2020 Product Showcase: S&S’s Gen2 Power Stroke CP4 Bypass Kits

S&S Diesel Motorsport has built upon the successes of its original CP4 bypass kit it developed for the 6.7-liter Power Stroke engines four years with a much-improved second-generation kit, it announced today.

CP4 high-pressure pump failure are a common theme with the 6.7-liters, and when that occurs, debris is sent through the high-pressure side of the fuel system and damages the injectors, the lines, and the fuel rails — in effect, an $800 pump takes out a $10,000 fuel system. So S&S went to work and developed a solution, resulting in its CP4 bypass kit, which supplies the CP4 case and the metering unit/plungers independently with clean, filtered fuel, and to reroute case fuel back to the tank. The result is improved reliability for anyone using a Power Stroke-equipped truck day in and day out, whether its a daily driver or towing a trailer down the interstate.

The first-generation bypass kit saved thousands of injectors from an untimely demise, and so successful was the design that it’s been often imitated in the industry. As S&S notes, “being a company founded by fuel system engineers, S&S Diesel Motorsport has the ability and responsibility to offer the best solutions to fuel system problems. While the original bypass kit offers really good protection from a CP4 failure, the last four years have given the S&S engineers plenty of time to discover and eliminate potential problems.”

The Gen2 CP4 bypass kit features all quick-connect lines that eliminate the need for cutting the factory supply line — a common debris introduction point, especially if the cut is not thoroughly deburred. It also eliminates the need to use a compression fitting, which is a potential leak point. The OE-style quick-connect lines also eliminates any threaded joints that are further leak points and have the potential of generating debris during install.

The Gen2 fuel supply is split into two separate lines 25-inches from the CP4, which eliminates the chance of contaminated case fuel back-feeding into the clean fuel supply line. The original bypass kit splits off within 1-inch of the pump, and is more susceptible to debris back-feeding if the CP4 failure produces enough debris to clog the fuel return system.

The other improvement is what happens to the debris once it exits the pump case; the Gen2 kit features a 2-micron filter in a clear firewall-mounted housing that prevents debris from reaching the tank, fuel lines, and supply pump. It can be visually inspected at a glance for debris, which will give notice to a failed pump. Previously, those enduring a CP4 failure with the first-gen bypass kit installed would still need to drop the tank and deal with all of the debris created by the failed pump.

While one would think that major improvements would come with a major price increase. Decades of engineering experience have enabled S&S to make improvements without increasing production costs, and thanks to efficient design and use of material, the Gen2 6.7L Power Stroke CP4 Bypass Kit will sell for $400.00. To improve debris management of a first-generation bypass kit, the S&S Fuel Return Filter Assembly can be purchased separately for $160.00 USD.

The Gen2 6.7 Power Stroke Bypass Kits are expected to be available for purchase from S&S dealers at the beginning of 2021.

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About the author

Andrew Wolf

Andrew has been involved in motorsports from a very young age. Over the years, he has photographed several major auto racing events, sports, news journalism, portraiture, and everything in between. After working with the Power Automedia staff for some time on a freelance basis, Andrew joined the team in 2010.
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