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Exergy got back to me. The response is a bit over my head. After wrestling with this, I just couldn't get by "am I the only one that put a 2015 CP4 in an 11 - 14"? I just couldn't get by how responsive Exergy has been, how they went way above & over what I think a company would do without saying "oh, you have a 2013, sorry, the 2015 pump is not going to work". These guys sent me another pump, I guess there are some fly by night companies out there that would do about anything to make a sale. I definitely do not think that Exergy is one of those companies. These guys have been so willing to help I am still astonished at their customer service. They went out and bought a DPK to test in their lab to help identify where my problem is steaming from. Here is their response:
Yes, it is true that Bosch increased the displacement of the CP4.2 pump for the ’15 model year. They did this by increasing the lift of the cam from ~6.8mm to ~7.5mm. This was done to support the 40 HP increase the engine gained in 2015. The increase in cam lift (plunger stroke) does not affect the number of cycles the cam makes. The pump is always spinning at crankshaft speed, so the number for cycles is only controlled by RPM. Since this CP4.2 pump is controlled by an inlet metering valve (MPROP)(FCA)(FPR), the characteristic of that valve determines the relationship between commanded valve current and pump output, as long as supply pressure to the valve is held constant. Between model year 14-15 there was not a change to the characteristic (or P/N) of the inlet metering valve and there was no change in supply pressure to the valve. So the increase in displacement gives the pump some additional top end when the valve is nearly wide open, but has little to no difference throughout the rest of the output curve. I have not heard of any tuning being required when installing the ‘15+ pump in a ’11-’14 with all stock parts / tuning. We offer this pump as an upgrade at no additional charge so people running performance tuning on a ’11-’14 can gain some extra HP.
According to White Bear Lake Ford parts look up, the same pump from 2011-2016 is the only replacement available. If that is the case, then no tuning should be required.
Man dude, I really feel for you. While their customer service has been beyond outstanding, you still have a problem to solve. Hopefully one of their suggestions will solve this. I hope you and your mechanic get to the bottom of this soon. This really sucks. Hang tough bud.
Getting closer to the day the problem will be solved one way or the other. I think I'm going to stick with my original plan, pull the DPK & inspect the o-rings. If nothing reaches out and grabs the mechanic or I remove the DPK and install the stock fuel lines. I am quivering from truck withdrawal. I've had enough of the 2001 Lincoln they let me use.
Larry - do you use White Bear? I've been using them for years. Back in the early 2000s when going to FordParts.com would take you to their site and they were Tousley Ford. I've always found their prices to be a few bucks cheaper than others and love the way you can find an illustration of just about any part you need.
I'm embarrassed to admit but I did crack my right side main mirror prior to this incident of me smacking that mailbox. They are Ford OEM parts. They are located in Dearborn, MI. So I ordered from them a second time for this second "accident."
After looking at all the different sites, Village was the cheapest I found. Compare their prices with the others.
Chuck, I have ordered from White Bear in the past. Sometimes I print the price displayed on their web page for the part I need and then ask the local Ford dealer if they can match it.
Thanks guys - I’m starting to get a little nervous. I’m going to be a wreck tomorrow, especially after putting the thing together. I forgot to mention this. When this started they had me drive the truck into the bay where they were going to do the work. Put the truck in park and before I could get out of the truck the mechanic removed the core from the valve stems in my front tires to lower the truck. Great idea, just felt ‘wrong’ and was strange seeing my truck sitting there on 2 flats. I guess it’s like when you have an operation, you really don’t want to know what they are doing to you when you’re out.
Well folks, I'm happy to report that the debacle has ended. I have a 2015 CP4 pump, and Exergy module, new fuel lines and the sensors on the fuel line; no DPK. Took everything apart and inspected the 2 places Exergy said to look. The o-rings looked fine. We did see a ware spot (see picture) on the DPK in 1 of the spots Exergy said the problem was probably occurring. I called Exergy when the truck was apart and asked if I could replace the slightly used Exergy module that is in the 1st pump with the one in the new pump they sent. They gave me the "ok" to do that. So now we don't know if it was the DPK that was bad or the Exergy module that was bad. Exergy asked me to send them the DPK, their new pump with the slightly used Exergy module in it and they will test the setup in their lab to see if they can determine where the problem is. I wanted to go overboard on protection having the Exergy module and a DPK. I totally am not going to tear the truck apart again and put a new DPK in. It's life with a '15 CP4 and an Exergy module to protect the injector system.
Also looks like no tuning is needed when putting a '15 pump in a '11 - '14. Truck is running perfectly. Brought it up to temperature, jumped on it, went through the gears 2nd to 6th each at it's little over 3,000 RPM shift point and no CEL. Thanked everyone at the shop, was all smiles and then drove home through town 20 - 35 mph in 90 degree heat. Turned onto a side road, jumped on it again going up a fairly substantial hill, 3rd to 4th and 4th to 5th at it's a little over 3,000 RPMs shift point and it did fine. Took a bit longer to get up to the 3,000 RPM + shift point pushing itself up the hill. Ran out of hill to get it from 5th to 6th. No CEL, I'm satisfied we resolved the issue.
