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STC/HPOP Removal/Install with Tips & Pic's

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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

STC/HPOP Removal/Install with Tips & Pic's

 
  #1  
Old 05-12-2017, 02:56 PM
silverbullet6oh
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STC/HPOP Removal/Install with Tips & Pic's

Good Afternoon everyone. As many of you know, I had my truck die on me from a failed stock STC fitting.

I am so thankful for the tremendous help I had from Sean (Yahiko), (who probably wishes he didn't give me his phone number) and Bill (Performance). They lead me through some tough times I was experiencing on this project.

I am going to share some pics of what I did with my removal and install. Not everything will be in detailed fashion. I will not be referring any torque specs.

But hopefully from these pictures and tips, you can gain some insight and tips to help with the process.

Here we go:

To Get To The HPOP:

1
) Disconnect Battery Cables
2
) Remove Alternator
3
) Remove Passenger Side CAC Tubeand remove air intake tube from filter
4) Remove Turbo
5) Remove Turbo Pedestal Mount

General Steps to remove HPOP:

1
) Remove turbo drain tube
2
) Disconnect IPR electrical connector and remove IPR
3) Remove EGR Cooler clamp
4
) Remove HPOP cover bolts, the 3 on the passenger side will un-thread but not come out
5
) Pry open HPOP cover with handle end of screwdriver and remove carefully not to drop the 3 bolts on the passenger side
6
) Remove 2 STC bolts
7) Remove 3 HPOP bolts
8) Lift out HPOP
9
) Clean the HPOP housing where the cover bolts to
10) Clean the HPOP cover
11
) Remove the black and yellow o-rings and replace
12
) Remove Dowel Pin from under HPOP on the STC side
13
) Remove STC from HPOP and install replacement upgrade
14
) Remove HPOP blue o-ring, install replacement
15
) Install HPOP and tighten down HPOP and STC bolts
16
) Install HPOP cover gasket w/ TA31 sealant on rear part of cover corners, and install cover
17) Tighten cover bolts, start from rear of engine to front of engine
18
) Reinstall EGR Cooler band
19
) Install IPR and IPR electrical connector
20) Install Turbo Pedestal Mount
21
) Install Turbo
22
) Install Alternator
23
) Install CAC tube
24
) Connect battery cables
25) Check oil dipstick, fill accordingly
26
) Pull FICM relay (#304 under hood fuse box)
27) Turn engine over 3-4 times for 10 seconds each time
28
) Check for fluid leaks on top of the engine and on the ground while the other person is cranking engine
29
) Reinstall FICM relay, start engine (it will take a little while with cranking time) and recheck for fluid leaks on top of the engine under the turbo, and on the ground.

Now you should be done. If everything was installed tightly with the STC then you should not have any leaks. I did not air test the HPOP as i was confident with my install. The initial cold starts will take longer than normal, until the air is out of the system.


Here comes the pics and tips:............................













 
  #2  
Old 05-12-2017, 02:59 PM
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Name:  #3 ipr.jpg
Views: 17796
Size:  3.45 MB


Name:  #4 IPR gasket sequence.jpg
Views: 17734
Size:  3.23 MB





Name:  #8 screwdriver hpop cover.jpg
Views: 17714
Size:  2.81 MB
 
  #3  
Old 05-12-2017, 03:02 PM
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Name:  #9 screwdriver long.jpg
Views: 17915
Size:  3.56 MB




Name:  #11 broken stc.jpg
Views: 18032
Size:  4.55 MB


Name:  #12 failed stc.jpg
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Old 05-12-2017, 03:04 PM
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Name:  #14 2 bolts holding hpop.jpg
Views: 17883
Size:  4.19 MB





Name:  #17 razor cleaning hpop cover.jpg
Views: 17674
Size:  3.53 MB
 
  #5  
Old 05-12-2017, 03:06 PM
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Old 05-12-2017, 03:09 PM
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Name:  #21 stc fitting.jpg
Views: 17623
Size:  3.37 MB


Name:  #22 stc fitting set.jpg
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Size:  3.32 MB


Name:  #23 stc guide plate installed.jpg
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Size:  3.27 MB


Name:  #24 torque jam nut.jpg
Views: 17463
Size:  3.48 MB
 
  #7  
Old 05-12-2017, 03:10 PM
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Name:  #25 dowel pin.jpg
Views: 17346
Size:  3.01 MB









 
  #8  
Old 05-12-2017, 03:12 PM
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Okay everyone, I am done loading the pictures.



I know that some them are upside down or sideways. I at least wanted to get them loaded up and now I will try to fix their orientation.

Thank you - Preston
EDIT: I FIXED ALL THE PIC's
 
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Old 05-12-2017, 03:38 PM
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Great write up Preston, reps!

Good to know she's up and running again

Did you leave the EGR cooler out? Currently the kid(and myself by default) is taking one out of his friends 6.0
 
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Old 05-12-2017, 04:05 PM
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Originally Posted by navistarnut View Post
Great write up Preston, reps!

Good to know she's up and running again

Did you leave the EGR cooler out? Currently the kid(and myself by default) is taking one out of his friends 6.0
Although I had to pull it out for this project, because I couldn't do a sneak attack on the passenger side bolts, I decided to put it back.


I should not have any problems with the EGR cooler. So it is back to stock.
 
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Old 05-12-2017, 05:17 PM
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So now that it is all back together, did it start?
 
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Old 05-12-2017, 10:23 PM
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Awesome write up. I chickened out 2 yrs ago and paid Ford to do it. My oil cooler needed to be done and I did not have time for all of it. AND I thought it might be tougher than it sounded. Seeing all the hints and details, I am sure without this guide it would have been a long and frustrating weekend for me. Anyway, the Ford tech did an excellent job. If I ever need to get to the HPOP I'll be looking up this thread. Should be a sticky
 
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Old 05-12-2017, 11:15 PM
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Originally Posted by Splash67 View Post
So now that it is all back together, did it start?
Of course!

1.5 days I have put 300 miles on it since the fix.........
And it runs like a champ!

Originally Posted by Sullid01 View Post
Awesome write up. I chickened out 2 yrs ago and paid Ford to do it. My oil cooler needed to be done and I did not have time for all of it. AND I thought it might be tougher than it sounded. Seeing all the hints and details, I am sure without this guide it would have been a long and frustrating weekend for me. Anyway, the Ford tech did an excellent job. If I ever need to get to the HPOP I'll be looking up this thread. Should be a sticky
Dan, Thank you for the compliments.
 
  #14  
Old 05-12-2017, 11:44 PM
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Good job Preston. You can never have enough pics!
 
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Old 05-13-2017, 12:20 AM
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Originally Posted by 87crewdually View Post
Good job Preston. You can never have enough pics!
Thanks Pete.

There were some trying times in this process..... Lots of beer was needed, and not the expensive hoppy kind......
 

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