LML Dans Diesel Work, and CP4 failure

[99mpower]

The last week has been quite the roller coaster.

Leave October 20th (thursday) and drive straight from FL to Rockford, IL (1200 miles) and take a 2 hour nap before I drop my truck off at Dans Diesel Performance in Machesney Park, IL for a built trans/torque converter, and other work. Dan and his guys said they could knock out all the work in one day, and they followed through and kept their word. Picked up the truck at 8pm on Friday, with everything done

DDP 800 trans
Goerend 2200 TC
Suncoast Billet Flywheel
DDP trans tuning
FASS 150 install
DDP Traction Bars in Silver Artery
Edge Pyro Install
MA Merchant transfer case bracket

Drove the truck Saturday/Sunday (21st/22nd) to Michigan for a wedding and back to IL. Truck ran great, and seemed to get a little better gas mileage due to converter lock up, FASS and KW E-Maxx tune. I was thrilled with the truck, it was amazing

Stuck around on Monday to hang with family, and left for VA on Tuesday. Get to VA, no issues, hang out, spend the night, and leave for FL on Wednesday.

Get all the way down I-95, about 57 miles from my house, and I'm rocking out in the left lane at 85mph. Suddenly I have zero power, push gas pedal, nothing happens, and I immediately hit the blink and get all the way to the shoulder.

I try cranking the truck over, and I'm only getting .7kpsi at the FRP. YOU'VE GOT TO BE SHITTING ME!!!... Quick post on FB and some research and it appears my CP4 has taken a giant poo on me, 2500 miles after FASS 150 install and all the other DDP work. I cant afford this, FCUKKK...

Get the truck towed home, and start ordering parts. I talk with Dan and what my options are. I've seen the horror stories about the fuel rails/injectors/etc, and I'm terrified. I'm pretty sure I can tackle the CP3 conversion/EGR delete myself. I'm still on vacation until Monday, I can handle this.

Order the CP3 conversion with Sportsman (10%) pump from Dan with overnight shipping as I need to get started asap. Y-Bridge delete also gets ordered and set up for the same powdercoating as my traction bars and overnight shipping on those when complete. Dan was amazing to work with and went out of his way to make sure I got the parts by the weekend.

Time to get this party started

I cracked into the truck and finally was able to get to the FPR.

NOT what I wanted to see, I send the picture to Dan and he asks me to send him the regulator picture off the top of the cp4.

OUCH!!!!.... not what I want to see and I'm fearing the worst. Dan talks to me about how it was a sudden, catastrophic failure and I might be ok. Get the conversion done, and get the truck started. If it runs like crap, and smokes, it's getting injectors/rails.

Time to get plugging away. I'm not spending another $4k for a "possible" (30% overs and cover/63.5mm wheel if I was doing injectors).

Time to keep pulling this crap

Finally, CP4 is out.. praise the lord

prepping the valley as best as possible.

IN!!

I couldnt handle working on a step stool, I bought an over the engine creeper. WORTH EVERY PENNY!!!

Cut the top of the Up-pipe to help getting the bolts out

New up-pipe installed

I didnt take the crossover pipe out, so I put a towel in the valley, while I took an angle grinder to the bracket

Got a local Jacksonvile Duramax guy to swing by for a couple hours and help with the cp3 hook up. Thanks Paul

Hooking up the coolant from the heater core to the top of the thermostat housing

Driver side IC pipe going in

I ordered the DDP 4" intake today, but I wanted to get the truck started, so Air-Raid got hooked up after getting the passenger side IC pipe installed

I got the updated tunes from KW for the CP3, installed them, primed the truck and turned it over a couple times.

https://youtu.be/0Bg9nysuduI

I was STOKED!!! Truck runs, and idles great, with no smoke. So far so good, and no injectors/rails/lines required.

I used the Fleece CP3 Conversion youtube video, the S&S CP3 conversion instructions, and lots of questions from the couple duramax FB groups and Dan from DDP.

I can't thank Dan enough for all the help and answering all my annoying questions. I highly recommend giving Dan at Dans Diesel Performance a look if you need any diesel work done.

 

[99mpower]

Since the CP4 is garbage, I'll be tearing it apart and see what failed. Believe the shaft snapped, causing the sudden failure. Stay tuned.

 

[NC-smokinlmm]

Probably metering valve.

 

[99mpower]

metering valve cause metal shavings?

 

[GM_Guy]

Interested to see what failed in the cp4.. I had to replace my pcv because I was getting a code for it and mine looked like this

But my regulator on the top of the pump didn't have a spec of metal or debris so my truck is parked until I can investigate further.
It's currently still operational but I'm not going to risk it until I can find where that crap came from.

 

[NC-smokinlmm]

metering valve cause metal shavings?

