Factory Ford Engine Replacement
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Senior User
Joined: Dec 2005
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From: Columbus, Indiana
Factory Ford Engine Replacement
On a 94 powerstroke truck I purchased a while back, the owner told me that the engine was replaced by ford in 1996 due to the truck having a bad engine, and ford replaced it with a 96 model instead of a 94.5. I didn't believe him as I have never heard of ford doing that. However, what now strikes me odd is that I went to change the glowplugs today and the 94 model year glow plugs were completely different than what I took out of the truck. A 96 model year plug was the same. The plastic little cover over the fuel filter says 94 95 96 on it, and I doubt that would put 95 and 96 on an engine built in 94.
My question is, how can I verify what model year the engine is? It is seemingly pointing towards the fact that has it been switched. If it has been switched, won't the computer setup now be OBDII?
My second question is that when I pulled the front two glowplugs on the driver's side, the UVC wiring and the truck wiring that plugs into the UVC wiring through the valve cover gasket was burnt and melted. The plugs melted into many different pieces. What caused this? I don't want to put it back together and have this problem repeat itself the first time I start the truck.
My question is, how can I verify what model year the engine is? It is seemingly pointing towards the fact that has it been switched. If it has been switched, won't the computer setup now be OBDII?
My second question is that when I pulled the front two glowplugs on the driver's side, the UVC wiring and the truck wiring that plugs into the UVC wiring through the valve cover gasket was burnt and melted. The plugs melted into many different pieces. What caused this? I don't want to put it back together and have this problem repeat itself the first time I start the truck.
Post Fiend
Joined: Apr 2004
Posts: 12,835
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From: Silver Lake Dunes, MI
the 94.5 to 97 engine blocks, heads,fuel system with exception to the california 97 are all the same. so yes they probably did put a current (1996) engine in it. the reason for the different glow plugs is that in 94 there were 2 different diesel engines in that model year. the powerstroke direct injection and the 7.3 indirect injection engine with or with out a turbo charger. the IDI's use different glow plugs.
the melted plugs is a common issue and is caused by either a grounded glowplug wire or just over heated from constant use or maybe a stuck glow plug relay.
the melted plugs is a common issue and is caused by either a grounded glowplug wire or just over heated from constant use or maybe a stuck glow plug relay.
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Senior User
Joined: Dec 2005
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From: Columbus, Indiana
So all (94-97) powerstrokes use the same glow plugs? I watched them check part numbers, and I thought I was sure they selected the powerstroke.
Since everything is the same, then they could keep it the old OBD1 and it still function correctly even with a new 96?
I will replace the relay just for added insurance.
Since everything is the same, then they could keep it the old OBD1 and it still function correctly even with a new 96?
I will replace the relay just for added insurance.
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
all 7.3 powerstrokes use the same glowplug 94.5 to 2003. only use ford plugs though as other have been known to swell and not come out after use. and if they did infact put a 96 engine the computer would still be 94.5 unless they did a factory reprogram which is possible to correct other issues but i couldn't tell you how to find out unless there is sticker that staes the computer was reprogrammed. if you really want to be obdII get another computer and send it to dp-tuner and have them program it too a 96 or 97. either stock or performance tuned. if you provide the computer it 80 bucks from what i hear
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Senior User
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From: Columbus, Indiana
There is a sticker on the air box saying the computer was reprogrammed in 1996. It doesn't say why, and I know there was a PCM recall in 1996 as well.
I wouldn't mind OBDII at all. The truck does have an OBD1 data connector, so I would want that changed as well.
Is there a date code or some way for me to check the engine itself to see the date on it?
I wouldn't mind OBDII at all. The truck does have an OBD1 data connector, so I would want that changed as well.
Is there a date code or some way for me to check the engine itself to see the date on it?
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
you could probably get the serial number off the block which is stamped on the flat machined surface to the rear of the oil filter housing. then call your friendly international dealer and see if they can tell you the year the engine was made.
Mountain Pass
Joined: Feb 2002
Posts: 224
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From: Northern IN
The glowplug wires melt because even when the relay is working properly, the glow plugs remain energized long, long after the WTS light goes out. I suppose this is to reduce cold start emissions, but it sure is hard on those skinny little wires and connectors. Based on my observations on my 96, the WTS light goes out in about 20-30 seconds, but the GPR stays energized for up to 2 minutes on a cold start, and is reenergized on every restart, even when the engine is already warm. A dumb setup if you ask me.
Anyway, I installed a toggle switch that breaks the GPR activation circuit, and installed a dash mounted LED on the output side of the GPR to glowplug circuit. The LED glows whenever the glowplugs are energized, and I can control when the GPR is energized by the toggle switch. I don't use the glowplugs unless it is below 60, and then only the first start in the morning, or on a cold day, after the truck has set all day. On any warm starts the GPR isn't actually activated, even though the WTS light comes on. It's my little way of saving those little wires and connectors, because on a van they are a real PITA to get at.
Anyway, I installed a toggle switch that breaks the GPR activation circuit, and installed a dash mounted LED on the output side of the GPR to glowplug circuit. The LED glows whenever the glowplugs are energized, and I can control when the GPR is energized by the toggle switch. I don't use the glowplugs unless it is below 60, and then only the first start in the morning, or on a cold day, after the truck has set all day. On any warm starts the GPR isn't actually activated, even though the WTS light comes on. It's my little way of saving those little wires and connectors, because on a van they are a real PITA to get at.
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