Diesel Fuel in Coolant

[solar_nerd]

Just purchased a 1995 F350 with 7.3L powerstroke that has not been started for 5 years. Replaced batteries, starter and starter solenoid and was able to get it running. Found coolant leaking from the waterpump so replaced water pump. Had to use sealent on water pump due to pinholes in the mating surface for the waterpump. All was running good and no issues for about 2-weeks. I kept a close eye on all fluid levels and gauges. I then saw a puddle on the ground under the degas canister and found it had overflowed with diesel fuel in it. I did the research and found the most likely problem was the injector sleeves. Found a kit that I could change the sleeves without pulling the heads and so did the replacement. Removed valve covers, removed injectors, and oil plugs on the rail. Didn't read anything that told me to remove fuel plugs so didn't do that. Removed old sleeves with 1 1/4 tap tool with no issues. Installed new sleeves with red loctite and put everything back together. Tapped the key and it hit like it was seized up. took everything back apart and found back cylinders had fuel in them. Turned the key with injectors removed and blew all the fluid out of the cylinders. Put everything back together and if fired up after a bunch of cranking seemed to run fine. Ran a whole bunch of water thru all the different parts of the cooling system, vacuum tested the cooling system and then filled with antifreeze. Took for a test drive and everything seemed to be fine. On second test drive started to see fuel in the degas bottle again. Went for a longer test drive and it's back to overflowing the degas bottle with diesel fuel. Where did I screw up?? What should I do next

[jesilvas]

I see diesel doc is viewing. And probably typing
But I guess you mean injector cups instead of sleeves? Kinda the same thing, just diff names.
I don't know much, but I thought the only place fuel was next to coolant was in the injector cups.

[forddieseldoctor]

More than likely you didn't get all of the fuel out of the cooling system. Drain out your coolant, get 3 gallons of simple green degreaser, pour into your cooling system, top off with water. Go drive it or let it run at 1200 rpm for about an hour. Drain the cooling system and the block. Then run a bunch of clear water through it until you don't get any more soap coming out. Then fill with water and run it to warm it up, then drain and flush again. Then fill with 3 gallons of straight undilluted coolant and top off with water. Make sure you get 2 bottles of the coolant additive from your local dealer. Your coolant system holds 23 quarts of coolant. Read the directions on the bottle for the proper amount of additive. I think it's a bottle and a half but I don't remember for sure.

[solar_nerd]

Yes, I have seen them called cups or sleeves.

[forddieseldoctor]

Originally Posted by jesilvas

I see diesel doc is viewing. And probably typing

Yeah I can be a slow poster especially when I'm looking up specs and tsb's for reference. Plus I try to proof read everything and make sure it reads the way I wanted it to.

[jesilvas]

Shouldn't he use ELC?

[solar_nerd]

Forddieseldoctor, thanks for the ideas. The amount of diesel fuel coming out the degas bottle is way more than I believe could be 'still in the cooling system. We ran water thru heater core, engine and radiator and can't imagine there could still be that much diesel fuel left but you could be right. I like your method of cleaning out the coolant system and will definitely use that after I get the problem resolved.

[forddieseldoctor]

Originally Posted by jesilvas

Shouldn't he use ELC?

Nope just your standard green coolant with distilled water will work perfectly.

Originally Posted by solar_nerd

Forddieseldoctor, thanks for the ideas. The amount of diesel fuel coming out the degas bottle is way more than I believe could be 'still in the cooling system. We ran water thru heater core, engine and radiator and can't imagine there could still be that much diesel fuel left but you could be right. I like your method of cleaning out the coolant system and will definitely use that after I get the problem resolved.

Never mind I didn't read close enough.

I had one that the guy only wanted to replace the cup that was leaking. I added some dye to the cooling system, drove the truck to warm it up. Then I removed the injectors and pressurized the cooling system and looked down the injector holes with a black light to see the dye.

[solar_nerd]

doc, great idea on the dye. Will let you know how it turns out. thanks so much for the responses!

[glovemeister]

Originally Posted by solar_nerd

Just purchased a 1995 F350 with 7.3L powerstroke that has not been started for 5 years. Replaced batteries, starter and starter solenoid and was able to get it running. Found coolant leaking from the waterpump so replaced water pump. Had to use sealent on water pump due to pinholes in the mating surface for the waterpump. All was running good and no issues for about 2-weeks. I kept a close eye on all fluid levels and gauges. I then saw a puddle on the ground under the degas canister and found it had overflowed with diesel fuel in it. I did the research and found the most likely problem was the injector sleeves. Found a kit that I could change the sleeves without pulling the heads and so did the replacement. Removed valve covers, removed injectors, and oil plugs on the rail. Didn't read anything that told me to remove fuel plugs so didn't do that. Removed old sleeves with 1 1/4 tap tool with no issues. Installed new sleeves with red loctite and put everything back together. Tapped the key and it hit like it was seized up. took everything back apart and found back cylinders had fuel in them. Turned the key with injectors removed and blew all the fluid out of the cylinders. Put everything back together and if fired up after a bunch of cranking seemed to run fine. Ran a whole bunch of water thru all the different parts of the cooling system, vacuum tested the cooling system and then filled with antifreeze. Took for a test drive and everything seemed to be fine. On second test drive started to see fuel in the degas bottle again. Went for a longer test drive and it's back to overflowing the degas bottle with diesel fuel. Where did I screw up?? What should I do next

If you have pinholes in your timing cover, I'd bet you money that they were not running the correct sca's and you are going to have pinholes in your cylinder walls too...