Finally got the dealer to warranty my leaking CP3 after I got it to the shop when it was 0 deg out and it left a puddle of diesel on their floor. They told me I had to remove the road armor front bumper before they could do the work.

So, what do they need to tear into to get at the CP3 that requires the bumper to be off? I assume intercooler at least but are they going to have to pull a/c condensor, radiator, fan shroud ect.? Just wondering so i can double check it all when they are done

 

REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components.
This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible
plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (Fig.
7).
(3) Remove accessory drive belt.
(4) Thoroughly clean the rear of injection pump,
and attachment points for its 3 fuel lines (Fig. 8).
Also clean the opposite ends of these same 3 lines at
their attachment points.
(5) Disconnect Fuel Control Actuator (FCA) electrical
connector at rear of injection pump (Fig. 9).
CAUTION: Whenever a fuel line fitting is connected
to a secondary fitting, always use a back-up wrench
on the secondary fitting. Do not allow the secondary
fitting to rotate.
(6) Remove fuel line (injection pump-to-fuel pressure
limiting valve).
(7) Remove fuel line (injection pump-to-fuel rail).
Use back-up wrench on fitting at fuel pump.
(8) Remove fuel line (injection pump-to-fuel filter
housing).
(9) Remove fuel pump drive gear access cover
(plate) with a 3/8” drive ratchet. Plate is threaded to
timing gear cover (Fig. 10).
(10) Remove fuel pump drive gear mounting nut
and washer.
(11) Attach C3428B, or L4407A (or equivalent)
gear puller (Fig. 11) to pump drive gear with 2 bolts,
and separate gear from pump (a keyway is not used
on this particular injection pump). Leave drive gear
hanging loose within timing gear cover.
(12) Remove 3 injection pump mounting nuts (Fig.
12), and remove pump from engine.


INSTALLATION
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components.
This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible
plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Inspect pump mounting surfaces at pump and
mounting flange for nicks, cuts or damage. Inspect
o-ring surfaces for nicks, cuts or damage.
(2) Clean injection pump mounting flange at gear
housing. Also clean front of injection pump.
(3) Install new rubber o-ring into machined groove
(Fig. 12) at pump mounting area.
(4) Apply clean engine oil to injection pump
o-ring only.
The machined tapers on both injection pump
shaft and injection pump gear must be absolutely
dry, clean and free of any dirt or oil film.
This will ensure proper gear-to-shaft tightening.
(5) Clean pump gear and pump shaft at machined
tapers with an evaporative type cleaner such as
brake cleaner.
(6) Position injection pump to mounting flange on
gear housing while aligning injection pump shaft
through back of injection pump gear.
(7) After pump is positioned flat to mounting
flange, install 3 pump mounting nuts and tighten
finger tight only. Do not attempt a final tightening
at this time. Do not attempt to tighten (pull)
pump to gear housing using mounting nuts.
Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten 3 mounting
nuts.
(8) To prevent damage or cracking of components,
install and tighten nuts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nut finger tight only.
(b) Do preliminary (light) tightening of injection
pump shaft nut.
(c) Tighten 3 injection pump mounting nuts to
24 N·m (18 ft. lbs.).
(d) Do a final tightening of pump shaft nut to
105 N·m (77 ft. lbs.).
(9) Install drive gear access cover (plate) using a
3/8” drive ratchet. Plate is threaded to timing gear
cover. Tighten to 8 N·m (71 in. lbs.) torque.
(10) Install fuel line (injection pump-to-pressure
limiting valve). Tighten bolts to 24 N·m (18 ft. lbs.)
torque.
(11) Install fuel line (injection pump-to-fuel rail).
(a) Tighten fitting at fuel pump to 37 N·m (27 ft.
lbs.) torque. Use a back-up wrench.
(b) Tighten fitting at fuel rail to 37 N·m (27 ft.
lbs.) torque.
(12) Install fuel line (injection pump-to-fuel filter
housing). Tighten to 24 N·m (18 ft. lbs.) torque.
(13) Connect Fuel Control Actuator (FCA) electrical
connector to rear of injection pump.
(14) Install intake manifold air intake tube (above
injection pump). Tighten clamps.
(15) Install accessory drive belt.
(16) Install cooling fan shroud.
(17) Install cooling fan assembly.
(18) Connect both negative battery cables to both
batteries.
(19) Check system for fuel or engine oil leaks.




How's that?

 

madhat... that is excellent.

bradler... the ONLY thing I could think of is they don't want to ding up/scratch your RoadArmor during the work process. Other than that, there's no reason to remove it.

 

That's the only way I know how to do it...
Good point... however, if that's the case, tell them to put a dang blanket over it.