I know for a fact if you do a turbo upgrade with stock tuning it doesn't run quite right, but the trucks don't need a tune to run the upgraded turbo. They just achieve full potential with tuning in place. I wish Ford would come up with an update to the 11-14 trucks for the upgraded turbo, being as they offer the kit as an upgrade straight from dealerships, would also be nice to add the factory exhaust braking capability. Glad you got your problem solved without tuning, being as it was a hard parts upgrade to the CP4.2 it makes sense that no tuning is required, to gain full benefit from the extra capability of the pump tuning may be desired by some, Exergy is second to none in the injection business, at least they were a few years ago, still sounds like it holds true. Glad you got the truck fixed and everything is working well for you.

 

Dave, The kit is by XDP

The more I think about it the more I think it was that o-ring. Or rather that o-ring wasn’t enough. Why would the modules and the S&S kit have 2 seals to prevent fuel from getting through and the XDP kit only have 1? That’s gotta be it.

UGA, Glad I didn’t wreck your source of 6.7 knowledge - lol

 

That sounds logical Chuck. S&S it will be.

 

Verdict is in and it's not the o-ring we thought it was. Also nice picture of the screen Exergy adds to their modified module.






Test #1 - Original System Saver Valve - Without XDP kit - Ran normal, passed calibration test



Test #2 - Original System Saver Valve - With XDP kit - Pump output did not change as valve current was adjusted - failed calibration test



Test #3 - New System Saver Valve - Without XDP kit - Ran normal, passed calibration test



Upon further investigation I was able to determine the root cause. The XDP kit has the wrong size o-ring installed where there machined piece seals in the MPROP (system saver valve) cavity in the pump. See attached comparison picture which shows their o-ring (too small) compared to the valve it replaces. The OD of the o-ring is ~1.5mm smaller than what it needs to be, so it doesn’t seal against the pump case. This allows fuel to simply bypass the metering spool in the MPROP which does not allow the valve to serve its purpose.

 

That's crazy Chuck, but great find. They screwed up there. You contacting them about this?

 

PM on the way.

 

Well it looks like I may have really lucked out with this debacle and fortunately found 2 excellent companies to deal with. So far XDP has said all the right things and may have found a customer for life. They have issued an RMA for the kit and we are negotiating the cost of the fuel line which I believe will result in a positive outcome. I have trouble putting into words the reduction in stress and overall reduction in negative feelings when you deal with a company that deals fairly with you. XDP recognized the issue, reached out to me and is dealing fairly with me. I think that’s going the extra distance to demonstrate the type of company they are and they value they place on their customers. To me spending a couple of extra dollars is well worth it knowing the people you’re dealing with value their customers. When involved in something like this you’re so focused on your situation and not wanting to feel like your getting ripped off it’s easy to forget these companies are in business to make money. They need to pay their employees who have lives and families. All you can hope for is to be dealt with honestly, fairly and treated with the respect you are showing towards them. So far XDP has checked all the boxes. I’ll be sure to post once everything is taken care of.

 

That's great Chuck. Good to hear. How much more from mechanic to put in the correctly gasketed new DPK?

 

Dave, it's around $400 to re-install the kit. The concern is that there is so much stuff that needs to come off the engine that disassembling and reassembling it could lead to a different issue as well as the wear on the various clips, push on wire holders ... which need to come off that I think I'm just going to live without a DPK. Continuing to add PM22-A with each fill up, the updated 2015 CP4 pump and the Exergy module should be enough.

All, recommend you bookmark:

Exergy Performance - https://www*****rgyperformance.com/

and XDP's - https://www.xtremediesel.com/

web sites. These 2 companies provide some of the best customer service I've ever experienced. They certainly have my business for the rest of my life / as long as they're around which I hope is well past my life. I'll be searching their sites before I check the large on-line warehouses anytime I need something for my truck. You'll never get any where near this type of customer service from the on-line warehouses.

 

Thanks so much for all the kind words and support. Your feedback really means a lot to us and I'm glad we were able to help make this situation right. Please don't hesitate to let us know if there is anything else we can help with. We're always a PM, or call away!

 

so question for XDP , is this a one off or is there a material defect in the product? I don't see a happy ending yet until some final answer is disclosed (material defect in a casting run, new hire included the wrong o-ring, product not compatiable with XYZ year, etc, and /or problem resolved.

the CP4 bypass is a great idea, but if it cant be executed, its just an illusion.

I was going to buy one...but I don't need these headaches ...it needs to be a drop in and go.

please advise

 

This seems to be an isolated incident. We just opened a bunch of inventory and the o-rings were sitting properly in the machined adapter (unlike the image shown above). I don’t have Chuck’s specific kit back in our hands yet, but we will thoroughly go over it when we do get it.

At this point it’s likely this was some sort of one-off machining error, or an issue with the o-ring seal. The ownership, manufacturing, tech support, and QC teams are all aware of this issue and are on heightened alert.

 

I'm still waiting for the kit to be returned from Exergy. According to UPS it's going to be here today. I'm going to visit my son for the weekend so I'll get it shipped back to Alligator on Tuesday. Jeremy, I'll shoot you a PM with the tracking number when I drop it off with UPS.

 

I did manage to get the package shipped before I left for Vermont

 

Hey guys I bought the Exergy module, and was planning on buying a DPK as well, then installing them both at the same time.

Theoretically the incident that generated this forum should be a freak/isolated one, correct?

Or is there a compatibility issue with these two products when used together?

Thanks