Coolant leak/Intake Manifold O-Ring issue possibility - Ford Powerstroke Diesel Forum
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post #1 of 10 Old 01-15-2013, 12:12 AM Thread Starter
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Coolant leak/Intake Manifold O-Ring issue possibility

I replaced the o-ring for my intake manifold less than a year ago and it seems to have blown again. I haven't taken anything apart yet to check exactly what the issue is though so I'm not exactly sure.

Last Thursday when I was leaving work I noticed that my fan was coming on. I was not overheating, but it still struck me as odd because it was like 30 degrees outside. I had a really busy weekend and did not get around to checking what the issue was until today. I had no coolant in my degas bottle whatsoever, so I decided to poor some distilled water in and unfortunately all the water immediately leaked out from the middle of the engine compartment. I'm assuming its from that same o-ring I previously replaced.

I'm wondering if there is another issue that is causing this o-ring to blow, or maybe I did something wrong? Want to get some ideas of what to do here, especially to prevent this from happening again. The repair took me a really long time last time, and my work schedule is even more odd now so it's going to be another project. I may end up trying to find a good diesel mechanic to do the work for me.

Any help/past experience is greatly appreciated!
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post #2 of 10 Old 01-15-2013, 03:16 AM
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If you need to replace it again I did it by just undoing all the intake manifold bolts and the gently prying up on the manifold. I was able to just sneak that oring in like that. I know its not the best way but it saved me hours.

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post #3 of 10 Old 01-15-2013, 05:30 AM
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A good torque wrench, and the proper torque sequence is absolutely necessary.

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Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE - http://www.powerstroke.org/forum/gen...tml?highlight=
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post #4 of 10 Old 01-15-2013, 07:27 PM Thread Starter
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That's what I did the first time. Is this a common issue on the 6.0? I really didn't want to have to make this repair again because it turned into a huge project due to my schedule. I'm thinking about looking for a diesel mechanic and getting an estimate
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post #5 of 10 Old 01-15-2013, 07:34 PM
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That large oring is not a common leak, the egr hose is though.

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Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE - http://www.powerstroke.org/forum/gen...tml?highlight=
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post #6 of 10 Old 01-15-2013, 07:50 PM Thread Starter
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I don't know for sure if it is that o-ring yet, I haven't had spare time to dig into it and won't until the weekend. If its the EGR hose, is it pretty straight forward to replace or does everything have to be taken apart?
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post #7 of 10 Old 01-15-2013, 08:01 PM
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I don't believe it's too bad, the turbo might have to come out. Iirc.

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Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE - http://www.powerstroke.org/forum/gen...tml?highlight=
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post #8 of 10 Old 01-15-2013, 08:06 PM Thread Starter
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I'll take a look at it this weekend then, thanks!
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post #9 of 10 Old 01-16-2013, 12:20 AM
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No the turbo doesn't have to come out to swap the egr cooler hose.

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post #10 of 10 Old 01-16-2013, 07:43 AM
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Quote:
Originally Posted by Tuscany View Post
No the turbo doesn't have to come out to swap the egr cooler hose.
Thanks brian.

Sent from my phone that somebody didn't help me get.

Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE - http://www.powerstroke.org/forum/gen...tml?highlight=
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