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Call or Text (352) 722-5295Injection pumps on the 2020-2022 Ford 6.7L Powerstroke
Every 6.7L Powerstroke since 2011 uses the Bosch CP4.2, a two-plunger high-pressure pump that is lubricated by the fuel it moves. For 2020, Ford raised its output to as much as 36,000 psi to feed the third-gen injectors, up from 30,000 psi on 2011-2019 engines. Low-pressure fuel reaches it from the in-tank lift pump through a 10-micron frame-mounted primary filter and a 4-micron engine-mounted secondary filter, and it feeds two rails and eight injectors.
What fails and why
Ford recall 24S78 (NHTSA 24V957000) covers 295,449 2020-2022 Super Duty diesels because biodiesel deposits can form on the pump's roller components and lead to failure of the high-pressure pump. Ford links the deposits to aged biodiesel, including fuel left sitting during extended parking. The remedy is PCM and TCM software only, with no hardware replaced, and recall 26S17 (26V158000) re-covers trucks that were repaired incorrectly. Water and debris in the fuel are the other causes. Symptoms include extended cranking, a check engine light, unusual pump noise, a derate, a no-start or loss of power while driving. A failure can contaminate the entire fuel system and has been documented as early as 200 miles.
Protect the pump or replace it
There are two hardware routes. A disaster prevention or bypass kit keeps the CP4.2 and changes how it is fed and drained to protect the rest of the system if the pump fails. The S&S Diesel Motorsport Gen2.1 kit, for example, supplies clean fuel to the pump case on its own circuit and routes the case return through a dedicated Donaldson P550943 filter before it reaches the tank. In this section, the SPE Motorsport Disaster Prevention 2.0 Kit and the No Limit Fabrication CP4 Bypass Disaster Kit take on the same job; check each listing for its layout. The second route is the S&S DCR Pump Conversion, which replaces the CP4.2 outright with a Stanadyne-designed two-piston pump on a different eccentric drive. Either way, keep the filters fresh and the water separator drained.
What we carry
The S&S Diesel Motorsport DCR Pump Conversion. SPE Motorsport's Disaster Prevention 2.0 kit, Dual Fueler kits sold with a CP3 or without one, -6 AN fittings for the CP4 pump and a Billet Exo Filter 2.0 lid. The No Limit Fabrication 67CP4BPK CP4 Bypass Disaster Kit. The Alliant Power AP0190 fuel injection pump install kit and AP57003 fuel contamination kit, and the XDP MFG XD599 stock-replacement contamination kit. An Exergy Performance Fuel System Saver, an improved stock inlet metering valve (FCA/MPROP), and a Fleece Performance Engineering lift pump pigtail.
Fitment notes
Many parts here carry wide listings because the CP4.2 has been used since 2011: the SPE Dual Fuelers are listed for 2011-2026, and the Alliant Power install kit, the No Limit Fabrication bypass kit and the Exergy inlet metering valve for 2011-2024. Others are narrower. The SPE Disaster Prevention 2.0 kit is listed for 2020-2026, the contamination kits for 2020-2022 only, and the Fleece lift pump pigtail for 2017-2024. Remember that 2020-2022 trucks have the lift pump in the tank, unlike 2017-2019 trucks, so check any part that touches low-pressure supply for 2020+ notes. Verify by VIN.
Frequently asked questions
Will the dealer put a new pump on my truck under recall 24S78?
No. The remedy for 24S78 (NHTSA 24V957000) is PCM and TCM software only, with no hardware replacement. If your truck was repaired incorrectly, 26S17 (26V158000) covers the re-repair. Check your VIN with Ford or NHTSA to see whether either one is open.
What is the difference between a bypass kit and a DCR conversion?
A bypass or disaster prevention kit keeps the factory CP4.2 and changes how its case is fed and drained, to protect the rest of the system if the pump fails. The S&S DCR conversion removes the CP4.2 and puts a Stanadyne-designed two-piston pump in its place. One protects the system around the pump; the other replaces the pump.
Do I still need a contamination kit if my pump already failed?
If the pump shed metal, plan on it. A CP4 failure can contaminate all eight injectors, both rails, the high-pressure and return lines, the low-pressure parts and the tank and sending unit. The Alliant Power AP57003 and XDP XD599 kits are listed for 2020-2022 trucks for that repair.
Not sure what fits? Call the shop in Wildwood, FL at the number in the header, or use the fitment checker on any product page. We install everything we sell.