Dead HPOP
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Senior User
Joined: Mar 2010
Posts: 153
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From: Kearns, UT
Dead HPOP
Recently I was on my way to work when the truck in my signature (Late '04 build) lost power and died. It would crank, but not start. Luckily I was able to coast right up to my job location :-) I had the truck towed to one of the local Ford dealers and they diagnosed a dead HPOP. Since my job is slow right now and I have some free time, I've decided to repair it myself.
Per dealer recommendation, I am replacing the following parts;
HPOP 4C3Z-9A543-AARM
HPOP Cover Gasket 3C3Z-6619-EA
Fuel Pressure Regulator cm5054
Motorcraft Thermostat Housing/water Outlet RH153
Housing 3C3Z9P458AA
While I am into the engine that deep, should I replace anything else while I am in there? The turbo oil lines were updated 2 years ago when I rebuilt the turbo.
Per dealer recommendation, I am replacing the following parts;
HPOP 4C3Z-9A543-AARM
HPOP Cover Gasket 3C3Z-6619-EA
Fuel Pressure Regulator cm5054
Motorcraft Thermostat Housing/water Outlet RH153
Housing 3C3Z9P458AA
While I am into the engine that deep, should I replace anything else while I am in there? The turbo oil lines were updated 2 years ago when I rebuilt the turbo.
Fleet Owner
Joined: Nov 2003
Posts: 27,901
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I am not much of a fan of the early OEM HPOP.
More money, but there are more reliable options IMO. The DieselSite Adrenaline is a good one, but expensive. There is a modified one available at CNCFab that has had good reviews.
Have you updated the dummy plugs and standpipes? If not, it would be good to do so.
More money, but there are more reliable options IMO. The DieselSite Adrenaline is a good one, but expensive. There is a modified one available at CNCFab that has had good reviews.
Have you updated the dummy plugs and standpipes? If not, it would be good to do so.
Hotshot
Joined: Dec 2014
Posts: 17,829
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From: Jersey Shore
When I've looked over months it appeared CNCFab always shows "not available".
Thought the OE manufacturer (Bosch???) updated the pump a while back, but I've not paid too much attention to the issue.
Thought the OE manufacturer (Bosch???) updated the pump a while back, but I've not paid too much attention to the issue.
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Senior User
Joined: Mar 2010
Posts: 153
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From: Kearns, UT
I was thinking about taking the existing EGR cooler and welding both ends shut. This was once an option some people used. What is the latest opinions on this?
Postmaster
Joined: Aug 2015
Posts: 3,910
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From: NW IA
You can also just get it out of there completely.
The nice thing about the early builds is you don't need a tuner to shut off the CEL.
I would advise leaving the EGR valve in place regardless so you don't risk messing with the cooling fan functions.
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My pump recently died and I replaced with the DieselSite pump. I'm very happy with the upgrade. It seems to me that the truck is running better than ever, but it is just subjective.
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Lead Driver
Joined: Dec 2006
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From: So. Jersey
Weld up BOTH ends of the cooler and don't look back. Call me a weirdo but I prefer the welded option and keeping the blue snap connect hose over a China kit that leak at his clamps or the oringed port. Install it correctly they don't leak. At the same time I replace the up-pipe too on the 05+ with one that does not have the scoop. On your 04 you could keep the pipe.
Fleet Owner
Joined: Nov 2003
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Bosch doesn't exactly advertise an upgrade either:
https://www.dieselpowerproducts.com/...werstroke.aspx
Terminator offers a T500 that is upgraded. I just don't know of anyone using it. The T500 has certainly done well in the 7.3L arena, so it is probably a good choice for this application also.
Fleet Owner
Joined: Nov 2003
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IMO, if you delete the EGR system, you really should install a tuner that accounts for that in the combustion controls.
Tuned
Joined: Nov 2005
Posts: 294
Likes: 24
From: Double Oak, TX
I will second Bismic's opinion of the Ford remanufactured HPOP. On the way to the beach before Christmas, the truck broke down in Beeville, TX. Fortunately, I noted a rough running situation so I diverted from the bypass road and literally coasted to a stop beside the Ford dealer in Beeville. Two injectors had oil leaks and it turned out the HPOP had failed. The HPOP had been replaced at the Ford dealer in Lewisville a little less than two years ago. I was lucky that Ford has a two year warranty on parts and labor so Ford paid for another HPOP. The two year warranty was due to expire in five days. So i would recommend you spend a little more with Dieselsite and maybe your replacement will last a bit longer. I had to pay for the fuel injectors and labor. Good luck.