7.3 Power Stroke Starving for Fuel – How to Improve Gas Mileage?

Ford started offering a diesel engine with a 7.3-liter displacement in its cars in 1994. The Ford F-series pickup trucks utilized the Power Stroke engine that year, along with various vans and commercial vehicles. As Ford discontinued making these engines in 2003, any car currently utilizing one is likely to be rather old. Changing old and worn components is a great method to improve gas mileage.

Key features and my opinion about the engine

• Production years:1994-2003
• Average lifespan of 7.3 Power Stroke:380,000-450,000 miles
• Fuel supply type:direct injection
• Power range:250-275 hp
• Fuel efficiency:bad
• Engine block material:cast iron
• Engine reliability score:high
• The most common problems:electronics problems, wiring issues, pretty bad fuel economy.

How Does the 7.3 Ford Power Stroke Engine Work?

For optimal performance, the 7.3L Power Stroke engines produced by Ford between 1999 and 2003 need a high fuel delivery pressure. Low or uneven fuel pressure is a common issue in trucks, and it might be the root cause of power loss, EGT problems, and excessive smoke.

If you want the most performance out of your Ford, set the fuel pressure between 45 and 65 psi. Various factors, such as fuel system design and fuel pressure management strategy, impact the engine's ability to regulate and receive fuel pressure.

The diesel is sucked from the tank by an electric fuel pump, squeezed, and then delivered to the filter housing above the engine. The fuel gets filtered before being sent to the injectors and rails. The fuel pressure regulator, located above the fuel filter bowl, is responsible for returning any excess gas to the fuel tank.

Just remember that the gas that flows from the regulator back into the tank doesn't purify. The outcome is the same whether the diesel's impurities sink to the bottom of the filter bowl or reroute via the pressure regulator before returning to the tank.

7.3 Power Stroke Fuel Pressure Problems - How to Fix Them

Low fuel pressures and pressure fluctuations might result from debris in the gas system collecting between the rubber seal of the regulator piston and the degrading pressure spring. The fuel return housing contains the regulator's spring and piston and links to the return fuel line.

Maintaining a fuel pressure of 60 to 65 psi is well within the manufacturer's suggested range. It should provide optimal performance for your fuel system. A quality fuel filter on the suction side of the fuel pump and a rebuilt and shimmered regulator should give you the most stable fuel pressure possible.

You can mount a Wix 33418 filter outside the frame rail in front of the fuel pump. However, the regulator's effectiveness may get impaired by dirt and dust. Luckily, both are getting filtered out by the filter. The filter should occupy a position to safeguard the pump and maintain a spotless fuel filter housing in the engine.

A constant force maintains the fuel pressure in the filter housing from the regulator piston, which is under constant tension from the spring. Once the engine is off, the pressure within the filter housing gets released. There's a tiny hole at the tip of the piston that helps with this.

Ford offers a repair kit that includes all the components for the regulator if you notice your fuel pressure is low or if any of the regulator's parts get broken. After replacing the old regulator components, you may verify the fuel pressure by turning the key to "on" but not "start." After turning the key, the fuel pump will operate for around 20 seconds. It might take several times for the engine to warm up and for the reading to stabilize.

The ideal operating range for fuel pressure is 60 to 65 psi, which should remain constant for maximum efficiency. Small shims may be put between the piston and the spring to increase fuel pressure if it falls below the recommended level but is still within the 45 to 65 psi operational range.

Shims between the spring and the regulator should have a central hole and rest flush with the piston's recessed base. Flattened #4 lock washers, around 0.023" thick, may be used as shims as the last option. You should fit each shim individually and monitor the pressure at regular intervals. When inserting the spring into the top, take care not to cock or deform it.

Your Power Stroke's noise, smoke, and exhaust gas temperatures (EGTs), as well as its fuel economy and overall performance, might benefit from a fuel pressure boost.

