Hey everyone, I just posted this but in the wrong section (94-98) like i stated new to the forum, my bad. My 03 has 170,000 miles, started leaking fluid that smelled like diesel, it was blowing out the coolant cap. Ford service said it is an injector cup cracked and letting fuel get into the coolant. Motor runs good and has noy lost any power that I can tell. They said it is about an 1800.00 dollar job, replaceing all hoses and flush coolant. has any one had this happen and or could the fuel be getting into the coolant some other way.Changeing the oil and filters no problem but im no diesel machanic, any replies would be appreciated.
Just noticed i posted this in the wrong section, my bad
This is really the only place where fuel & coolant meet, which is at the injector cup in the head. Because the injector has more pressure than the coolant - it's a pretty obvious sign it's a cup failure.
It could be o-rings - but, to check - you're going to have to pull the injectors anyways.
Sad thing is - the cups themselves only cost about $100. The Kit with the cups, the removal and insert tool plus the proper loctite is about $400 or so.
But - the labor to do it (especially with the heads on) is kicker. To properly do it - is about 8hour job - not to mention once the new cup(s) is in, you need to get the injector back in fairly quick, and torqued down to keep the cup seated, then another few hours (if not 24 hours) to allow the loctite to cure/seal properly before you fire it back up.
So $1800 (from any service shop) is about right.
Edit - depending on how long this has been going on - it is wise to replace the hoses (and possibly the waterpump) Just because it does deteriorate the rubber/seals.
2003 EX, 7.3L 4inch Lift, Nitto Trail Grappler's, KMC XD Spy's
220k Miles, Currently 605tq, 312hp