Helpful Tips About Replacing Stock Ford Diesel O-rings and Fuel Injector O-rings

1. September, 2011

Blog, Resources

Stock O-rings for Ford diesel trucks are a common maintenance repair issue. Powerstrokes use a variety of O-rings and they never fail at a time that’s convenient for you. I’ve had it happen enough that I’ve put together a few helpful tips that might help you identify the problem as well as a kit that will eliminate the unnecessary worry associated with the normal wear and tear of stock Ford O-rings.

Every Ford diesel truck owner knows that one of the most common wear and tear problems is going to be with the O-rings. Replacing diesel O-rings isn’t a question of if, it’s just a matter of when. O-rings are integral for several critical components to the Ford diesel engine. When one of these o-rings goes there could be several side effects to your trucks’ performance.

If you’ve blown a ring and are trying to locate the source of your problem, here are some helpful tips that might get you to the source quicker.
A) Problem Starting the Truck:
If you’re having trouble starting the truck or the truck doesn’t start at all this could be associated with the fuel injectors. A leaking injector ring could be the cause of this problem, unfortunately this could also be attributed to a faulty oil pump or multitude of other issues, but a leaking o-ring would be a great place to check first.

B) Simple Deterioration:
If you are experiencing a rough idle or loss of power this could be due to deteriorating injector o-rings. These symptoms are usually diagnosed as being caused by using the wrong oil type, however deteriorating rings are an often overlooked item.

C) Fuel Injector Replacement:
O-rings are often damaged during the replacement or removal of fuel injectors. Typically, you have to push the o-rings through a pretty tight space to get the fuel injector into the fuel rail. This can often damage the rings if you’re not careful. Lubricating o-rings and other parts before any installations will help prevent damage and make the install go quite a bit smoother.

D) Heat Damage:
The overheating of diesel engines can cause severe damage to O-rings. When superheated the rings can expand beyond their maximum capacity causing permanent distortion and damage and consequently gaps which will cause leaks. This is most common with injector rings.

E) Oil Leak:
A common problem in the 7.3L Ford Powerstroke is developing an oil leak related to the HPOP. This can sometimes look like a fuel leak related to the fuel bowl, but if after changing out the o-rings on the fuel bowl the leak continues, it is definitely the HPOP.

F) Parts are Getting Old:
As with all of us, age takes it’s toll. Over time O-rings will simply harden losing their ability to expand and contract. They will begin to crack and lose the ability to create an effective seal. If you see a leak at or near the fuel rail connection this is almost certainly an O-ring failure.

Sadly, I’ve been caught in a situation where I’ve had to run around town hoping that a dealer would have the part I need. I like to avoid inconvenient situations when at all possible. It might be presumptuous, but I thought some of you might like to avoid the inconvenience of running around town looking for replacement parts and then paying a premium when you find them. There are o-rings for a wide array of fuel and oil related applications on Ford trucks, and because they tend to be a common maintenance issue, I have put together a kit that any Ford diesel enthusiast should own. As I mentioned previously, eventually, your 7.3L Powerstroke will develop a fuel or oil leak. It’s only a matter of when.

A Complete Replacement Kit includes:
• A full set of Turbo pedestal (4) o-rings, both upper and lower
• GTP38 turbo outlet o-ring
• HPOP outlet fittings (4) o-rings, both internal and external
• HPOP rear plug o-ring
• HPOP reservoir fill plug o-ring
• HPOP “non-serviceable” plug o-ring
• IPR to HPOP body o-ring
• Head oil rail o-rings (8) for oil rail plugs, ICP or cross-over line
• HPOP Hose to head internal o-rings (2)
• Loctite 608 retaining compound (2 – .5ml packets for HPOP and oil rail)
• GTP38 EBPV solenoid o-rings (2)
• GTP38 EBPV piston backplate o-ring
• New Garrett EBPV pushrod clip
• Fuel Drain Valve core o-rings (2) choice of bi-polymer Viton or tri-polymer Viton
• Fuel Drain Valve Stem o-ring (1)
• Fuel Filter Check Valve o-rings (2)
• Fuel Bowl Heater/water in fuel sensor o-rings (2)
• Fuel Bowl plug o-rings (2)
• Fuel Bowl return regulator o-ring
• Sleeve gaskets for the fuel rail lines, both ends (4)
• Sleeve gasket for the fuel return line
• Sleeve gasket for the main fuel feed line
• Turbo mounting bolts (2)

This kit will cover all of your O-ring needs. I recommend swapping out all of your stock rings with DuPont Viton O-rings. You won’t have to worry about the diesel o-rings drying out or cracking, because the shelf-life of DuPont Viton is indefinite! No joke, they won’t go bad from air, heat, sunshine or time.