Must read for 7.3 Powerstroke owners, FPR filter
#1
12-11-2012, 07:26 PM
Must read for 7.3 Powerstroke owners, FPR filter
96 7.3 PowerStroke
Dies won’t start, No smoke when cranking, Runs for a few miles or a few minutes then dies, Dies when decelerating…
Whatever your symptoms are check or replace the Fuel Pressure Regulator or (FPR) *Return Filter*!!! Very Important!
I’ve had an issue with my PowerStroke recently and with no luck just throwing hundreds of $$$.$$ at it I think I’ve stumbled across the gremlin.
With the same symptoms as described above I started replacing parts.
Parts List replaced with no luck.
1 New ICP sensor (since I was getting a P1211 code every time it staled)
2 New CPS sensor (since I was getting this generic code as well)
3 New IPR regulator & IPR coil
4 New HPOP pump (High Pressure Oil Pump)
5 New wiring harness (top of motor)
6 New fuel lift pump
7 Checked ICM with a known good one (Injector Control Module)
8 Checked PCM with a known good one (Power Control Module)
9 Replaced the IPR wiring pig tail on the fuel bowl wiring harness since it was melted and/or gooey from diesel fuel leaking on it
That brings me the symptoms, I saw and overlooked.
1st
I noticed a little spot on the drive way and thought it was oil but since I’ve never had a leak of any kind I was a little stumped on why. After sitting in the sun a few hours I noticed the little spot evaporated and left a stain on the concrete. At this point I knew it wasn’t oil and figured I’ve got a fuel leak somewhere and I would get to it later.
2nd
I would smell diesel in the cab when the heater was running and knew I needed to find this leak soon.
3rd
Driving down the interstate one morning going to work the truck sputtered and threw a code with the CEL on. I drove to the house and started replacing parts. A few simple parts and on my way. Ya right!
4th
Once again another CEL and stalling out in intersections, I thought did I get a bad CPS? Well after replacing this one in a parking lot and then again at home still no luck.
5th
Everyone had their opinions and not that I didn’t appreciate them, I was still not finding or fixing the issues.
6th
While replacing parts I noticed fuel would drip out of the Schrader valve on the FPR and not really caring about the fuel leak at this point I thought there is the fuel leaking source. I just replaced it with a plug I had laying around and kept looking for my major issues.
7th
Still noticing some fuel under the truck some time especially after revving it up in the driveway to see if it would die.
I found the fuel was leaking out of the fuel bowl drain tube, and had just replaced the drain valve. So I thought maybe some crap got into the valve after replacing it and didn’t give it a second thought.
8th
Screw it! I’m going to do the Adrenalin HPOP & Stage 1 injectors I’ve been wanting to do for awhile now maybe that’s the problem? NOT!!!!
9th
Although the truck actually started and ran at this time after changing the pump and injectors it died when decelerating to a stop.
10th
Symptoms have changed but still not running. Scratching head…..
11th
My wife gets me back to earth and tells me diesels are like women and need to be treated nicely. LOL Although it kind of made sense and got me rethinking the entire situation.
12th
Looking around on the internet and not finding any solutions to this problem and found that a lot of people seem to be having the same issue, I stumbled across an idea of fuel.
13th
Thinking back to the original issue, dying on the highway, and not restarting until it wants to and not in a predictable time frame. Noticing fuel in the drive way, finding the Schrader valve leaking… Hmmmmm?????
I did a little research and found there was a fuel return on the FPR and it had a screen or filter inline. My thought at this point was could I be pressuring the fuel system in the FPR and or Bowl and be causing some kind of Hydro locking situation? Since I had nothing to lose I was off to ford to get the O-ring kit.
There is a little round screen or filter between the fuel bowl and FPR assembly located on the driver’s side of the fuel bowl. After disassembling the FPR and cleaning with break parts cleaner then replacing all the O-rings and replacing the little screen/filter that came with the ford parts kit. Reattaching the FPR and starting the truck instantly the truck ran smoother and purred like a kitten!
My theory is the fuel pressure was greater than the oil pressure from the original HPOP and was locking up the injectors. After replacing the HPOP the oil pressure then was greater and allowing the truck to start and run for a few. (Note: I had noticed a lot of extra black diesel smoke from the exhaust that seemed strange as well) After driving a little ways the fuel pressure couldn’t flow back to the tank and was stalling the motor. Once the fuel pressure got large enough it had to go somewhere and would start leaking out anyway possible. Weather the drain valve, Schrader valve, Bowl gasket… you name it?
I would think if you’re suspicious about maybe having this problem you could crack the drain valve a little allowing some pressure to escape and see if that helps with any of your symptoms. This is only a hunch and since mine seems to be fixed I can’t test this theory.
Since I replaced the screen/filter the truck runs great and of course with all the new parts I would hope so. I wanted to do a write up about this to try and help whoever may be dealing with some similar issues and maybe get them going in the right direction straight out of the gate. As our trucks are hitting and passing 200,000 miles we need to think maintenance as well as performance. I’m sure my gas mileage alone will have a direct increasing result from this repair.
You should be able to get this kit at your local ford parts counter. When I was there they said they needed to order the first kit and then they noticed a different kit they had in stock so I’ve included its part# here
Ford Kit Part #2C3Z-9157-AA
About $40.00 US out the door
The first picture on the bottom shows the FPR removed from the fuel bowl once you remove it you will see the screen/filter sandwiched between those two parts. I would recommend removing and replacing this screen/filter after a good break parts bath. Very simple project and should only take about an hour.
