Replacing HPOP o-rings - Ford Powerstroke Diesel Forum

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post #1 of 15 Old 02-19-2010, 03:21 PM Thread Starter
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Replacing HPOP o-rings

I got the kit from ford to change the HPOP orings and i was wondering if anyone knew where I could find some good instructions on how to do them.

For anyone that needs the kit, the part number from Ford is 2C3Z9G804-AB
It comes with 3 o-ring, loctite, and some crappy instrutions.

1997 Single Cab Dually, S366 w/ Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s, Corbeau seats w 08 console, 19.5s, 6637, Black Interior with swede headliner and visors, Custom badges, Flight Fab Traction Bars.
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post #2 of 15 Old 02-19-2010, 04:08 PM
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HPOP O ring removal- no special tool required

I used this when I replaced mine. Pretty simple just takes a lot time to get the fittings out using the stubby wrench. You can only turn it a few degrees at a time. Also I didn't remove anything like the article says to. I just removed the fittings and then took the lines off the fittings.

Alex Bauld


2002 F350 Crew Cab Long Bed
- Napa 6637 Intake
2001 F250 Crew Cab Short Bed
- Stock
1995 Acura Integra GSR
-Way too many mods
1991 Acura Integra LS
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post #3 of 15 Old 02-19-2010, 04:15 PM Thread Starter
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ok thanks man ill read it and check it out

1997 Single Cab Dually, S366 w/ Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s, Corbeau seats w 08 console, 19.5s, 6637, Black Interior with swede headliner and visors, Custom badges, Flight Fab Traction Bars.
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post #4 of 15 Old 02-19-2010, 04:53 PM
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Super easy to do. First thing I ever did to the truck was replacing the o-rings on the HPOP. Just remember to fill the HPOP reservoir otherwise you're truck will never start. Made that mistake when I did mine.

Alex Bauld


2002 F350 Crew Cab Long Bed
- Napa 6637 Intake
2001 F250 Crew Cab Short Bed
- Stock
1995 Acura Integra GSR
-Way too many mods
1991 Acura Integra LS
- CRVtec Swap
- Built from ground up

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post #5 of 15 Old 02-19-2010, 05:05 PM Thread Starter
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i guess it seems a little harder just by looking at it. There is alot of crap all around the pump. It dont look like its all that easy to get too. Im gonna tackle it tomorrow. Thanks for the tip on the resivor

1997 Single Cab Dually, S366 w/ Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s, Corbeau seats w 08 console, 19.5s, 6637, Black Interior with swede headliner and visors, Custom badges, Flight Fab Traction Bars.
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post #6 of 15 Old 02-19-2010, 07:11 PM
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The only way I was able to do it was with a stubby wrench. I mean you could take the lines off and then use a socket. I was not able to get the lines off while the fittings were still in.

Alex Bauld


2002 F350 Crew Cab Long Bed
- Napa 6637 Intake
2001 F250 Crew Cab Short Bed
- Stock
1995 Acura Integra GSR
-Way too many mods
1991 Acura Integra LS
- CRVtec Swap
- Built from ground up

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post #7 of 15 Old 02-19-2010, 10:09 PM
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... what lines are leaking two side ones or rear plug??..i didnt fill my hpop..truck fired up like normal...easiest way to make the tool is with a panel popper and just make the square cut out bigger, i never did them before either took 30seconds to take line off, once lines off i used an extension and i think its like a 24mm or something on my electric impact and it came right out..replaced o-rings fired up and watched for leaks... overall 10mins per one.. there really not that bad..

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post #8 of 15 Old 02-19-2010, 10:22 PM
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you can buy STC fitting tools. they are becoming more common, lost of tractors use them now.

Vince
John Deere product developement
FOR SALE '99F350 2008 F350 mini maxx'd

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post #9 of 15 Old 02-20-2010, 06:31 AM
Let's go B's!!!!

 
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Here man this has everything you need.


http://www.dieselorings.com/docs/fullHPOP.pdf

Chris

2002 Crew Cab Long Bed
4" BDS, 35x13.50 Cooper STT on 20x10 Black Rockstars, and other stuff.....310,000 miles and counting...
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post #10 of 15 Old 02-21-2010, 04:53 PM Thread Starter
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I got em changed today and they was not bad at all. I did not unhook the high pressure lines i just un screwed the fitting the changed the orings. It was very easy, just kinda time consuming. Here is what my old o rings looked like.


1997 Single Cab Dually, S366 w/ Irate mount and plenums, EFuel, Intercooler, P.I.S 175/80s, Corbeau seats w 08 console, 19.5s, 6637, Black Interior with swede headliner and visors, Custom badges, Flight Fab Traction Bars.
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