The legendary 7.3 Power Stoke Diesel engine, when properly maintained can provide years of trouble free service. However there are several common problems that can develop over time. Generally speaking these can all be resolved relatively easily. Listed below are 9 common problems of the 7.3 Liter Power Stroke Diesel engine, in no particular order.
7.3 Power Stroke Diesel Common Problem #1 : Causes No Start :
Injection Pressure Regulator (IPR) Valve, 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, 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 which the sealer could plug.
Rebuild IPR Valve from $14 or replacement part number F81Z-9C968-AB. Cost $140-$300 for new.
7.3 Power Stroke Diesel Common Problem #2 : Causes No start :
Injector Driver Module (IDM), 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. Be sure to check your specific IDM part number as it is engine specific. For 99-2003 F-Series Pickups and E-Series Cargo van, IDM 120, includes part number: XC3F-12B599-AA. Replacement cost $50-$350 for used-new.