Options to Improve Gas Mileage in 7.3 Power Stroke Engines

Here are some ways in which you could improve the gas mileage in your 7.3 Power Stroke Engine:

1. Cut down on the Ford pickup's resistance to the wind: When traveling on the highway, it's best to have the windows closed. You may reduce the lack of airflow by installing a cover over the truck bed. The covers may cost you up to $500, but it's money well spent. In addition, increasing aerodynamics may help save money at the pump.
2. Your Ford truck will run better with a new, high-quality air filter. If you keep it clean: You should expect to pay twice as much for them as for standard filters, but they won't become clogged nearly as frequently and will last four times as long. Also, more air may get into the engine if the air filter is more efficient. More air means less fuel used for operating an engine.
3. Installing a chip or module might boost your Ford's diesel performance: You can get these gadgets from many places, including the internet and car parts shops. In addition, the engine's fuel injection system will function better if you add these components.
4. Keep up with your truck's scheduled maintenance: Per the owner's manual's guidelines, you should perform a tune-up and oil change every 3,000 miles. In addition, the fuel pressure regulator and engine compression should be checked by a professional. Poor fuel economy is the result of a malfunctioning of either component.
5. The lighter your automobile is, the better: Remove any unnecessary goods from the bed and the cab. Upgrades like larger wheels and tires, chrome accents, and bright lighting are not permitted. The vehicle's weight and fuel consumption will increase because of these upgrades.
6. Check the tire pressure and adjust as necessary: Reduced tire pressure leads to higher diesel usage. On the other hand, unproperly inflated, balanced, inflated, and aligned tires, or those worn down to the cords, are just as deadly.
7. As soon as possible, practice safe driving habits: Take caution to avoid letting the engine warm up for too long. Don't go beyond the posted speed limit. It's possible that the overdrive gearing on your vehicle might help you save money on petrol by reducing engine speed. Just turn on the air conditioning when it becomes too hot. Compress several tasks into one. For example, highway driving calls for the use of cruise control.
8. Replace the old exhaust system with one built specifically for diesel trucks: Because of the increased exhaust flow made possible by the bigger and more streamlined exhaust pipes, a quality exhaust system may significantly boost an engine's output. Therefore, changing the exhaust flow may increase output and reduce fuel use.

How Dependable is the 7.3 Power Stroke?

The 7.3 Power Stroke is a reliable and efficient engine. There are many problems with it, but they are not always major. And Ford 7.3L diesels are showing their age quickly. Therefore, most potential breakdowns are fair game, considering the age and mileage.

However, the 7.3 Power Stroke has a B50 lifespan of around 350,000 miles. About half of these 7.3L engines have a lifetime of more than 350,000 miles. It's rather respectable, even among diesel engines, which often outlast gasoline engines. The internal workings of Ford 7.3L diesel engines are rugged and powerful. These engines are not perfect, but none of them are. Reviews on the reliability of 7.3 Power Strokes are consistently above average. If you take good care of the engine, you'll have a terrific trip.

The 7.3L Powerstroke engine's ease of operation is a selling point, but it was complex during its introduction. The 7.3L Powerstroke engine's impressive specs are significant to its use of direct fuel injection using Hydraulic Electric Unit Injectors (HEUI).

If you want to employ these new injectors, install a high-pressure oil pump and a low-pressure fuel lift pump. In addition, the engine's fixed geometry turbocharger is more effective than the turbocharger in 7.3 IDI motors. Newer versions of the 7.3 improved because they could draw in more cold, dense air.

The 1994 Ford Superduty's 7.3L Diesel engine can produce 210 hp and 425 lb-ft of torque when properly equipped. And this is a boost from the IDI's 40 hp and 87 lb-ft of torque. The 7.3l Power Stroke also had annual upgrades, resulting in more power in subsequent truck models. Late model 7.3s produced between 2000 and 2003 had 275 hp and 525 lb-ft of torque when paired with a 6-speed manual transmission.