I have a 2002 7.3 that I bought at a BP auction last month. These slope trucks usually have LOTS of idle time, 150,000 miles, 4x4.
I noticed the oil level was growing. Thus I thought it was bad injector seals, so I took the valve covers off and found the drivers side #2 from the front piston intake valve rods bent and the rocker arm carriage was broke.
The oil is not filled with anti freeze and neither is the radiator filled with oil, so I assume #1 that it is fuel leaking into the engine and thus causing the turbo run away and thus the high RPMs and thus the bent rod (if not more). There are no leaks on the ground and no smoke coming out the pipe since the runaway.

#2 question. Where is the fuel coming from? The local diesel shop says it's my fuel rail located somewhere inside the engine. The local Ford dealer says it may be the injectors seals. Any ideas of where the fuel is coming from would seem to be the number one reason for all the other problems.

 

Since the runaway? The truck had a runaway?

Injector O-rings are a primary suspect, but the damage in #2 make me suspect a broken injector nozzle as well. It sounds like you will find something obvious when you pull the injectors.

 

Things i would be checking...
You mentioned runaway...
Thats not good.
But it could be caused by a few things...
Ipr could be stuck wide open
Burnt rings/scored cylinders
I dont see a blown nozzle tip causing runaway...

Check compression
Injector orings for sure

Oilfield trucks are typically habitually abused and neglected.
If your compression looks to be in good shape...
Give her some fresh orings and fluids.

 

An IPR stuck closed (max ICP) would likely put the PCM in shut-down and cause a SES light.

When I mentioned the nozzle, that was for looking for the cause of bent rod and damaged rocker arm. I suspect cylinder 2 hydrolocked at some point... fuel in oil and valve system damage?

 

Rich, I think you are onto something with the #2 being hydro-locked at some point.

I had an IPR stuck closed recently. Nothing shut down, but I did get an SES light. Truck just made 2700 all the time and idle was obviously wrong.

 

Thanks all!
It's snowing here in North Pole as I type!

1) What is IRP and PCM in shut-down and cause a SES light. Sorry to be dull, but not sure what these do and where and how to fix them? Pictures worth a million words to me. Thx

2) No leaks on driveway or on engine, EXCEPT pool of fuel/oil near turbo pedestal.
Runs good, even after run away and new turbo. (thanks to this site I found a good "how to" thread on installing it.) Starts well, no smoke out pipe, etc.

3) should I replace all seals in injectors or inspect them? I got Ford kits for all 8. I'll assume replace is in order here.

 

Injector Pressure Regulator (IPR) is a valve that opens and closes quickly to regulate the Injector Control Pressure (ICP). You have solenoids on your injectors, but the solenoids do just one thing - open the port for High Pressure Oil (ICP) to force the fuel at great pressure out of the injectors. Think of a syringe - with the fuel being the medicine, the injector nozzles are the needle, and the oil pressure is the thumb.

Anyway, the Power Control Module (PCM) monitors all the sensors and controls all this activity.

I'd pull all the injectors and inspect everything... you need to get in there to check all the other push rods and torque as well. Do yourself a favor and acquire an in/lb torque wrench that goes up to 240 in/lbs max. I skipped over this tool and really paid for it.

 

Got it
I assume all those parts are inside the injectors
Now that I have all this good feedback it started to snow this Am and now we are at 2 inches
I hope for a warm snap before winter in North Pole

 

Figure out where that's coming from.... I wonder if its part of the cause of the runaway in the first place...

 

Correct
I have a feeling that is why they auctioned this slope truck off
The other turbo was a mess

 

When inspecting the seals on the injectors
What should I look for?
Pictures anyone?

 

They will be deformed/melted, or torn. Usually they will be very soft from years of heat/cool/heat/cool, and when you pull the injectors they will sometimes tear from being pulled out of their holes. The o-rings of today are made of a different material, so it is well worth the effort to just pull them for new o-rings without any known problems in my opinion. But that is just me...mine will be replaced soon, but hopefully because I can get new injectors.

 

Thanks
The injectors all say refurbished on them so I wonder if they were replaced?

 

Inspect the pass/side fuel line. It runs through a "P" clamp, which, overtime rubs a wear pattern, into the line, causing a leak. And/Or inspect the pass line where it attaches to the back part of the head. But if that was to leak, i'd think, it would run down the back of the motor.

 

Would that leak outside the motor?
Driveway and motor amazingly clean and leak free
It is all internal bleeding