S&S Fuel Pump: The Ultimate Guide to Performance, Reliability, and Upgrade Options

The bottom line: S&S Diesel Motorsport fuel pumps are widely recognized as the gold standard in diesel performance, offering unmatched durability, precision engineering, and real-world reliability for everything from daily-driven work trucks to full-on competition race vehicles. If you own a diesel truck—whether it's a Ford Power Stroke, Dodge Cummins, or Chevy Duramax—upgrading to an S&S fuel pump can save you thousands of dollars in repair costs and deliver performance that factory components simply cannot match.

Why S&S Fuel Pumps Matter for Your Diesel

When it comes to diesel fuel systems, the fuel pump is the heart of the entire operation. A failing or inadequate pump can cause everything from poor acceleration to complete engine failure. S&S Diesel Motorsport has spent decades solving these exact problems. With a combined 63 years of OE diesel fuel injection and engine development experience, their team includes former Bosch and Cummins engineers who understand the intricacies of common rail diesel systems better than almost anyone in the aftermarket.

S&S doesn't just sell parts—they engineer solutions. Their fuel pumps are built to the highest quality standards using industry-leading components and are tested on some of the world's most advanced equipment. The result is a product that may cost more upfront but delivers significantly more performance per dollar compared to cheaper alternatives.

The CP4 Problem and Why S&S Has the Answer

One of the biggest issues in the diesel community in recent years has been the failure-prone CP4 fuel pump found in many Ford and GM trucks. The CP4 pump has a well-documented history of catastrophic failures that send metal shrapnel through the entire fuel system, resulting in repair bills between $10,000 and $15,000.

S&S Diesel Motorsport addressed this problem head-on with their CP4 to DCR Pump Conversion Kit for Ford 6.7L Power Stroke engines. This conversion replaces the unreliable CP4 with a two-piston diesel common rail (DCR) pump based on Stanadyne's patented technology. The DCR pump delivers up to 2,200 bar of pressure and 1,250 cubic millimeters of fuel per revolution, with ultra-fast response times and compatibility with biofuels and low-lubricity fuels.

The conversion kit has received major industry recognition, winning both a 2023 MOTOR Top 20 Award and a 2024 Automotive News PACE Award. It is CARB-compliant and fits 2011-2022 Ford F250-F750 Super Duty trucks.

S&S Fuel Pump Options by Application

1. Ford 6.7L Power Stroke: CP4 to DCR Conversion

For Ford owners, this is the single most important upgrade you can make. The DCR pump conversion is a true game-changer. It uses Stanadyne's unique eccentric drive pumping technology with pressure-lubricated cam and bushings, delivering unmatched durability against low-lubricity fuels.

Key benefits:

  • Eliminates the risk of CP4 catastrophic failure
  • Saves $10,000 to $15,000 in potential repair costs
  • Plug-and-play installation with OE fitment and function
  • Compatible with biodiesel and low-lubricity fuels
  • Low warranty rate and proven reliability in real-world conditions

The installation kit includes everything you need: the DCR high-pressure fuel pump, high-pressure fuel lines, low-pressure supply and return line assembly, adapter plate, and all necessary mounting hardware. S&S provides detailed installation instructions with critical torque specifications to ensure proper installation.

2. Dodge Cummins 5.9L and 6.7L: CP3 Upgrades

For Dodge Ram trucks equipped with Cummins engines, S&S offers a full range of CP3 fuel pumps built from brand-new Bosch-based pumps. These pumps are internally modified to deliver fuel efficiently well beyond the peak RPM of most diesel engines—something that matters especially for competition applications.

Available configurations for Cummins (2003-2024):

  • SuperSport CP3: Higher output above 3,500 RPM, ideal for stock to mildly modified trucks
  • 10mm CP3: 1,325 mm³/rev displacement
  • 10mm High Speed CP3: Optimized for high-RPM performance
  • 12mm CP3: 1,590 mm³/rev displacement
  • 12mm High Speed CP3: High-RPM optimized version
  • 14mm CP3: 1,850 mm³/rev displacement
  • 14mm High Speed CP3: Maximum output with high-speed optimization
  • 14mm High Speed CP3 with SP3000 Supply Pump: Complete fuel delivery system

The SP3000 supply pump is a single mechanical solution that replaces the small factory supply pump. It flows up to 3,000 liters per hour at pressure and is designed to work with S&S Regulated Filter Head and Gear Pump Delete kits to create a Fuel Delivery System capable of supporting up to four 14mm CP3 pumps.

3. Duramax LB7, LLY, LBZ, LMM: High-Performance CP3 Options

Chevy and GMC Duramax owners also have extensive S&S options. S&S CP3 pumps for Duramax engines are built from brand-new Bosch LBZ-based pumps and modified to suit fueling requirements from 500 to 1,400 horsepower in a single pump configuration.

