Helpful Tips on Replacing Genuine Ford Diesel O-Rings and Fuel Injector O-Rings

Every Ford diesel truck owner knows that one of the most common wear problems will be with the O-rings. Replacing diesel O-rings is not a question of if, it’s just a question of when. O-rings are an integral part of several critical components of the Ford diesel engine. When one of these O-rings breaks, there can be several side effects on the performance of your trucks.

If a ring has sounded and you are trying to locate the source of your problem, here are some helpful tips that can get you to the source faster.

A) Problem starting the truck:

If you are having trouble starting the truck or the truck won’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 a multitude of other problems, but a leaking O-ring would be a great place to check first.

B) Simple deterioration:

If you experience rough idle or loss of power, this could be due to deterioration of the injector o-rings. These symptoms are generally misdiagnosed as caused by using the wrong type of oil, however, deteriorated rings are an often overlooked item.

C) Fuel injector replacement:

O-rings are often damaged during replacement or removal of fuel injectors. Usually you have to push the O-rings through a fairly narrow gap to fit the fuel injector into the fuel rail. This can often damage the rings if you are not careful. Lubricating the o-rings and other parts before any installation will help prevent damage and make the installation a little smoother.

D) Heat damage:

Diesel engines overheating can cause severe damage to the O-rings. When overheated, the rings can expand beyond their maximum capacity, causing permanent deformation and damage, and consequently gaps that will lead to leakage. This is most common with the injector rings.

E) Oil leak:

A common problem on the 7.3L Ford Powerstroke is the development of an HPOP-related oil leak. This can sometimes look like a fuel bowl related fuel leak, but if after changing the fuel bowl O-rings the leak continues, it is definitely the HPOP.

F) The pieces are getting old:

Like all of us, age takes its toll. Over time, the o-rings will simply harden and lose 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, it is almost certainly an O-ring failure.

Sadly, I have been caught in a situation where I had to run around town hoping that a dealer would have the part I need. I like to avoid inconvenient situations when possible. It may be presumptuous, but I thought some of you would 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 range of fuel and oil related applications in Ford trucks, and because they tend to be a common maintenance issue, I have put together a kit that any Ford diesel enthusiast should have. As I mentioned earlier, eventually your Powerstroke 7.3L will develop a fuel or oil leak. It’s just a matter of when.

A complete replacement kit includes:

• One complete set of Turbo Pedestal (4) O-rings, both top and bottom

• GTP38 turbo outlet O-ring

• HPOP outlet connections (4) O-rings, both internal and external

• HPOP rear cap o-ring

• HPOP tank fill cap O-ring

• HPOP “non-serviceable” plug o-ring

• Body O-ring from IPR to HPOP

• Header oil rail o-rings (8) for oil rail plugs, ICP or crossover line

• Internal hose to head HPOP O-rings (2)

• Loctite 608 retention compound (2 x 5 ml packs for HPOP and oil rail)

• GTP38 EBPV solenoid o-rings (2)

• GTP38 EBPV piston back plate O-ring

• New Garrett EBPV Push Rod Clip

• Fuel drain valve core O-rings (2) bi-polymer or tri-polymer Viton option

• Fuel drain valve stem O-ring (1)

• Fuel filter check valve O-rings (2)

• Fuel container heater / water fuel sensor O-rings (2)

• Fuel cup cap o-rings (2)

• Fuel bowl return regulator O-ring

• Sleeve gaskets for fuel rail lines, both ends (4)

• Hose gasket for fuel return line

• Sleeve gasket for main fuel supply line

• Turbo mounting bolts (2)

This kit will cover all your o-ring needs. I recommend replacing all of your original rings with DuPont Viton O-rings. You won’t have to worry about the O-rings drying out or cracking, because the shelf life of DuPont Viton is indefinite! No kidding, they won’t be spoiled by air, heat, sun, or time.