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The Bosch CP4.2 represents the change of high-pressure agent ammunition pump technology. It costs beneath for the architect to aftermath yet produces abundant college bang pressures than its predecessors. This agency agent agent manufacturers can accommodated acutely acrimonious chapped amount discharge standards while befitting the all-embracing accumulation costs of their engines down. Unfortunately, the CP4.2 has a baleful blemish that can spell adversity for not abandoned the pump itself, but the blow of the [expensive] bang arrangement and possibly alike the engine. One agent that is awfully affected to CP4.2 pump abortion is the LML Duramax, the 6.6L agent V-8 GM offered in its ’11-’16 archetypal year HD trucks.

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Although Ford’s 6.7L Power Stroke utilizes a actual agnate adaptation of the CP4.2, it’s accurate abundant added reliable in ’11-present Super Duty applications. The primary acumen for this is the actuality that the Power Stroke comes branch with an electric lift pump agriculture it constant airy ammunition supply. The LML Duramax doesn’t accept a branch lift pump. Luckily, the accession of an aftermarket electric lift pump can advice ensure that absolute burden (and no air) is supplied to the airy ancillary of the CP4.2—and can be installed almost affordably. Below, we’ll explain why the CP4.2 fails, appearance you what it looks like aback it self-destructs and again lay out how you can accumulate this abortion from accident to you.

Bosch’s CP4.2 is the accompanying agent high-pressure another in its CP4 pump band (the CP4.1 is the distinct agent version, active across in assorted agent engines). Anniversary butt of the CP4.2 appearance a agent assembly, plunger, bounce and head. A distinct camshaft with two actuation lobes drives the pistons up and bottomward aural their corresponding bores. In the LML Duramax, the CP4.2 pressurizes agent ammunition as aerial as 29,000 to 30,000 psi. This acute aerial burden facilitates accomplished atomization aural the engine’s cylinders. With future, tighter chapped amount discharge standards in mind, Bosch advised the CP4 band to aftermath (and handle) as abundant as 39,000 psi.

The camshaft drives the pistons by way of a roller tappet amid in the basal of anniversary piston. Both roller tappets are press-fit into a able follower. Not abandoned does the roller tappet crave a attenuate band of agent ammunition to accumulate the point of acquaintance with the cam’s affiliate lubricated, but it charge additionally abide alongside with the cam’s lobe. Unfortunately, aback a abridgement of ammunition lubrication is present or (worse) air infiltrates the high-pressure pump, the pistons float and are decumbent to alternating in their bores. Aback this happens, the roller tappet rides perpendicularly on top of the cam affiliate and the inconsistent armament from up aloft due to awful pressurized yet aerated ammunition advance to acquaintance actuality fabricated amid the two components.

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After the roller tappet in the agent and the cam accomplish abundant contact, both pieces activate to breach down. Due to the architecture of the CP4.2 pump, metal bits is acceptable to access the high-pressure alcove and avenue the high-pressure outlet. This agency that shrapnel-laced ammunition is accustomed to breeze into the ammunition rails—fuel which is eventually beatific to the injectors. At the aforementioned time, the acknowledgment ambit and all ammunition actuality baffled aback to the catchbasin is contaminated. By the time you apprehension the problem, it’s already too late. Best CP4.2 failures abide of the agent shutting off unexpectedly, never to restart.

As you may accept already guessed, the amount of a CP4.2 abortion can be expensive. Aliment can ambit from $6,000 to $10,000 depending on what is replaced (vs. bankrupt and reused) and who handles the work. For optimal accord of mind, the high-pressure ammunition arrangement should be absolutely replaced. This agency installing a new CP4.2, injectors, ammunition rails, high-pressure ammunition lines, acknowledgment ammunition curve and a absolute catchbasin cleaning. Best absolute agent shops can accomplish the job in almost 30 activity hours, and the activity acutely represents a solid block of the all-embracing amount of repairs.

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One of the aboriginal things to analysis in the accident of a doubtable CP4.2 abortion is the VCV, or aggregate ascendancy valve. This valve regulates the breeze amount of the high-pressure pump and is able with an 80-micron awning in the LML Duramax engine. Finding the awning in this affectionate of shape, coated in metal debris, is usually a admonition assurance that the CP4.2 has lunched itself. Exergy Performance developed a two layer, 25-micron awning to abduction added bits and additionally shut the agent bottomward eventually in the accident of a pump failure. Unfortunately, while this can advice absolute the accident acquired by a declining CP4.2 (making the aliment beneath expensive), it can’t accumulate the CP4.2 from failing.

An aftermarket lift pump arrangement is the best affordable way to accumulate the CP4.2 alive. FASS, AirDog and Fuelab are the big names in boondocks here. Anniversary of them action a complete arrangement that not abandoned provides acceptable ammunition accumulation burden for the CP4.2, but all of them affection bigger clarification and air abatement capabilities over the OEM equipment. Approved ammunition clarify and baptize separator changes and actual clarify accession are additionally a big allotment of befitting air out of the LML’s bang system.

On this FASS Titanium Signature Series lift pump system, the pump, ammunition clarify and baptize separator are all allotment of the aforementioned assembly, which can be army to a cantankerous affiliate or forth the truck’s anatomy rail. Its 2-micron ammunition clarify outperforms the branch 10-micron AC Delco assemblage and the lift pump allows the CP4.2 to adore a abiding 8 to 10 psi of absolute ammunition burden supply. As a bonus, alike an entry-level lift pump arrangement will abutment an added 200 to 300 hp over stock.

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GM’s 6.6L Duramax V-8 has continued been accepted for its durability. With able affliction and approved maintenance, the alternating accumulation abandoned can go an accessible bisected a actor miles. On LML models (’11-‘16), the CP4.2’s lifespan can be continued abundantly with the simple accession of a lift pump. Seeking a bit of high-mile insurance, the buyer of this ‘13 Silverado 2500 HD added a FASS system. The ¾-ton Chevy now has added than 200,000 trouble-free afar on the odometer and counting.

While the accession of a lift pump can accumulate the CP4.2 alive, long-term, the ultimate fix is to alter it with an another pump. By reverting aback to the Bosch CP3, the high-pressure ammunition pump active on ’01-’10 Duramax engines and that accepted acutely reliable, LML owners can accumulate a potentially adverse accident from occurring. Assorted CP3 bandy systems are accessible in the agent aftermarket and, while adequately pricey, action the abandoned 100-percent cure for CP4.2 failure.

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