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Oct 3, 2018 · The S&S 6.7L Ford Power Stroke CP4.2 Bypass Kit, or commonly called the “Disaster Prevention Kit,” does exactly what the nickname implies, it prevents the disastrous consequences of an inevitable CP4 pump failure from destroying the rest of a very expensive high-pressure fuel system. CP4 high pressure pumps are the Achilles heel of the 6.7L ...
- Ch Cp4.2: Everyone’S Using It
- What Happens Internally
- Irreversible Carnage
- No Fail Safe from The Factory
- 2 Bypass Kit
- The Pivotal Part
- Clearing The Way
- Modifying The Factory Fuel Line Clamp
- Need to Pull The CP4.2
- A Good Seal
Bosch’s CP4.2 high-pressure fuel pump has been used on the 6.7L Power Stroke since Ford released it for the ’11 model year Super Dutys, but this is far from its only application. Along with being employed on the LML Duramax(’11-‘16), the 5.0L Cummins V8 available in Nissan’s Titan XD, the 3.0L V6 VM Motori in the EcoDiesel Ram 1500, the 3.0L Power ...
Within the CP4.2 there are two high-pressure chambers, each with its own piston that’s driven up and down by dedicated lobes on the pump’s camshaft. The bottom of each piston integrates a roller lifter that rides on the cam lobe. Unfortunately, there is no mechanical lock or keyway in place to keep the piston from floating and rotating in its bore,...
When the piston rotates (usually 90 degrees) in the cylinder, the roller lifter on the bottom (which sits in a fixed position due to being pressed into a follower) hits the cam lobe at a perpendicular angle. From this point on, the roller lifter begins to beat itself to death against the cam lobe, slowly sending metal shards out the high-pressure o...
In this diagram of factory fuel flow through the CP4.2, you can see how the metal debris resulting from the failure of the roller lifter is allowed to contaminate the high-pressure fuel within the pump. Pieces of the disintegrating roller lifter and cam lobe are passed directly on to the fuel rails, injectors and the volume control valve (i.e. MPRO...
The CP4.2 Bypass Kit comes with everything you need to install it on your ’11-present 6.7L Power Stroke. The contents include an aluminum adapter block, O-rings, one section of braided stainless steel fuel hose with fittings and detailed installation instructions. We’ll note that due to a different length fuel line being required for the install, S...
This is the key to the bypass system. The aluminum adapter block stops fuel from entering the plungers within the CP4.2 and reroutes it back to the fuel tank. This allows the return circuit to catch any metal debris should the CP4.2 fail, and not the pricey components downwind in the high-pressure system (namely the aforementioned fuel rails and in...
To install the CP4.2 Bypass kit you first have to gain access to the top of the CP4.2 located at the front of the lifter valley on the 6.7L Power Stroke. This calls for the removal of both the upper and lower intake plenums. In its installation pamphlet, S&S points out that cutting or grinding off the leg on the bottom side of the cast-aluminum, lo...
To accommodate the supplied braided stainless steel hose, the black plastic supply and return line clamps near the fuel filter base are removed from the hard supply and return lines. In order for the S&S braided stainless steel hose to be able to rotate in the bracket (and clear the crimp collar on the braided stainless hose), the bracket closest t...
With access gained to the CP4.2, the circlips for both the supply fitting and return fitting are removed. From there, the factory T-bar is removed and discarded but the 10mm flanged head bolt that secured it is retained (it’s used to mount the aluminum adapter block). Then the hard fuel supply line is pulled, with the return line at the pump going ...
Though you can get away with reusing the factory supply tube O-rings on the adapter block, S&S sends fresh versions for peace of mind. In addition, new O-rings (the two largest units) are included to be fitted to the MPROP before it’s installed in the adapter block. All O-rings should be lubricated.
Apr 30, 2021 · S and S Diesel Motorsport, the creator of the original CP4 bypass kit for the 6.7 Power Stroke, is at it again with a much-improved second generation kit. Since its debut in 2016, the original S and S 6.7L Power Stroke CP4 Bypass Kit has safeguarded thousands of injectors from CP4 debris.
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- Vehicle Specific Fit
- S&S Diesel
- OE
We've been seeing a lot of questions, and even doubts, on how the S&S Diesel Motorsport Ford CP4.2 Bypass Kit safeguards the high-pressure fuel system from d...
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- 36.1K
- SSfueled
For those looking to improve the debris management of their first-generation Disaster Prevention Kit, the S&S Gen2.1 Fuel Return Filter Assembly (#CP4-6.7F-BP-G2.1-RFA)can be purchased separately for $160.00 USD. The new Gen2.1 return filter head uses the same quick connect fittings and mounting hardware as the previous Gen2 filter, which ...
- 3
- $120 - $400
Jun 7, 2011 · The new Gen 2.1 S&S 6.7L Ford Power Stroke CP4.2 Bypass Kit, or commonly called the “Disaster Prevention Kit,” does exactly what the nickname implies, it prevents the disastrous consequences of an inevitable CP4 pump failure from destroying the rest of a very expensive high-pressure fuel system.
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Protect your 6.7L Ford Powerstroke engine from expensive damage caused by a failed CP4 high pressure pump with the S&S Disaster Prevention Kit. This fail-safe kit redirects pump flow back to the tank and filters, preventing debris from contaminating the rest of the high-pressure fuel system. Don't risk costly repairs - install the S&S kit and ...
