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  • Fueling Around: 6.7L Power Stroke Fuel System Upgrades

Fueling Around: 6.7L Power Stroke Fuel System Upgrades

Lift and Injection

Chris Tobin
May 15, 2019

There is no doubt the current generation of Ford Super Duty trucks are serious performers, with the stout 6.7L Power Stroke diesel engine leading the charge for the Blue Oval's faithful followers. However, despite the trucks' plusses, they're also hindered a bit by a somewhat fragile CP4.2 high-pressure injection pump that fails without warning.

Due to the way the 6.7L engine's fuel system is designed, when a CP4.2 fails, debris from the pump's internals contaminates and likely damages the entire fuel system—including the fuel lines, in-tank pump, and injectors, which leads to a very expensive bill for replacing the entire fuel system and its associated components. Even after completing repairs using new factory-replacement components, the system is still at risk for another failure.

As Grandma and Grandpa used to say: "An ounce of prevention is worth a pound of cure." So the team at S&S Diesel Motorsport developed a CP4.2 Fail Safe Kit to prevent the debris of a failed high-pressure fuel pump from contaminating the entire fuel system. Granted, if your rig's CP4.2 fails, you still have to replace the pump, but with the Fail Safe system installed, those costly injectors and the rest of the fuel system are spared from being damaged.

Photo 2/55   |   001 6 7l Power Stroke Fuel System Upgrades Truck
001 6 7l Power Stroke Fuel System Upgrades Truck
  |   001 6 7l Power Stroke Fuel System Upgrades Truck

We spent a long day at RLC Motorsports in Cookeville, Tennessee, following the installation of an S&S Diesel Motorsport Fail Safe Kit as well as a FASS Diesel Fuel Systems Titanium Signature Series TS-F18-125G lift pump and filter system. RLC wants to improve fuel delivery and filtration capabilities of the shop's show-and-tow '17 Ford F-350 (the FASS unit will also be a great foundation of solid fuel delivery for future injector upgrades should they decide to upgrade the 6.7L further down the road) and protect the rest of the fuel system in case the CP4.2 high-pressure pump bites the dust.

Seasoned diesel technician Logan Gregory performed the installation using standard and topside creepers to work below and over the lifted truck's engine bay. He completed the entire installation process in about 12 hours. We recommend do-it-yourselfers set aside a weekend to complete the job. Also, installing the lift-pump system requires lowering the fuel tank and modifying the internal pump and sending unit. So, get the tank as close to empty as safely possible before starting the project.

While this installation/upgrade does not provide the immediate gratification of our typical performance improvements—especially in the seat-of-the-pants department—it will lessen the negative financial impact of a future CP4.2 injection-pump failure. In addition to the peace of mind the S&S and FASS combination provides '17-to-'19 Ford diesel owners, it also forms a solid foundation for future fuel-system upgrades, such as bigger injectors and other supporting modifications to coax more power out of Ford's 6.7L Power Stroke engine.

