Ford 7.3L Power Stroke (1999-2003) :: Testing High Pressure Oil System / Air Coming Out Of CCV

'99 7.3, 258k miles, looses oil fast, oil found in coolant (though not a lot) and the fuel bowl is full of oil.

I re-ringed the oil cooler. Most of the coolant and oil is drained. The HPOP holds its oil level and does not leak down.

Someone shared the below test. Though it says #4 ORB, the actual thread on my IPR is #8. I removed the IPR and threaded in the #8ORB to air hose adapter. I regulated the pressure to 20 psi. The air is rushing out of the CCV.

I suspect I am missing something in the below test and that I'm pushing air back through the low pressure oil pump and into the crank case.

The test shared with me elsewhere:

Apparently someone named "Cody" on the forum did a test and it was labeled that way.

AIR TESTING THE HPO SYSTEM:

7.3L Powerstroke engines may experience hard start and or no start issues. In some cases the no-start issue may occur only with the engine hot. If the observed ICP pressure during cranking is less than the required 500 PSI, then the problem is in the high pressure oil system.

One of the first checks that should be made is to remove the plug from the top of the high pressure oil reservoir (in front of the fuel filter) to observe if the reservoir is full. If the oil is standing within an inch of the top of the reservoir, then the problem is in the high pressure oil system and could be caused by one of three things:

- The high pressure oil pump itself
- The IPR Valve
- A high pressure oil leak

Tools: Adaptor ORB #4, Air Compressor capable of maintaining 90-100 psig, Air Line Adaptors which will allow connection to the #4 OBR , IPR Test Harness, Grease Gun Whip or any whip with a .0625" NPT.

Remove the IPR valve and insert the ORB #4 Adaptor. Attach Shop Air and pressurize the system. Wait for approximately 30 - 60 Seconds while the air travels throughout the HPO System. Listen for air escaping through the Oil Fill Tube (cap removed).

External high pressure oil leaks would have, of course, been obvious. The primary concern is internal leaks under the valve cover(s). These could include leaking injector O-rings, or leaking injectors. Listen for any air escaping under the valve covers and correct if present.

If the center injector O-ring has failed, high pressure oil may be forced into the fuel system. Remove the fuel filter cap and observe for air bubbles in the fuel. If necessary, individual fuel lines running from the fuel filter assembly to the cylinder heads can be disconnected in order to isolate the problem to which side it is occurring.

2. 7.3L: If no air leaks are observed, the next step is to isolate whether the problem is with the IPR or the high pressure oil pump. Remove the IDM fuse or unplug the IDM or injector connectors at the valve covers to prevent starting.

3. If this test does not assist in diagnosing the issue, remove both valve covers and witness oil from the deflectors as being uniform, look closely at the injector base for any sign of air or oil escaping during test. This is an indication of a loose injector or O-Ring failure.

The same can be done at the ICP Ports (Oil Rail) on either side to determine leaking O-Rings in that Bank.