S S DIESEL CP4 Gen2 6.7L Power Stroke Bypass Kit Installation Guide
- June 6, 2024
- S S DIESEL
Table of Contents
CP4 Gen2 6.7L Power Stroke Bypass Kit
Page |1
Gen2 6.7L Power Stroke CP4 Bypass Kit
. 2011 2021 Ford Truck 6.7L Power Stroke Diesel CARB EO Pending
Installation Instructions
S&S Diesel Motorsport
Rev 2, 20April2021
Installation Tools Needed
Tools Required:
· Sockets: o 7mm (Some years), 8mm, 10mm, 12mm
· Assorted Extensions, wobble extensions and universal joint is extremely
helpful · Using ¼” Drive tools is very helpful for tight areas · Inch-pound
torque wrench for FCA and plastic intake · 4mm allen socket · T25 Torx · Flush
cuts for zip ties · Plastic Fastener Removal Tool
o Similar to Lisle PN: 35260 · Stick Magnet (Useful to have on hand if you
drop a tool or fastener)
Page |2
Change Log: 1. Rev1 Initial Release 2. Rev2 2020+ Instructions Added, return
filter instructions updated
S&S Diesel Motorsport
Rev 2, 20April2021
Page |3
Skip to step 5 for Bypass Kit specific instructions if you have experience
taking apart the intake system. 1-4 is removing intakes to get to CP4 HPFP
1. Remove intake tube between air filter and lower intake a. 2 hose clamps
8mm, some models may be 7mm. b. Some models have an additional bolt holding
the plastic resonator chamber that must be removed.
2. Remove hot side charge pipe from turbo outlet and intercooler inlet for
more room and accessibility 3. Remove plastic upper intake
a. There are 15x 8mm bolts (Figure 2). Use ¼” drive sockets, deep well and
short, universal joint, and wobble socket to ease removal. An electric ratchet
is recommended.
b. One bolt doubles as a fastener for dipsticks (10mm nut). c. Remove the
other 2 bolts holding the dipsticks to the intake and to each other. d. Remove
all electrical connections and wires from the intake. Also removing the
exhaust pressure sensor
insulation (Figure 3) and wire clip can aid in access to intake fasteners. e.
Remove fuel filter housing for extra room to remove intake. 4 bolts (Figure 4)
may have to push/rotate
fuel hardline upwards to access the bolt under them. Once you remove the fuel
line, place it back on the lower hardline to keep it clean. Take special care
to not introduce debris into the filter or fuel line.
Figure 2: Intake removal
Figure 3: Insulation Removal
Figure 4: Fuel Filter housing removal
4. Remove EGR tube between cooler and lower intake a. 4x 8mm bolts b. Be sure to keep track of the gaskets c. Disconnect the electrical connection and remove wire clip from bottom of lower intake
S&S Diesel Motorsport
Rev 2, 20April2021
Page |4
5. Remove Lower Intake a. Remove 3x 10mm bolts (Figure 5) b. Remove crankcase
breather (Figure 6, this hose may be very brittle, be cautious to avoid
damage) c. Loosen hose clamps that hold the intake to the turbo d. Remove clip
with a flat screwdriver to take charge tube off the throttle body assembly e.
Disconnect the electrical connection to the throttle body
Figure 5: Lower Intake Bolts
Figure 6: Crankcase Breather
Figure 7: Failing CP4 FCA
S&S Diesel Motorsport
Figure 8: Clean FCA
Rev 2, 20April2021
Page |5
6. Install Bypass Block (For 2020+ please see page 7 for special
instructions) a. You should now have easy access to the FCA on the CP4.
Thoroughly clean the area around the FCA with brake cleaner and compressed air
before removing FCA (Figure 9) b. Remove FCA using T25 torx and ensure pump is
healthy by checking metering unit for debris. It should match figure 8 above,
if it looks like figure 7, the pump and fuel system must be replaced. c.
Remove dust covers from bypass hose assembly quick connects and blow out hoses
with compressed air while being careful to not damage o-rings inside the quick
connect fittings. Replace dust covers for install after it is blown out.
(Hoses are clean before shipping, but blowing them out again ensures no debris
was able to enter the bypass block passages during transport or handling). d.
Install O-rings onto Bypass Block (Figure 10) e. Install Bypass Block and FCA
onto the CP4 using supplied 4mm allen bolts. Torque to 60 inch-lbs.