Photo 3/55   |   002 6 7l Power Stroke Fuel System Upgrades Ss
002 6 7l Power Stroke Fuel System Upgrades Ss
  |   The S&S Diesel Motorsport CP4.2 Fail Safe Kit for 6.7L Ford Power Stroke diesel engines is a simple setup that includes everything needed to protect the rest of the fuel system in the event of a high-pressure fuel-pump failure.
Photo 4/55   |   003 6 7l Power Stroke Fuel System Upgrades Fass
003 6 7l Power Stroke Fuel System Upgrades Fass
  |   The TS-F18-125G fuel pump and filter system from FASS Diesel Fuel Systems replaces the in-tank pump and external tank-mounted fuel filter with a single unit that flows more diesel than the stock unit and filters better, while also removing entrained air from the fuel system.
Photo 5/55   |   004 6 7l Power Stroke Fuel System Upgrades Engine
004 6 7l Power Stroke Fuel System Upgrades Engine
  |   While the 6.7L Scorpion engine looks safe enough, there is unseen danger lurking below the surface in the CP4.2 that will wreak havoc on the rest of the fuel system—including the expensive injectors—if it fails.
Photo 6/55   |   005 6 7l Power Stroke Fuel System Upgrades Harness
005 6 7l Power Stroke Fuel System Upgrades Harness
  |   Logan Gregory starts installing the FASS system by routing the wiring harness from the passenger side of the engine bay down to the intended mounting location for the pump (below the bed on the passenger side). Yes, installation on '17-to-present Ford Super Duty calls for the pump to be mounted on the passenger side of the truck.
Photo 7/55   |   006 6 7l Power Stroke Fuel System Upgrades Fuseholder
006 6 7l Power Stroke Fuel System Upgrades Fuseholder
  |   After using a digital probe to determine which fuse is a viable source for Key-On power, Logan uses the supplied piggyback fuse holder to add a protected circuit for the fuel pump. Once the fuse location is measured and verified with the key in the On and Off positions, he disconnects the negative battery terminal from each battery to avoid any possible damage to the electrical system while installing the pump.
Photo 8/55   |   007 6 7l Power Stroke Fuel System Upgrades Heatshrink
007 6 7l Power Stroke Fuel System Upgrades Heatshrink
  |   After shortening the power lead to the correct length for this effort, Logan solders the wires back together then wraps the connection with heat-shrink tubing to protect against the elements and prevent it from shorting to ground.
Photo 9/55   |   008 6 7l Power Stroke Fuel System Upgrades Completebattery
008 6 7l Power Stroke Fuel System Upgrades Completebattery
  |   With the ground mounted on the inner fender and the positive lead passing through a fuse holder before being connected to the positive post on the battery, Logan covers all the wiring with loom to compete the underhood portion of the project.
Photo 10/55   |   009 6 7l Power Stroke Fuel System Upgrades Fueldrain
009 6 7l Power Stroke Fuel System Upgrades Fueldrain
  |   Moving on to the fuel-tank modifications, Logan disconnects the lines using a bucket to catch the diesel that drains from the hoses. He also disconnects the fill and vent tubes from the top of the tank.
Photo 11/55   |   010 6 7l Power Stroke Fuel System Upgrades Fillhose
Photo 12/55   |   011 6 7l Power Stroke Fuel System Upgrades Droptank
011 6 7l Power Stroke Fuel System Upgrades Droptank
  |   With the fuel tank supported from below, Logan removes the front and rear straps and lowers the tank enough to unplug the harness from the sending unit.
Photo 13/55   |   012 6 7l Power Stroke Fuel System Upgrades Tank
012 6 7l Power Stroke Fuel System Upgrades Tank
  |   Drew Richards helps remove the tank from the truck and place it on a pair of stands, making it easier to work on. (Note: Fuel is heavy, so it's best to empty the fuel tank as much as possible before starting this project.)
Photo 14/55   |   013 6 7l Power Stroke Fuel System Upgrades Tank
013 6 7l Power Stroke Fuel System Upgrades Tank
  |   Logan removes the stock fuel pump and sending unit assembly.
Photo 15/55   |   014 6 7l Power Stroke Fuel System Upgrades Tank
014 6 7l Power Stroke Fuel System Upgrades Tank
  |   The original hoses are also extracted.
Photo 16/55   |   015 6 7l Power Stroke Fuel System Upgrades Tank
015 6 7l Power Stroke Fuel System Upgrades Tank
  |   The new fuel pickup is mounted in the same spot where the original pump was located.
Photo 17/55   |   016 6 7l Power Stroke Fuel System Upgrades Tank
