The CP4 Fuel Pump Failure Problem – And a Long-Awaited Fix for Ford 6.7L Powerstroke Owners
If you drive a 2011–2023 Ford Super Duty fitted with a 6.7L Powerstroke diesel engine, the perils of the factory CP4 high-pressure fuel injection pump may already be known to you. When it fails, it does so without warning, and usually in the worst way possible. Fuel system contamination or power loss is common, as is stalling altogether. As an unwanted side effect, countless truck owners are facing thousands of dollars in repairs because the damage is done.
Why CP4 Pumps Fail
The Bosch CP4.2 pump used in 6.7L Powerstroke applications certainly has not been the darling of the automotive world, and for good reason. There are several suspected causes of failure:
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Low viscosity due to ultra low diesel (ULSD)
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In ability to cope with dirty substandard fuel
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Metal wear from roller lifter rotation
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Shavings and debris damaging the entire fuel system It is common knowledge that replacing injectors, lines, rails, and even the pump is often mandatory due to injectors failing, which nearly always occurs due to the diesel fuel system's propensity to be contaminated.
Restricted Aftermarket Options Until Now
Up until now, aftermarket solutions for CP4 pump issues only included disaster mitigation bypass kits. These bypass kits did nothing to remedy the problem of the CP4 failure but were designed to avert damage to downstream components.
A New Plug-and-Play Solution: S&S Diesel’s DCR Conversion Kit
S&S Diesel Motorsport collaborated with PurePower Technologies, which is the aftermarket branch of fuel system supplier Stanadyne, to completely resolve the dilemma with a permanent solution—the DCR High-Pressure Fuel Pump.
What Makes the DCR Pump Different?
The DCR (Diesel Common Rail) fuel pump is based on a proven Stanadyne design and specifically adapted for the Ford 6.7L Powerstroke platform. This pump fits and replaces the CP4 precisely; no recalibration or modification is needed.
Some of the primary design factors include:
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Tight fit for the V8 engine bay
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OE-grade braided hoses and steel fuel lines for better integration
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Avoid using any CP4 parts
DCR Pump Technical Highlights
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Fuel Delivery: 1250 mm³/revolution (25% increase from CP4.2)
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Pressure Output: Maximum 2200 bar
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Design: Two–Piston, compact and modular.
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Noise Levels: Low Hydraulic and acoustic noise.
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Fuel Compatibility: Compatible with biofuels and low lubricating diesel.
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Durability: Corrosion resistant and debris divergent Volume Control Valve.
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Efficiency: Eccentric drive patented with cam and pressure lubricated bushings.
Better yet, this pump has improved compactness, enhanced durability, and increased flow capacity. This is a huge advantage with trucks utilizing highly worn injectors or upgraded nozzles.
When Should You Change to the DCR Pump?
Option 1: Preventive Installation
By far, the most cost effective strategy is adapting the S&S CP4 to DCR Fuel Pump Conversion Kit for installation before damage such as CP4 failure is encountered. This greatly minimizes the risk of pump failure contaminating the fuel system, and pump in turn eliminates the thousands in repair costs.
Option 2: Post CP4 Failure
In the case of an expected CP4 failure, you can combine the DCR conversion kit with a fuel contamination kit (without CP4). This allows you to replace all the critical components while simultaneously upgrading to a more dependable pump.
Summary
The CP4 pump has been a pain point for Ford 6.7L Powerstroke owners for more than 10 years. Thanks to the new S & S Diesel DCR Conversion Kit which, within seconds, transforms not just the Super Duty, but allows further extending the Super Duty platform with a modular, long lasting, worry-free pumping system. It is now possible to fit an easy-install replacement that supercharges the versatility and trust needed.
Best of all, whether you’re trying to optimize potential problem areas ahead of time or picking the pieces after a failure, this kit addresses the concern with a dependable solution that’s time tested and tackles the problems at the center—the root problems that decimates confidence in operational resiliency—for good.
