselves for the last pull unfortunately, now it may be cancelled due to rain