Good Luck!
Hope this helped!
Dies won’t start, No smoke when cranking, Runs for a few miles or a few minutes then dies, Dies when decelerating…
Whatever your symptoms are check or replace the Fuel Pressure Regulator or (FPR) *Return Filter*!!! Very Important!
I’ve had an issue with my PowerStroke recently and with no luck just throwing hundreds of $$$.$$ at it I think I’ve stumbled across the gremlin.
With the same symptoms as described above I started replacing parts.
Parts List replaced with no luck.
1 New ICP sensor (since I was getting a P1211 code every time it staled)
2 New CPS sensor (since I was getting this generic code as well)
3 New IPR regulator & IPR coil
4 New HPOP pump (High Pressure Oil Pump)
5 New wiring harness (top of motor)
6 New fuel lift pump
7 Checked ICM with a known good one (Injector Control Module)
8 Checked PCM with a known good one (Power Control Module)
9 Replaced the IPR wiring pig tail on the fuel bowl wiring harness since it was melted and/or gooey from diesel fuel leaking on it
That brings me the symptoms, I saw and overlooked.
1st
I noticed a little spot on the drive way and thought it was oil but since I’ve never had a leak of any kind I was a little stumped on why. After sitting in the sun a few hours I noticed the little spot evaporated and left a stain on the concrete. At this point I knew it wasn’t oil and figured I’ve got a fuel leak somewhere and I would get to it later.
2nd
I would smell diesel in the cab when the heater was running and knew I needed to find this leak soon.
3rd
Driving down the interstate one morning going to work the truck sputtered and threw a code with the CEL on. I drove to the house and started replacing parts. A few simple parts and on my way. Ya right!
4th
Once again another CEL and stalling out in intersections, I thought did I get a bad CPS? Well after replacing this one in a parking lot and then again at home still no luck.
5th
Everyone had their opinions and not that I didn’t appreciate them, I was still not finding or fixing the issues.
6th
While replacing parts I noticed fuel would drip out of the Schrader valve on the FPR and not really caring about the fuel leak at this point I thought there is the fuel leaking source. I just replaced it with a plug I had laying around and kept looking for my major issues.
7th
Still noticing some fuel under the truck some time especially after revving it up in the driveway to see if it would die.
I found the fuel was leaking out of the fuel bowl drain tube, and had just replaced the drain valve. So I thought maybe some crap got into the valve after replacing it and didn’t give it a second thought.
8th
Screw it! I’m going to do the Adrenalin HPOP & Stage 1 injectors I’ve been wanting to do for awhile now maybe that’s the problem? NOT!!!!
9th
Although the truck actually started and ran at this time after changing the pump and injectors it died when decelerating to a stop.
10th
Symptoms have changed but still not running. Scratching head…..
11th
My wife gets me back to earth and tells me diesels are like women and need to be treated nicely. LOL Although it kind of made sense and got me rethinking the entire situation.
12th
Looking around on the internet and not finding any solutions to this problem and found that a lot of people seem to be having the same issue, I stumbled across an idea of fuel.
13th
Thinking back to the original issue, dying on the highway, and not restarting until it wants to and not in a predictable time frame. Noticing fuel in the drive way, finding the Schrader valve leaking… Hmmmmm?????
I did a little research and found there was a fuel return on the FPR and it had a screen or filter inline. My thought at this point was could I be pressuring the fuel system in the FPR and or Bowl and be causing some kind of Hydro locking situation? Since I had nothing to lose I was off to ford to get the O-ring kit.
There is a little round screen or filter between the fuel bowl and FPR assembly located on the driver’s side of the fuel bowl. After disassembling the FPR and cleaning with break parts cleaner then replacing all the O-rings and replacing the little screen/filter that came with the ford parts kit. Reattaching the FPR and starting the truck instantly the truck ran smoother and purred like a kitten!
My theory is the fuel pressure was greater than the oil pressure from the original HPOP and was locking up the injectors. After replacing the HPOP the oil pressure then was greater and allowing the truck to start and run for a few. (Note: I had noticed a lot of extra black diesel smoke from the exhaust that seemed strange as well) After driving a little ways the fuel pressure couldn’t flow back to the tank and was stalling the motor. Once the fuel pressure got large enough it had to go somewhere and would start leaking out anyway possible. Weather the drain valve, Schrader valve, Bowl gasket… you name it?
I would think if you’re suspicious about maybe having this problem you could crack the drain valve a little allowing some pressure to escape and see if that helps with any of your symptoms. This is only a hunch and since mine seems to be fixed I can’t test this theory.
Since I replaced the screen/filter the truck runs great and of course with all the new parts I would hope so. I wanted to do a write up about this to try and help whoever may be dealing with some similar issues and maybe get them going in the right direction straight out of the gate. As our trucks are hitting and passing 200,000 miles we need to think maintenance as well as performance. I’m sure my gas mileage alone will have a direct increasing result from this repair.
You should be able to get this kit at your local ford parts counter. When I was there they said they needed to order the first kit and then they noticed a different kit they had in stock so I’ve included its part# here
Ford Kit Part #2C3Z-9157-AA
About $40.00 US out the door
The first picture on the bottom shows the FPR removed from the fuel bowl once you remove it you will see the screen/filter sandwiched between those two parts. I would recommend removing and replacing this screen/filter after a good break parts bath. Very simple project and should only take about an hour.
Good Luck!
Hope this helped!
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Kooper (12-24-2012)
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