016 6 7l Power Stroke Fuel System Upgrades Tank
  |   The FASS lift-pump system uses a much larger fuel-pickup line than the stock hose. To accommodate the increase, a hole is drilled in the top of the sending-unit assembly and a high-flow fitting is installed.
Photo 18/55   |   017 6 7l Power Stroke Fuel System Upgrades Tank
Photo 19/55   |   018 6 7l Power Stroke Fuel System Upgrades Tank
018 6 7l Power Stroke Fuel System Upgrades Tank
  |   Once the fuel-pod modifications are complete, Logan drops the assembly back into the tank and secures it with the original O-ring and hardware.
Photo 20/55   |   019 6 7l Power Stroke Fuel System Upgrades Tank
019 6 7l Power Stroke Fuel System Upgrades Tank
  |   New lines are routed between the tank and the FASS lift-pump system.
Photo 21/55   |   020 6 7l Power Stroke Fuel System Upgrades Wiring
020 6 7l Power Stroke Fuel System Upgrades Wiring
  |   To trick the ECM into thinking the original fuel pump is still in the tank and operational, a load resistor is installed in the harness. Logan mounts it under the bed rather than to the framerail.
Photo 22/55   |   021 6 7l Power Stroke Fuel System Upgrades Mount
021 6 7l Power Stroke Fuel System Upgrades Mount
  |   Moving over to the passenger side, Logan installs the supplied body-mount-bracket adapter on the forward bolt as directed.
Photo 23/55   |   022 6 7l Power Stroke Fuel System Upgrades Mount
022 6 7l Power Stroke Fuel System Upgrades Mount
  |   To keep the pump and filters high and out of the way of road debris, Logan installs the bracket pointed upward, with a small notch to clear the body panel (arrow).
Photo 24/55   |   023 6 7l Power Stroke Fuel System Upgrades Mount
023 6 7l Power Stroke Fuel System Upgrades Mount
  |   With the bracket mounted, Logan can install the pump and tighten the hardware to keep it securely in place and out of harm's way.
Photo 25/55   |   024 6 7l Power Stroke Fuel System Upgrades Wiring
024 6 7l Power Stroke Fuel System Upgrades Wiring
  |   Logan modifies the wiring harness by removing a section of the pump's wiring and then connecting the ends accordingly and using solder and heat-shrink tubing to insulate and seal the unions.
Photo 26/55   |   025 6 7l Power Stroke Fuel System Upgrades Tank
025 6 7l Power Stroke Fuel System Upgrades Tank
  |   Next, the fuel tank is reinstalled using the stock hardware, and then the lines, filler-, and vent tubes are all reconnected.
Photo 27/55   |   026 6 7l Power Stroke Fuel System Upgrades Heatshield
026 6 7l Power Stroke Fuel System Upgrades Heatshield
  |   FASS supplies heat shield for the fuel lines that go between the tank on the driver side and the pump located on the passenger side.
Photo 28/55   |   027 6 7l Power Stroke Fuel System Upgrades Hoses
Photo 29/55   |   028 6 7l Power Stroke Fuel System Upgrades Pumpfilters
028 6 7l Power Stroke Fuel System Upgrades Pumpfilters
  |   The completed FASS installation looks great and will deliver plenty of well-filtered fuel for the '17 F-250's 6.7L Power Stroke engine, while also simplifying service with the easily accessible filter and water separator attached directly to the pump housing. Be sure to install the filters in the proper positions.
Photo 30/55   |   029 6 7l Power Stroke Fuel System Upgrades Intake
029 6 7l Power Stroke Fuel System Upgrades Intake
  |   After completing the FASS pump and filter installation, Logan turns his attention to the S&S Diesel Motorsport CP4.2 Fail Safe Kit, which bolts in under the hood. The job requires removing the stock intake-air tube from between the filter housing and the intake manifold.
Photo 31/55   |   030 6 7l Power Stroke Fuel System Upgrades Egr
030 6 7l Power Stroke Fuel System Upgrades Egr
  |   The EGR tube has to be removed as well.
Photo 32/55   |   031 6 7l Power Stroke Fuel System Upgrades Intake
031 6 7l Power Stroke Fuel System Upgrades Intake
  |   The composite upper intake manifold is removed first. Having a topside creeper makes reaching the rear bolts much easier.
Photo 33/55   |   032 6 7l Power Stroke Fuel System Upgrades Intake
Photo 34/55   |   033 6 7l Power Stroke Fuel System Upgrades Fuelfilter
033 6 7l Power Stroke Fuel System Upgrades Fuelfilter
  |   The engine-mounted fuel filter and housing are temporarily removed as well, in order to get the manifold out of the truck.
Photo 35/55   |   034 6 7l Power Stroke Fuel System Upgrades Intake