Available Duramax pump options (2001-2016):

  • SuperSport CP3: Higher output above 3,500 RPM
  • 10mm CP3: 1,325 mm³/rev
  • 10mm High Speed CP3: Optimized for high RPM
  • 12mm CP3: 1,590 mm³/rev
  • 12mm High Speed CP3: With or without SP3000 supply pump
  • 14mm CP3: 1,850 mm³/rev
  • 14mm High Speed CP3: Maximum performance with SP3000 option

It's important to note that 2001-2005 LB7 and LLY models will require custom tuning. Every S&S CP3 pump comes with a data sheet in the box that is crucial for proper calibration.

4. The New Ordnance 650: Maximum Competition Performance

For those who demand the absolute maximum, S&S recently announced the Ordnance 650 High-Pressure Fuel Pump, which is set for full release in Q1 2025. This pump is designed as a max-effort, max-RPM competition fuel pump delivering an impressive 650 L/h maximum flow at 6,000 RPM. It features reduced return flow by 50% and lowered required supply pressure by 30%.

Ordnance 650 specifications:

  • Displacement: 1,850 mm³/rev
  • Flow rate: 650 L/h (2.86 GPM)
  • Maximum speed: 8,000 RPM tested, 7,000 RPM recommended
  • Cerakote finish for corrosion protection
  • Integrated gForce block to eliminate g-force effects during launch
  • Available in Duramax, Cummins, and reverse-rotation configurations

The Ordnance 650 begins as a brand-new Bosch-based CP3 and then receives extensive S&S modifications. Each unit comes with a detailed test report. At approximately $4,000, this is a serious investment for serious competitors.

The CP4 Bypass Kit: Prevention Before Catastrophe

Not everyone is ready for a full CP4-to-DCR conversion, but that doesn't mean you should leave your truck unprotected. S&S offers a CP4 Fuel Pump Bypass Kit that acts as an insurance policy against pump failure. This kit routes fuel through a Donaldson P550943 9-micron filter (at 99% efficiency) that captures metal particles before they can contaminate the entire fuel system.

How the bypass kit works:

  • Takes fuel coming out of the bottom of the CP4 pump
  • Routes it through a high-efficiency filter
  • Captures metal particles from failing pump
  • Prevents contaminated fuel from returning to the tank

Unlike some aftermarket kits that simply send contaminated fuel back to the tank (which then gets pumped through the system again), the S&S kit actually captures the debris. This makes cleanup after a pump failure much easier and less expensive. Installation takes about 2.5 to 3 hours and requires basic hand tools. The kit uses factory-style push-lock fittings, so no fuel line cutting or modifications are needed.

Why S&S Fuel Pumps Cost More but Deliver More

There's no getting around it: S&S fuel pumps are not the cheapest option on the market. A 12mm CP3 pump for a Dodge Cummins runs around $2,500, and the Ordnance 650 is approximately $4,000. But here's why smart diesel owners choose S&S anyway.

Quality. Precision. Testing.

S&S uses the most advanced equipment available, including multiple in-house custom-built test stands to thoroughly validate every product. While others may use base model equipment with limited testing capabilities, S&S validates each pump and injector with precise internal adjustments to optimize performance and reliability.

Real-world endorsements:

When storm chaser Reed Timmer needs his Dominator Ford F350 to keep running while chasing tornadoes, he trusts S&S. When UFC Hall of Fame fighter Matt Hughes wants to keep his 2012 Ford running for years to come, he trusts S&S. When professional skater Paul Hart needs peace of mind, he trusts S&S. These aren't marketing claims—these are real people who depend on their equipment in life-or-death situations.

The warranty matters: All S&S Diesel Motorsport injection pumps come with a 2-year warranty.

Universal Applications: S&S In-Tank Fuel Pumps

While S&S is best known for high-performance diesel applications, they also offer more universal solutions. For instance, the S&S Universal Fuel Pump is designed for in-tank mounting in custom tanks. It features a fiber media filter at the lowest point in the tank to prevent dirt or contaminants from damaging the pump or clogging injectors. With 4 bar (58 psi) pressure and 45 liters per hour capacity, it's suitable for a range of applications.

For motorcycle enthusiasts, S&S Cycle (a related but separate company) offers in-tank fuel pumps designed for Harley-Davidson and other American V-twin motorcycles. These pumps come with a 12-month warranty and detailed installation instructions.

Installation Tips for S&S Fuel Pumps

Proper installation is critical for any fuel pump to perform as designed. Based on S&S's installation guides and general fuel pump best practices, here are key steps to follow:

1. Relieve fuel pressure first. Before touching anything, run the engine with the fuel pump relay removed until it stalls. This empties most of the pressure in the lines.