Figure 9: Step 5 Starting Point
Figure 10: Install O-Rings
Figure 11: Install Block and FCA
7. Reinstall the lower intake a. Torque 3x 10mm bolts to 18 ft-lbs b. Tighten
hose clamps
8. Reinstall the EGR Tube with gaskets in place a. Torque 4x 8mm bolts to 89
in-lbs
9. Reinstall the upper plastic intake a. Torque 15x 8mm bolts to 89 in-lbs b.
Install fasteners for dipsticks c. Reconnect all electrical connections and
reinstall insulation on pressure sensor d. Ensure that all wires are routed
away from hot exhaust parts as they were previously
10. Reinstall the fuel filter and housing
S&S Diesel Motorsport
Rev 2, 20April2021
Page |6
11. Complete bypass kit installation a. Reinstall crankcase breather hose to
lower intake (take special care if the hose is brittle) b. Remove factory fuel
line from lower hard line c. Remove dust covers from the cleaned bypass kit
quick connect fittings d. Push quick connect fittings onto their respective
barbs (Figure 12) until you hear and audible click. Give them a small tug to
ensure they are seated all the way. e. Use supplied zip tie hose clips to keep
the hose from chafing on nearby components (Figure 12) i. Use one on the crank
case vent and if needed on the oil filler neck ii. Adjust as necessary to
ensure hose does not rub on nearby components
Figure 12: Hose Routing
12. Reinstall hot side charge tube between intercooler and turbo outlet 13.
After ensuring all connections are secure and fasteners tight, cycle the key
without starting to purge air from
the system. Watch the clear-view bowl in the S&S return filter to confirm when
air is purged. Then start the vehicle and check for leaks.
S&S Diesel Motorsport
Rev 2, 20April2021
2020+ Special Instructions
Additional parts provided: – Hose clamp – Hose and male quick connect assembly
Page |7
1. Remove the factory plastic hardline and quick connect assembly a. This is best done by removing the factory supply and return line assembly and using a heat gun to soften the hose enough to pull it off the factory hardline as shown below.
2. Install the supplied hose and quick connect barb assembly a. Slide the hose over the barbs on the factory supply tube. Ensure there is not metal to metal contact from the aluminum fitting to the tube inside the hose. b. Tighten hose clamp behind the 2nd barb (Reference image below) c. Take special care to not introduce debris into the system, or clean before reinstalling d. Reinstall hardline assembly e. Continue the install as normal on step 6
S&S Diesel Motorsport
Rev 2, 20April2021
Page |8
6.7L Power Stroke CP4 Return Fuel Filter
2011 2021 Ford Truck 6.7L Power Stroke Diesel . Installation Instructions
S&S Diesel Motorsport
Rev 2, 20April2021
Page |9
Installation Tools Required
· Wrenches: o 10mm, 7/16, 3/8
· 4mm Allen · Flush cuts for zip ties · Plastic Fastener Removal Tool
o Similar to Lisle PN: 35260
· SEE LAST PAGE for filter change and interval instructions
The return filter mounting is slightly different between 2011-2016 trucks and
2017+. Please see pages below pending your truck model year.
2011-2016
2017+
Model Year Compatibility:
This kit has been designed to cover a wide range of model years even though there are some differences in the fitment. Because of this, there are some extra parts provided which you may not need based on the year of vehicle. The list below outlines the extra parts you’ll have leftover after install for the various years.
Unneeded parts after a 2011-2016 install: · Long pan head bolt (60mm) · Aluminum spacer · 1x fender washer · M6 locknut · 2x ¼-20 flange bolts
Unneeded parts after a 2017+ install: · 2x rubber isolators · 2x ¼-20 flange nuts · 1x short pan head bolt
Change Log: · Rev 1, initial release · Rev2, Added model year compatibility/extra parts list
S&S Diesel Motorsport
Rev 2, 20April2021
P a g e | 10
2011-2016 Model Years
1. Assemble filter bracket to provided angle bracket with isolators a. Use
the fender washers under the nuts on the black filter bracket side b. Use the
flange nuts on both sides. Tighten with 7/16 wrench c. Ensure that the
stainless bracket is centered with the black bracket. (The slotted holes allow
side to side adjustment later if needed for clearance to nearby components.)
Figure 1: Bracket installation with Isolators Figure 2
2. Remove the bolt holding the ground strap to the upper firewall/cowl above
the brake fluid reservoir 3. Disconnect return side quick connect and rotate
the fitting
a. Place some absorbent towels around the joint to catch diesel fuel b.
Disconnect the return line quick connect fitting (Circled in blue, figure 3)
from the factory return barb
(Circled in red, figure 3) c. Rotate the plastic female quick connect fitting
inside the molded tube 180°, so it’s facing upward. This
may have to be slightly adjusted later.