Photo 36/55   |   035 6 7l Power Stroke Fuel System Upgrades Intake
035 6 7l Power Stroke Fuel System Upgrades Intake
  |   The cast-aluminum lower intake manifold is much easier to remove.
Photo 37/55   |   036 6 7l Power Stroke Fuel System Upgrades Intake
Photo 38/55   |   037 6 7l Power Stroke Fuel System Upgrades Cp4
037 6 7l Power Stroke Fuel System Upgrades Cp4
  |   Our focus is on the fuel-inlet and return lines on top of the pump, as well as the metering unit on the top (arrow).
Photo 39/55   |   038 6 7l Power Stroke Fuel System Upgrades Cp4
038 6 7l Power Stroke Fuel System Upgrades Cp4
  |   Exercise caution when removing the C-clips, as they can easily go flying and get lost or even worse: end up somewhere very difficult to retrieve like the turbo inlet.
Photo 40/55   |   039 6 7l Power Stroke Fuel System Upgrades Cp4
039 6 7l Power Stroke Fuel System Upgrades Cp4
  |   Logan removes the fuel-supply line to the CP4.2.
Photo 41/55   |   040 6 7l Power Stroke Fuel System Upgrades Cp4
040 6 7l Power Stroke Fuel System Upgrades Cp4
  |   Then he removes the metering unit from the top of the pump.
Photo 42/55   |   041 6 7l Power Stroke Fuel System Upgrades Cp4
041 6 7l Power Stroke Fuel System Upgrades Cp4
  |   New O-rings for the S&S Diesel Motorsport adapter block are supplied with the kit and placed in the block.
Photo 43/55   |   042 6 7l Power Stroke Fuel System Upgrades Cp4
Photo 44/55   |   043 6 7l Power Stroke Fuel System Upgrades Cp4
043 6 7l Power Stroke Fuel System Upgrades Cp4
  |   The block assembly is then bolted onto the CP4.2 injection pump.
Photo 45/55   |   044 6 7l Power Stroke Fuel System Upgrades Fuelline
044 6 7l Power Stroke Fuel System Upgrades Fuelline
  |   In order to fit the new stainless steel supply line to the pump, the original line is cut as directed 1 inch from the fitting. Be sure to deburr the inside of the line after cutting it to ensure no debris is introduced to the fuel system.
Photo 46/55   |   045 6 7l Power Stroke Fuel System Upgrades Fuelline
Photo 47/55   |   046 6 7l Power Stroke Fuel System Upgrades Fuelline
046 6 7l Power Stroke Fuel System Upgrades Fuelline
  |   Logan installs the locking ferrule on the line to prevent leaks and then tightens the connection.
Photo 48/55   |   047 6 7l Power Stroke Fuel System Upgrades Fuelline
047 6 7l Power Stroke Fuel System Upgrades Fuelline
  |   The modified fuel line is installed as directed, with Logan being careful to make sure the stainless braid does not make contact with any surfaces that could damage the hose. In the area where it is close to another line, Logan installed a rubber hose to serve as an insulator and prevent wear.
Photo 49/55   |   048 6 7l Power Stroke Fuel System Upgrades Fuelline
Photo 50/55   |   049 6 7l Power Stroke Fuel System Upgrades Intake
049 6 7l Power Stroke Fuel System Upgrades Intake
  |   Since a little filing and/or grinding must be done on the lower intake manifold for clearance, Logan masks off the openings to prevent debris from getting into the manifold and ultimately the engine.
Photo 51/55   |   050 6 7l Power Stroke Fuel System Upgrades Intake
050 6 7l Power Stroke Fuel System Upgrades Intake
  |   Casting flash and a locating lug are removed from the manifold for additional clearance.
Photo 52/55   |   051 6 7l Power Stroke Fuel System Upgrades Intake
051 6 7l Power Stroke Fuel System Upgrades Intake
  |   Logan reinstalls the lower intake manifold, followed by the composite upper intake.
Photo 53/55   |   052 6 7l Power Stroke Fuel System Upgrades Intake
Photo 54/55   |   053 6 7l Power Stroke Fuel System Upgrades Plumbing
053 6 7l Power Stroke Fuel System Upgrades Plumbing
  |   Reinstalling the fuel filter and housing, air-intake tube, and air filter, are the final tasks of installing the S&S Diesel Motorsport CP4.2 Fail Safe Kit. Logan also double-checks the boost tubes and any harnesses that were unplugged during the intake-removal process to confirm they are secure.
Photo 55/55   |   054 6 7l Power Stroke Fuel System Upgrades Finalassembly
054 6 7l Power Stroke Fuel System Upgrades Finalassembly
  |   While visually the engine looks no different, the team at RLC Motorsports now has peace of mind knowing the S&S Diesel Motorsport Fail Safe Kit will keep their truck's fuel system clean even if the CP4.2 injection pump does fail at some point.

Sources

S&S
Escondido, CA

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