After Loren Taylor's '02 7.3L Power Stroke started running hot, he took the truck to his shop, Diesel Tech, in San Jacinto, California, where he soon discovered the problem-a head gasket failure. We often think of the diesel engines powering our trucks as being bulletproof and indestructible, but that is not always the case. And, if your bulletproof engine ever lets you down, you usually want to know two things: why did the failure occur, and how can it be upgraded to ensure it never happens again?
As any resourceful mechanic or technician will tell you, the best time to upgrade internal components of an engine is when it is disassembled. Well, Taylor is pretty resourceful, and knowing that he didn't want to ever experience this type of failure again, he decided to install ARP head studs along with new head gaskets. He took further advantage of having access to the 7.3L's internals, which consisted of checking the wear and tear on pistons, valves, pushrods, and injectors, and also prepared it for future performance upgrades.
While failed head gaskets are a rarity on 7.3L Power Strokes, Taylor knew he wanted to address a much more common problem in the HEUI fuel system-inadequate fuel flow to the injectors. For Taylor, having the engine apart was the opportune time to provide the Power Stroke with more fuel, and do so as efficiently as possible. After two quick phone calls, he had a new set of higher flowing injectors from Diesel Performance Unlimited and a new regulated return fuel system from ITP Diesel on the way. In the meantime, he made sure that the factory pistons, pushrods, and valves were in good shape. Here's how the buildup went. DP
 Obviously, the head gaskets...  Obviously, the head gaskets were replaced, but the factory pistons were retained. From this view of the driver side of the head you can get a good idea of what the injector spray pattern looks like on the piston. |  After the new head gaskets...  After the new head gaskets and head studs were installed and handtightened until bottoming out, the cylinder heads were lowered onto the block. While the heads were off, Taylor took the opportunity to clean up the intake manifolds and have them powdercoated. |  Taylor used a deep-well socket...  Taylor used a deep-well socket to push the ARP washers onto the head studs. Assembly lube supplied by ARP was also used to ensure proper torque specifications. |