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.

 

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.

 

Thanks Bismic for the stand pipe/dummy plug suggestion. I've just ordered that. I anxiously wait for all the parts to arrive now.

 

The late 04's also had the weak EGR cooler. Are you deleted? If not, that might be another good upgrade (ie an EGR cooler from BulletProofDiesel).

 

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.

 

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?

 

You can weld it shut, sure.
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.

 

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.

 

I made a 24ga stainless plate to fit at the connection between the EGR cooler and intake. The other end, not so sure yet.

 

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.

 

I hadn't seen anything on OEM updates on the HPOP. I also haven't seen a new part number for it. It certainly good have happened, but I missed it if it did.

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.

 

IMO, if you delete the EGR system, you really should install a tuner that accounts for that in the combustion controls.

 

And leave the EGR valve plugged in.The easy place to store it is back in the manifold.

 

I will for sure leave the egr valve plugged in and in its place. I've read about how unplugging causes problems with the fan.

 

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.