replacing hpop 02 7.3 - Ford Powerstroke Diesel Forum
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post #1 of 3 Old 03-15-2013, 07:11 AM Thread Starter
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replacing hpop 02 7.3

hey yall i gotta buddy that just bought an 02 7.3 and the hpop is going out and i was wondering if someone could guide me through the process of replacing it cause im trying to help him out and money is tight but he does have a new pump already so any help would be greatly appreciated. thanks.
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post #2 of 3 Old 03-15-2013, 07:58 AM
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Open the hood Remove the fancy plastic cover that says "power stroke." Now remove the metal bracket that was holding the fancy cover. At the back of the fuel filter housing, turn the yellow knob to the right, this will drain the housing. Disconnect both fuel lines on the lower left, and both on the right. Unplug the "water in fuel" sensor from the back of the housing and remove the drain hose. Then, using a deep well 1/2" socket, remove the studs on the HPOP reservoir, and using a 10mm socket, remove the rest of the bolts holding on the HPOP res. Unplug the sensors in the HPOP res. (one in the top, one on the backside on the drivers side). Might have to tap it lightly to get it to break loose, but after the bolts are out, remove the HPOP reservoir and the fuel filter housing will come with it. Yes oil will spill out, so make sure there's a drain pan beneath you. Remove the gasket/screen and use a vacuum pump or turkey baster to finish emptying the reservoir on the side and cover with a lint free cloth. Remove the oil lines (also now a good time to get the updated o-rings from Ford if they didn't come with the new pump). Make sure everything is very clean around the base of the oil pump, I don't care if you have to use 4 cans of brake cleaner and a whole box of rags, you DON'T want dirt in there. Once you're clean, remove the pump, and install the new one. Re-connect the oil lines. Re-fill the side reservoir with fresh clean oil. Make sure everything is absolutely clean when you put it back together.

While its out, you can remove the fuel filter housing from the HPOP reservoir and clean the inside of that out really well too (T30 torx heads) and take off the lid and clean out the fuel filter housing (you may be suprised how much crap is in there). Put everything back together and make sure you get your sensors plugged back in. Fill the diesel bowl with diesel. Turn the key to "on" for 30 seconds, then back off. Do this 4-5 times as it will help purge all the air from the system. Turn the key to start and she should kick off Not too bad of a job, takes me about 1-1.5 hours start to finish, but it helps having all the tools and knowing what needs to come off.

Nick "Shadow" Kokos
2005 King Ranch F-350: Studded and O-Ringed, BPD Oil Bypass System, Stage 1.75 KC Turbo, ODAWG Ported Intake Manifold, 4" TB MBRP Exhaust, Stage 2 AFE Intake, Billet Torque Converter, BPD 58V FICM, Atlas 40 and a Tweaked SPD tune

2.5" Leveling Kit, 35s, Fusion Bumper, ProTech Headache Rack, OnBoard Air, and a custom tailgate in the works
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post #3 of 3 Old 03-15-2013, 08:08 AM Thread Starter
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ok great. thanks for the advice i appreciate it. im not to familar with the 7.3 i got a 6.0 and ive learned that its made me a pretty good mechanic lol
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