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Completed installation of my S&S DPK yesterday. Some takeaways from the install:
S&S kit is top notch quality
Instructions are geared toward earlier trucks - the intake manifolds on 2020+ trucks are slightly different. See PTT's video on youtube for guidance on the newer trucks - though the one he did was easier because the EGR and CCV were deleted.
To get the CCV hose off the lower intake, slide the rubber sleeve back and then you can carefully pry up the plastic retaining piece and pull the hose off.
The toughest part of the job was the 2 rear bolts on the passenger side of the upper intake manifold. One bolt you cannot get a socket on due to the exhaust pressure sensor. Not sure if a wobble socket would work as I don't have one. Perhaps a flex head ratchet wrench would make it easier, though you still couldn't torque it.
I dropped my 8mm wrench while reinstalling the intake manifolds. After spending 45 minutes trying to find it with a mirror I pulled the intakes back out only to still not be able see the wrench with a mirror. I was able to fish around with my magnet and retrieve the wrench. This little adventure cost me an hour or more.
FVCV was clean, so
I didn't have a 4mm bit so I wasn't able to torque the FVCV bolts, but I'm sure they're close to the required 60 inch pounds.
To get the factory end off the supply line, I hit it with the torch for a bit, then made a slight cut with a razor knife (taking care not to score the metal pipe) and then after a bit more heat with the torch it came right off.
To reinstall the lower intake, remove the rubber ring from the turbo that you see in my pictures and insert it in the lower intake, then the lower intake will slide right on the turbo. Tighten clamp after intakes are installed.
Upper and lower intakes need to be removed together and installed together.
I may put some corrugated plastic over the spot where the fuel supply hose and return hose touch.
While I had it apart, I replaced the cold side pipe with one from H-S Motorsports
Some pics Hardest bolt on upper intake Pre DPK S&S DPK installed on CP4 S&S DPK kit installation complete HSM cold side intake pipe
20326027[/url]]^^^ The problem here is the fuel system warranty is now voided. It's a slippery slope when performing this change.
I don’t think so, but don’t really care. Ford would try to weasel out of coverage anyway. I can’t say that I have ever made any life decisions based on a product warranty and I’m not going to start now.
I concur as well. The way I see it is Ford would try weasel their way out of it and not cover it. I would rather just have to buy the pump instead of the whole system and just pay to have a new pump put in.
And good job Jolly!!
Last edited by Overkill2; Mar 14, 2022 at 08:34 AM.
Reason: Add to post
I concur as well. The way I see it is Ford would try weasel their way out of it and not cover it. I would rather just have to buy the pump instead of the whole system and just pay to have a new pump put in.
And good job Jolly!!
if you can install a gen 2 s&s DPK, you are only a few steps away from being able to replacing the pump yourself.
I think I could replace the pump, though "a few steps" really means removing a bunch of **** off the front of the engine in addition to the stuff removed to install the DPK. Good news is, since I've done it I think I could remove the intakes fairly quickly.
I finally worked my nerves up to ordering the DPK! I will install it during my next oil change, which will also be time for my first fuel filter change too, so I’ll knock it all out at once. I may have some more questions along the way… but for starters, is that just split loom you put on the hoses? If so, you remember what size?
I finally worked my nerves up to ordering the DPK! I will install it during my next oil change, which will also be time for my first fuel filter change too, so I’ll knock it all out at once. I may have some more questions along the way… but for starters, is that just split loom you put on the hoses? If so, you remember what size?
When I get a chance, I'll pull mine out and measure those hoses. I'm glad you posted this. I'm going to do the same before I install mine. Or have it installed...
Unless Jolly remembers and posts up...
Okay I measured the OD of the 3/8 inch ID fuel hoses with a micrometer, they all are 3/8 inch ID, the OD is approximately 16.25mm (loosely measured) which converts to 0.639 inches OD. I bet 5/8 inch (0.625") OD loom would work.
I'll post pics and have some additional info to post up.
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