The legendary 7.3L Power Stroke was introduced mid-model year alongside a turbocharged and naturally aspirated version of the 7.3L IDI. One could argue that the 7.3L Power Stroke is roughly based on the design of the IDI, but the engines are polar opposites by nature of their operation. By 1999, International had built 1 million of the Power Strokes, and the 2 millionth engines rolled off the production line in 2002. The 7.3L Power Stroke failed to meet strict federal emissions regulations, and was ultimately retired after the 2003 model year. The 7.3L laid the foundation for Ford's prosperity in the diesel marketplace, giving new meaning to the terms performance, reliability, and longevity. It is not uncommon for a 7.3L Power Stroke to serve well past the 500,000 miles mark without requiring major repair, and for many owners it is a million mile motor. While the performance figures for the 7.3L Power Stroke are relatively low by today's standards, the engine is largely responsible for fueling the race between Ford, Dodge, and GM in the marketplace.
Common Problems With 7.3 Power Stroke Diesel Engines
Causes No Start: Injection Pressure Regulator (IPR) Valve
It located in the valley on the High Pressure Oil Pump (HPOP). These can stick, seals get damaged, have the sensor go bad or the wires get damaged. Locate the IPR Valve, check for loose or damaged wires, and check that the tin nut on the back of the IPR sensor is tight. When reinstalling the IPR unit torque the IPR to 35ft/lbs and do not use sealer on the IPR threads, as there is an orifice in the threaded area that the sealer could plug.
Rebuild IPR Valvefrom $14 or replacement cost $140-$300 for new.
Causes No start : Injector Driver Module (IDM) It located on drivers side fender. These can go bad or get damaged from water and will cause a no start or rough running and cut outs in revving/rpm. Check for damaged wiring, moisture or water intrusion. Replacement cost $50-$350 for used-new.
How to clean your engine?
Try CARBON CLEANING!
Decarbonizing allows to burn the carbon and cleans your engine
Preventive engine cleaning enables you to restore engine parts rather than replacing them, thereby saving vehicle owners on costly parts, such as a new turbocharger ($ 1.350 - 3.100), catalytic converter ($ 600 - 2.000), DPF ($ 600 - 2.000) or EGR valve ($ 370 - 500).
These problems result mainly from poor combustion, which stifles the engine.
So before replacing your engine parts, try Carbon Cleaning. A dirty engine as the result of carbon deposits is the new threat to vehicle performance.
Cam Position Sensor (CMP)
Can cause the engine to cut out and eventually die. Making it not start until it sits or is reset on the batteries. An easy way to make sure yours is good; on the Old Body Style (OBS), check if your tachometer moves while cranking, if it does your CMP is good, If not replace. Cost $24-$70. Don't buy the generic sensors from any parts store; get OEM because some aftermarket CMPs can be defective out of the box. Keep known well a spare in your glove box.
Under Valve Cover Harness (UVCH) Connectors
When these come loose or get shorted they can cause rough running conditions to the point where the truck sounds like it has 17* timing and it lopes bad and will often die and sputter. An easy way to fix this or check for it, there are four connectors on your block / heads that are under the valve covers unplug them and check for cut wires, loose or burnt connectors, if they are burnt or damaged, replace them. It's a simple fix.
Clogged fuel filter
A restricted fuel filter will often cause long cranking or a semi-loss of power, if the injectors can't get the fuel they need. Replace fuel filter.
Replacement cost $9-$30.
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