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Possible insurance for CP4 pump failure- Exergy System Saver?

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#21 ·
I'm likely going to get one (or a cp3...) but am not messing with the pump until the warranty is gone.
 
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#22 ·
yeah the more people that come off warranty the more demand for a universal bypass plate would be, looking at the CP4.1 pump in the 4cyl CR Diesels from VW/BMW/Merc its physically identical at the metering valve and hose barbs, it would also fit on those vehicles too.. and globally thats a buttload of HPFP's out there that would like some protection.

Here's a guy trying to create his own for the CP4.1 because the powerstroke specific plates wont work for him, unfortunately he uses a separate feed line that makes it incompatible w/a CP4.2: 328d HPFP Bosch CP4.1 "Disaster prevention plate"

Even at $300, thats a fraction of the cost of doing a CP3 retrofit, assuming your lucky enough that is an option.
 
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#23 ·
So I think I figured out how to make clearance for the bypass plate, removing EGR is tricky on this vehicle as its got a coolant sensor, v-band on intake, and a funky coolant flange.. but really what's in the way is the EGR Valve, and if the Turbo has a blanking plate on it this valve can go away entirely.. freeing up more than enough room for some HPFP mods.. so most of the EGR will be in place so coolant can still flow through it, blanking plates for the intake and turbo will close off the exhaust flow and permit the valve to be separated from the rest of the EGR.

237011
 
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#24 ·
Canton 1Micron Fuel filter for return line arrived, now to finish the mount and get all the fittings/hoses.
Image
 
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Discussion starter · #25 · (Edited)
#26 ·
casioqv said:
As I posted in another thread (some more comments here), there now seem to be some updated designs on the market that move around the connections a bit, such that I think they might be a direct install on a VW without interfering with the EGR or fuel lines:

Gen2.1 6.7L Ford Power Stroke CP4 Disaster Prevention Kit (2011+) - S&S Diesel Motorsport

Update: I sent them an e-mail to see if they would be interested in working with us to test this.
Click to expand...
Looking forward to hearing more about this!
 
Discussion starter · #27 ·
I just heard back from S&S with incredible news- they said they are actually actively developing a 3.0 TDI kit that is already installed on VW and Audi test vehicles, and will hit the market soon. They agreed to share regular updates with me, that I will post on the forum.
 
#28 ·
casioqv said:
I just heard back from S&S with incredible news- they said they are actually actively developing a 3.0 TDI kit that is already installed on VW and Audi test vehicles, and will hit the market soon. They agreed to share regular updates with me, that I will post on the forum.
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what exactly is this supposed to do ?
 
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Discussion starter · #29 · (Edited)
jeffnhiscars said:
what exactly is this supposed to do ?
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All of the information is in this thread, but I realize it's somewhat convoluted, so I will summarize:

These Bosch CP4.2 pumps fail at the low pressure cam and follower, in the main crankcase of the pump, ejecting metal shards. This system provides a "sandwich plate" between the pump and fuel metering valve, which provides a clean filtered fuel supply to the high pressure side, such that any metal flake contaminated fuel from the crankcase can only flow out through the return line, instead of feeding into the high pressure side. You can then simply pass this 'dirty' return line through a filter, and any metal shards from a failure will be fully contained, and not contaminate the rest of the system.

These are already widely available and used for most full sized diesel american pickup trucks, which use the same CP 4.2 pump. Yet, those kits so far haven't been found to fit on our cars because the EGR system and fuel hoses are in the way.

This is an "ideal" solution to contain the damage from this failure, unlike the Exergy system posted at the beginning of this thread. That just adds a 20 micron screen to the fuel path, which likely isn't small enough to actually save the injectors from destruction.

This system won't prevent a failure, but can turn it from a ~$10k repair into a ~$1k repair. For the ultra paranoid, you could even carry a used pump and fix a failure roadside.
 
#34 ·
Even if it cost $500 it would be good insurance for US owners (who seem to endure poorer quality diesel than those in Europe) against pump grenade given that some people have reported subsequent repair costs of well over $10,000.

I see the makers claim better fuel flow above 3,000 RPM too, though what that means in practice doesn't appear to be explained.
 
Discussion starter · #35 ·
I’m not convinced that replacing a working HPFP reduces the chance of failure unless you swap it for a more reliable model, as it does not seem to be correlated with the age of the pump. Many of the documented failures were on very new vehicles, and there are many pumps with over 300k miles still working fine.
 
Discussion starter · #37 ·
jeffnhiscars said:
This is too much like the IMSB posts in the 996 forums. I'm over my limit :)
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Hah, I was thinking the same thing- almost exactly the same situation, there is no real agreement on what, if anything, to do about it. I have an LN Retrofit.
 
#39 ·
TommiT said:
Even if it cost $500 it would be good insurance for US owners (who seem to endure poorer quality diesel than those in Europe) against pump grenade given that some people have reported subsequent repair costs of well over $10,000.

I see the makers claim better fuel flow above 3,000 RPM too, though what that means in practice doesn't appear to be explained.
Click to expand...
casioqv said:
I’m not convinced that replacing a working HPFP reduces the chance of failure unless you swap it for a more reliable model, as it does not seem to be correlated with the age of the pump. Many of the documented failures were on very new vehicles, and there are many pumps with over 300k miles still working fine.
Click to expand...











Exactly ^^^
 
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#40 ·
casioqv said:
Hah, I was thinking the same thing- almost exactly the same situation, there is no real agreement on what, if anything, to do about it. I have an LN Retrofit.
Click to expand...
I've got an EPS from when my engine was overhauled after dropping a valve seat in 2015. Had only 18k on the engine when I got it along with invoices and, after speaking to the shop owner who bought it as a roller and did the rebuild, I now have a thumb drive of the build.

i don't lose sleep over the engine...just that trooper in NC who nailed me doing triple digit in it in June. Glad I don't live there :)
 
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