S&S Diesel Motorsport
Figure 3: Quick connect to remove and rotate
Rev 2, 20April2021
P a g e | 11
4. Install filter bracket to the upper firewall/cowl a. Use provided short
metric allen drive button head bolt to hold the ground strap and filter
bracket to the firewall as circled in blue (Figure 4)
Figure 4: Bracket mounted, filter installed, hoses attached
5. Install the filter into the bracket, ensure flow is going from right to
left referencing the arrows on top
Figure 5: Filter orientation and flow direction
6. Install the longer of the 2 provided hoses (right side) a. The larger
quick connect goes on the barb that you removed the factory fitting from
earlier (Figure 3) b. The hose wraps around the back of the filter and the
small black/green quick connect attaches to the right side of the filter
S&S Diesel Motorsport
Rev 2, 20April2021
P a g e | 12 7. Install the supplied zip tie hose clip
a. Put the zip tie around the factory supply line and clip the hose to it,
adjust as necessary to keep the hose off the brake booster and reservoir
(Figure 6)
Figure 6: Zip tie clip placement
8. Install the shorter left side hose a. The aluminum barb goes into the
quick connect fitting that was previously disconnected and rotated b. The
other side connects to the left side of the filter c. Adjust rotation of quick
connect fitting as necessary to avoid chafing as pictured (Figure 7)
Figure 7: Left side hose installation
9. Cycle the key to run the electric supply pump. Monitor the clear view fuel
filter bowl to identify when the air is purged from the system. Start the
engine and check for leaks.
S&S Diesel Motorsport
Rev 2, 20April2021
P a g e | 13
2017+ Model Years
1. Assemble filter bracket to stainless bracket using supplied ¼-20 bolts and
flange nuts a. Use the fender washers under the nuts on the black filter
bracket side b. Put the flange nut on the opposite side of the filter so the
extra bolt length does not interfere with the filter.
Figure 1: Back side
Figure 2: Front Side
2. Loosen the cowel to access the hole for installing the fuel filter a. Release 3 clips in the front (red circle) and 2 clips underneath (near where blue circles are) that you relase by wiggling and prying up on the cowel gently. b. If you break a clip (Figure 4) the part number is: W708771-S300
Figure 3: Clip Locations
Figure 4: Clip under the cowl
S&S Diesel Motorsport
Rev 2, 20April2021
3. Remove plastic fastener from the hole under the cowl and discard it (Figure 5)
P a g e | 14
Figure 5: Remove plastic fastener
4. Disconnect return side quick connect and rotate the fitting a. Place some
absorbent towels around the joint to catch diesel fuel (Figure 6) b.
Disconnect the return line quick connect fitting c. Rotate the plastic female
quick connect fitting inside the molded tube 180°, so it’s facing upward. This
may have to be slightly adjusted later.
Figure 6: Removing Return line and reorienting fitting
5. Install the filter bracket in the same hole that the plastic fastener came
out of under the cowl a. Put the provided long bolt through the hole, then the
spacer, then the filter bracket (Figure 7). Tighten with the provided lock
nut. Be careful to not crack the plastic around the bolt.
S&S Diesel Motorsport
Figure 7: Bracket installed with spacer
Rev 2, 20April2021
6. Install the filter into the bracket, ensure flow is going right to left with the arrows on top
P a g e | 15
Figure 8: Filter orientation and flow direction
7. Install the longer of the 2 provided hoses (right side) a. The larger
quick connect goes on the barb that you removed the factory fitting from
earlier (Figure 9) b. The hose wraps around the back of the filter and the
smaller quick connect attaches to the right side of the filter
Figure 9
8. Install the shorter left side hose a. The aluminum barb goes into the
quick connect fitting that was previously disconnected b. The other side
connects to the left side of the filter c. If installing with Gen2 Bypass kit
the hose will likely have to wrap around the bypass kit hose to route nicely
9. Install the supplied zip tie hose clip a. Attach in location seen on
figure 10 and connect it further back on the return hose (Figure 9)
S&S Diesel Motorsport
Rev 2, 20April2021
P a g e | 16
b. May have to adjust zip tie clip and rotation of the factory quick connect
to ensure proper placement on that hose to not chafe on any components. It
should look like figure 11
Figure 10: Zip tie clip placement
Figure 11: Proper Hose Clearance
Filter Change Interval:
· The filter is designed to be easily serviceable and is a complete disposable
unit. You simply squeeze the tabs on the side of the filter, pull the filter
assembly forward out of the mount and dispose of the assembled unit. Purchase
a replacement filter from an S&S Diesel Motorsport dealer. Part Number:
6130120
· The return side fuel filter recommended change interval is the same as the
other fuel filters on the vehicle. See below for the factory Ford filter
change recommendations based on duty cycle and operating conditions.
· A major advantage to the return side filter is the ability to visually see
when air is purged from the system. When the factory fuel filters are changed
on the truck, it can take up to 7-8 key cycles to purge the air. Monitor the
S&S clear view return side filter bowl when the electric supply pump is
running to confirm when the system is primed. This prevents running the CP4
dry, pump damage, and air locks in the system.
S&S Diesel Motorsport
Rev 2, 20April2021