At some point I will tear the '13 CP4 pump apart to see if my debacle was warranted. Going to wait a bit and let the new pump, new fuel lines, the sensors in the new fuel lines and the Exergy module settle in a bit. Once I start tearing the old CP4 pump apart, it's not going back together.
Also want to think the folks here for their suggestions, well wishes and willingness to help - thanks folks!!
That's great news Chuck. I'm happy for you! Sucks about the DPK but I don't blame you in not wanting to disassemble again when she's dead nuts NOW. I looked at Exergy's stuff at least a dozen times and thought that's who I'd go with when it's time to R&R the HPFP. But the customer service you experienced is second to none. I'm truly impressed. So enjoy the ride and can't wait to see those pics of your disassembled CP4.2.
Since this thread is fuel related, I just want to pass this on for FYI. I went to a local dealer today in search of exhaust parts for my wife's 09 Escape. Anyways, the parts guy told me that Ford is coming out with new additives for the diesels. I'm curious to see what happens.
Good to hear you and back up and running. Also good to hear 2015 pump will work correctly as one will probably been in my future! I have to say the DPF kit looks to have some CNC issues or possibly the kits choice of oring style. For anyone interested in doing a DPK I highly recommend the S&S diesel kit. I am interested to hear if Exergy finds an issue with the valve sent back.
Good to hear you and back up and running. Also good to hear 2015 pump will work correctly as one will probably been in my future! I have to say the DPF kit looks to have some CNC issues or possibly the kits choice of oring style. For anyone interested in doing a DPK I highly recommend the S&S diesel kit. I am interested to hear if Exergy finds an issue with the valve sent back.
I would have to agree with you, cjssr. The seal on the S&S adapter block looks to be of a better quality than the kit that Chuck's did. I am posting this link that came from S&S's kit on their website. This is a very informative link here:
Definitely looks like a thicker seal specifically designed to do a better job at sealing the block to the pump and to possibly prevent what happened to Chuck's. But I'm just pondering here. I've seen S&S's instructions for their kit which look to be top notch.
UGA, I am extremely curious why the folks you spoke with said a tune was needed and what they would have changed. There’s a reason why they said that and I would really like to know what it was. Maybe they thought I was changing the turbo also? Maybe if you swap the CP4 and Turbo with a ‘15 CP4 and turbo you need a tune? I know the ‘15s gained 40 additional HP and believe it had to do with the combination of the CP4 and Turbo upgrades. And UGA, that’s exactly what this place is for, exactly why I started this thread, I can’t thank you enough for talking to someone about my problem and coming back with a suggestion. It made all of us more knowledgeable about how the CP4 works.
The seal on the S&S kit is exactly like the seal on the bottom of the Exergy module. The Exergy module also has an o-ring like the S&S kit. I suspect the problem was with that seal. It wasn’t held in place very well either. If you look closely at the picture I posted you can see just by leaning it up a bit the o-ring is not centered. The mechanic put a dab of grease on it to hold it in place.
I went with that kit because that’s the kit the folks that sold me the pump offered. My thought was if they are in the pump resale business they must have a good idea what DPK is best - wrong.
I went with that kit because that’s the kit the folks that sold me the pump offered. My thought was if they are in the pump resale business they must have a good idea what DPK is best - wrong.
UGA, I am extremely curious why the folks you spoke with said a tune was needed and what they would have changed. There’s a reason why they said that and I would really like to know what it was. Maybe they thought I was changing the turbo also? Maybe if you swap the CP4 and Turbo with a ‘15 CP4 and turbo you need a tune? I know the ‘15s gained 40 additional HP and believe it had to do with the combination of the CP4 and Turbo upgrades. And UGA, that’s exactly what this place is for, exactly why I started this thread, I can’t thank you enough for talking to someone about my problem and coming back with a suggestion. It made all of us more knowledgeable about how the CP4 works.
The seal on the S&S kit is exactly like the seal on the bottom of the Exergy module. The Exergy module also has an o-ring like the S&S kit. I suspect the problem was with that seal. It wasn’t held in place very well either. If you look closely at the picture I posted you can see just by leaning it up a bit the o-ring is not centered. The mechanic put a dab of grease on it to hold it in place.
I went with that kit because that’s the kit the folks that sold me the pump offered. My thought was if they are in the pump resale business they must have a good idea what DPK is best - wrong.
He must have interpreted what I sent him as you doing a turbo swap somehow as well because when I sent him a reply that you were up and running with no tuning, he then shot back a text saying “pump only requires no tuning, just a turbocharger swap.
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