This is what a bosch employee I know told me, they would come apart or start the process if water got into the fuel, they resigned and coated it in mid 2013. Hence, why there arent many failures after 14...

 

[Chevy1925]

Dont mean to rain on your parade OP but your not out of the woods yet. little vibration from driving and one extremely tiny piece of metal is all it takes to plug an injector. till you put quite a few thousand miles on it, you wont know for sure.

why you didnt atleast take the rails and hard lines off to spray them out and clean them is beyond me, you were right there...

 

[99mpower]

Dont mean to rain on your parade OP but your not out of the woods yet. little vibration from driving and one extremely tiny piece of metal is all it takes to plug an injector. till you put quite a few thousand miles on it, you wont know for sure.

why you didnt atleast take the rails and hard lines off to spray them out and clean them is beyond me, you were right there...

Easy enough to do anytime now that everything is deleted... only vehicle, and need mode of transportation caused time table to be pushed.

Truck runs and drives now.. ill take chances.. if metal is in fuel system.. I'm doing injectors either way.. now or in the future

 

[elliottw]

I'm going to lean towards you're going to need to do it eventually.. sorry about your bad luck after dropping tons of coin. I would actually venture to guess I've done as many fuel systems on the 13+ as the 11s and 12s. Some pickups were just snake bit I guess

 

[99mpower]

I'm going to lean towards you're going to need to do it eventually.. sorry about your bad luck after dropping tons of coin. I would actually venture to guess I've done as many fuel systems on the 13+ as the 11s and 12s. Some pickups were just snake bit I guess

cross that road when I get there... 30 overs and a cover/compressor if that happens...

 

[Chevy1925]

Easy enough to do anytime now that everything is deleted... only vehicle, and need mode of transportation caused time table to be pushed.

Truck runs and drives now.. ill take chances.. if metal is in fuel system.. I'm doing injectors either way.. now or in the future

you just say you cant afford the issue that came up at the beginning of the post and its your only mode of transport but you're willing to chance it . i truly hope she runs well and gives you no issues down the road. your not moving a high volume of fuel through the system so if you did get crap in there, it wont always show up right away. then you if/when swap injectors down the road and you jar something loose in the rails because again, nothing was atleast cleaned out, you just trashed a new injector/s.

 

[99mpower]

you just say you cant afford the issue that came up at the beginning of the post and its your only mode of transport but you're willing to chance it . i truly hope she runs well and gives you no issues down the road. your not moving a high volume of fuel through the system so if you did get crap in there, it wont always show up right away. then you if/when swap injectors down the road and you jar something loose in the rails because again, nothing was atleast cleaned out, you just trashed a new injector/s.

If I have to do new injectors down the road in MONTHS, (I'm active duty Navy, and I'm scheduled to be in and out at sea for quite a while) then I will be replacing the rails/lines/injectors all together, and possibly even doing ARP head studs with everything off the valve covers so it will be easy to go a little farther and pull the valve covers.

I need those months to replenish the bank account and get back to a position where I can afford to get new injectors/rails/line. If this will get me by for the next 6 months, thats what I need to do.

 

[nick31]

if you were running that cat filter prior to having the lift pump installed, that probably played a role in your CP4 taking a dump on you

 

[bigmackmiller]

if you were running that cat filter prior to having the lift pump installed, that probably played a role in your CP4 taking a dump on you

To much strain on the pump with the extra filtration?

 

[slowlml]

^^No water filtration with cat filter.

 

[99mpower]

^^No water filtration with cat filter.

no water filtration in stock filter??? CAT filter is still better than the stock filter setup

 

[minerigger]

I think they are saying if you ran the cat filter prior to the lift pump you were running with no water separation ability so that could be the likely culprit of the cp4 failure. After the lift pump shouldn't matter as the lift pump supplies positive pressure to the injection pump and come equipped with a water separater

 

[slowlml]

Probably metering valve.

metering valve cause metal shavings?

This is what a bosch employee I know told me, they would come apart or start the process if water got into the fuel, they resigned and coated it in mid 2013. Hence, why there arent many failures after 14...

This is probabaly why nick brought up the cat filter and why I said what I did. Like brock said if you run a cat filter without a lift pump you have no water filtration because the cat filters do not seperate water and the stock filters do. It doesn't matter when you have a lift pump because you have a water seperator and the additional fuel filter(s), if your still running one in the stock location.

 

[AJH]

Active duty explains a lot. No common sense. :hug:

 

[nick31]

Yes i was refering to the CAT filter not being a water seperator. What people fail to tell you when you order a kit to convert to those filters is that they aren't a seperator and you absolutely have to be running a lift pump setup with a water seperator, specially if you still have a cp4 in your truck...I ran those CAT filters on my fass and they sucked and gelled up big time, I had a few and since they were so cheap they just went in the garbage.