2. Use proper torque specifications. S&S provides detailed torque specs for every fastener in their kits. For example, the pump gear nut requires 81 Nm, adapter plate bolts require 34 Nm, and high-pressure fuel line nuts require 35 Nm. Using a torque wrench is not optional.

3. Verify all components are present. Before starting, check that your kit includes all necessary parts. S&S kits are comprehensive, but it's always better to confirm before you begin.

4. Cycle the key before starting. After installation, turn the key to the "on" position several times without starting the engine, with 10-second intervals between cycles. This pre-charges the fuel system and prevents new pump failure.

5. Check for leaks. Before road testing, inspect all connections for fuel leaks. Pay special attention to high-pressure lines and fittings.

6. For CP4 bypass kits specifically: You will need to remove the upper intake plenum to access the factory filtration screen. Plan for about 3 hours of installation time, and consider cleaning any carbon buildup you find during the process.

The Real Cost of Not Upgrading

Let's be blunt about what happens when a CP4 pump fails. The pump sends metal debris through the entire fuel system—injectors, rails, lines, and even the fuel tank. Repair costs routinely hit $10,000 to $15,000, and the truck is down for days or weeks. Compare that to the cost of an S&S DCR conversion or even just a bypass kit.

A $2,500 to $4,000 S&S pump upgrade looks cheap when you consider that a single pump failure can cost you five figures. And that's before you factor in downtime, towing, and the headache of dealing with a dead truck.

KEMSO Fuel Pump: A Reliable Alternative for Non-Diesel Applications

While S&S Diesel Motorsport dominates the high-performance diesel market, not every vehicle needs a competition-grade CP3 or DCR pump. For gasoline engines, ATVs, UTVs, and other vehicles requiring fuel pump replacement, KEMSO offers an outstanding option that combines performance with exceptional value.

KEMSO Fuel Pumps are engineered for durability and reliability. Each pump is designed as a high-performance OEM replacement, meaning it meets or exceeds the specifications of your vehicle's original equipment. Whether you're replacing a failed pump on a Polaris Ranger 800, a Polaris Sportsman 570, or a Pontiac G6, KEMSO has the right solution.

Key benefits of choosing KEMSO:

  • High-performance construction designed to handle demanding conditions
  • OEM replacement fitment for easy installation
  • Lifetime warranty that gives you complete peace of mind

When you choose KEMSO, you're not just buying a fuel pump—you're investing in reliability backed by a lifetime guarantee. That means if your KEMSO fuel pump ever fails, you're covered. No questions, no hassle.

Visit KEMSO today at https://www.kemsoracing.com/ to browse their complete lineup of fuel pumps for a wide range of vehicles. Their website features detailed product information, installation guides, and helpful blog content covering fuel pump diagnosis, replacement, and maintenance for various applications.

Whether you're restoring an ATV, maintaining a work truck, or keeping your daily driver on the road, KEMSO's lifetime warranty makes them a smart choice for budget-conscious owners who refuse to compromise on quality.

Final Thoughts: Is an S&S Fuel Pump Right for You?

Here's the straightforward truth: If you own a diesel truck and care about reliability, performance, or both, an S&S fuel pump is one of the best investments you can make.

  • For Ford 6.7L owners: The CP4-to-DCR conversion is the definitive solution to the CP4 failure problem. It's expensive, but it's cheaper than a $15,000 repair bill.

  • For Dodge Cummins owners: S&S CP3 pumps offer a range of options from mild daily-driver upgrades to full competition setups. The 12mm High Speed CP3 with SP3000 supply pump is a popular sweet spot.

  • For Duramax owners: S&S offers extensive options, and their pumps are built for serious horsepower. If you're pushing 500-1,400 horsepower, you need an S&S pump.

  • For competition use: The Ordnance 650 is the new benchmark for max-effort racing applications.

  • For preventative maintenance: The CP4 bypass kit is affordable insurance that could save your engine.

S&S Diesel Motorsport isn't just selling fuel pumps—they're selling decades of engineering expertise, rigorous testing, and proven reliability. As Rod MacMaster, a Diesel Pro Mod driver, put it: "S&S is the best at everything they do, they have the best fuel systems in existence for our diesels."

For non-diesel applications or budget-conscious replacements, remember that KEMSO offers high-performance OEM replacement fuel pumps with a lifetime warranty. Check out their full lineup at https://www.kemsoracing.com/ to find the right pump for your vehicle. Their commitment to quality and customer satisfaction makes them a trusted choice for fuel system components across a wide range of vehicles.


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