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By now, you’ve heard of all the problems surrounding the Bosch CP4.2—the high-pressure fuel pump that’s made its way onto most common-rail engines in the pickup truck segment.

You know the story well: The pump selfdestructs, sending metal fragments through the lines and rails, into the injectors and then out the return circuit. The failure is rarely noticed before it’s too late, and by then, you’re usually out a pump, lines, rails, injectors, a tank cleaning, 30 hours of labor and anywhere between $6,000 and $10,000. As expected, this potential catastrophe has many latemodel truck owners a little uneasy about their $60,000-to-$90,000 investments.

With its ultra-tight tolerances, the CP4.2 does not tolerate anything other than diesel fuel very well. However, what is the most commmon unwanted contaminant? Air. That’s right—aeration is the number-one “killer” of these pumps. Whether it is from lack of maintenance, running the truck out of fuel, improper fuel filter installation or not allowing the fuel system to properly prime after a filter change, nine times out of 10, air is what takes out the CP4.2.

We recently stopped by RCD Performance’s state-of-the-art fuel-injection shop for the full rundown on how the CP4.2 operates, what its key failure points are and how the average truck owner can prevent it from failing.

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Diesel World June 2019, OUR BEST ISSUE YET, Triple Turbo : It's the Perfect Truck, Save Yourself $15K, CP4 Failures Explained, Vintage Diesel With Spark Plugs, And More....