just so there is no confusion. bosch made no meaningful "updates" to these pumps since their introduction to correct the problem.
the biggest updates was coating changes to the roller follower and new body alloy (high silicone cast aluminum). the issue of the roller getting jammed up and not rolling on the cam will not be solved by this. also the bigger issue that seems to occur is the roller (and follower) turns 90 degrees to the cam and has no way to roll. this grinds a groove in the roller and cam sending metal into the fuel system.
all CP4s suffer from these failure modes, whether it is a CP4.1 or CP4.2. the design of the pump is the problem here. added lubrication MAY help extend the life of the pump but it seems that pumps still fail regardless.
the TDI club has this well documented with the CP4.1 used on the VW TDI
http://forums.tdiclub.com/showthread.php?t=299854
and
http://forums.tdiclub.com/showthread.php?t=286380
and of course my thread
http://forums.tdiclub.com/showthread.php?t=387252
the best guess and evidence as to why Bosch would make this change is to lower the cost of manufacturing. the CP3 has an almost all high strength steel body to handle the pressures, plus three precision ground/machined pistons, valves and related parts. in the CP3 each piston only makes one pressure stroke per a revaluation. the CP4 piston makes two. this is twice the strokes
the CP4 only has a steel piston head that retains the pressure. the body is all aluminum. there is only one piston in the CP4.1 and two pistons in the CP4.2. the parts count on the CP3 is several times higher than a CP4. being that a CP4 retails for roughly the same cost as a CP3 this was likely a way for bosch to increase profits. bean counters likely designed this pump.
what doesn't make sense is now they are paying more on the HPFP warranties along with replacement of contaminated parts as a result. whether they come out ahead is anyone's guess
luckily i am still driving an LMM so i don't have to worry there but i did experience a CP4.1 failure on my VW TDI. right now i am in the process of collecting the parts needed to convert that over to a CP3/R70 pump.
If my duramax had a CP4, converting it to a CP3 would be one of the first upgrades i did after the warranty was up