I would appreciate some directions in removing the high pressure oil pump from my 2002 7.3L. A significant leak developed a few days ago and after reviewing several posts on this topic it has lead me to find a leak under the HPOP. Not from the oil lines leading to the injectors. However, after removing the intake plenum, several sensors, the fuel/water separator, the drive nut and two bolts on the back of the HPOP, I still can not get it out. I even removed the snap ring on the back side of the pump. Does this thing slide out? Any suggestions? Thanks in advance for your help.

 

High Pressure oil pump removal:
When removing the HP oil pump, remove the fuel filter housing to allow more room to maneuver the pump in and out. Remove the EOT sensor from the reservoir to allow oil to drain, remove the HP oil pump gear access plate from the front of the timing cover. If necessary, remove the heater hose and nipple from the water pump and remove the gear retaining nut. Carefully remove the oil reservoir--it has a partial RTV gasket, so it may adhere to the timing cover. Remove the two oil supply hoses for the HP oil pump and the two retaining bolts anf remove the pump from the engine. Inspect the HP oil pump gasket for damage, and both the pump and timing cover surfaces. Clean the timing cover and reservoir mating surfaces. Carefully install the new pump, taking care not to damage the gasket. Seal the top shoulder of the pump bolts with Loctite 515 Gasket Eliminator and torque the pump bolts to 24 ft/lbs. Install the gear retaining bolt and torque to 95 ft/lbs. Check the pump gear for excessive back-lash. Check the outlet fittings on the pump to make sure they are tight and install the oil lines. Install a new gasket on the oil reservoir and run a bead of Wacker T-95 or Ford F5TZ-19G204-AB gray RTV silicone along the timing cover where the gasket does not seal, install the reservoir and torque the bolts to 24 ft/lbs. Use the same silicone sealer on the gear bolt access plate and install. Finish installing the remaining components. Flush the engine valley with a suitable solvent to remove the oil spilled. The engin will have to crank awhile to resupply the reservoir in order to start. Drive to purge any air from the system and clear any codes.

 

Thank you wlihntr for a very detailed response. I have replaced the pump with all new o-rings and gasket. No leaks! However, the check engine light keeps coming on. At first it would not start, so I check the torque on the gear bolt driving the pump and after making a 20lb adjustment - oops it started. The check engine icon lights after I let off the gas after hammering it hard. Everything is connected so I don't know if I should re torque the gear bolt or check for a vacuum leak somewhere. I am hoping it is just the backpressure sensor connection leaking. At any rate I appreciate your assistance.

 

I don't know if this works on the PSD, but it did with cars I had. Disconnect the battery for a minute or two and then see if it reset the light. There's always the option of going to an auto supply store to let them read the code it's throwing.