Overflowing coolant

[joshsill]

I've got a 2002 7.3 with 114,000 miles. A while back(October?) I noticed that the coolant looked a little low so I added more. The truck is not driven a lot, only to pull a horse trailer which isn't much in the winter. Yesterday we were pulling and I noticed that the coolant was overflowing out of the reservoir at a pretty good stream. Now I have not noticed this before with normal driving, not saying it didn't happen, but will the increased engine load cause this if I put too much coolant in? It is at the max point when cold. I have also noticed a bit of a diesel smell but I cannot tell if it is in my coolant(smelled reservoir and doesn't seem any diesel smell). Maybe the diesel is a separate problem. Where should I start to see what exactly is wrong? I have read possibly thermostat, new cap, cracked injector cups. Thanks for the help.

[makey98]

Sorry buddy, but its sound like a cracked injector cup. My truck had the same issue. Diesel fuel was leaking into the reservoir and the mix was overflowing. I had one cracked injector cup. It could the cap or thermostat or other things, but if it has a layer of diesel on top..... most likely. Other option is cracked head, which won't be pretty, so hope for one injector cup.

Find a good shop that can R&R the injectors and it isn't too bad. I think mine was 4-6hours of labor to get the injectors out, 180 bucks for new injector gaskets, new coolant, 1 new injector cup, and oil change. 1200 bucks or so. Find a good shop that is in that ballpark. Good luck.

[jc82chevyman]

X2 on the injector cups

[Instructor]

Did you fill the coolant up to the top line or bottom line. Depending on your particular vehicle the plastic fill tank may have two lines. one for cold and one for hot. If you fill the coolant up to the hot mark while cold it is very possible there was not enough room for expansion once it gets warm.

[joshsill]

Thanks for the replies.
So I finally got time to look at the situation a little closer....there is definitely something funky in the coolant which seems to be diesel. It looks like it is causing the coolant to almost thicken or gel or something weird. I siphoned some out and it is separating as shown in the picture.


Guess injector cups seem to be in order. I don't have a lot of money to throw at this so it will be a DIY job. Is there anyway to tell whether this is for sure the problem without just fixing it to see if it comes back? Any really good tutorials on how to do this and make a DIY cup remover? I am pretty decent at fabrication and mechanics so hopefully I can do this.

Picture doesn't seem to work, here is the link: https://picasaweb.google.com/lh/phot...eat=directlink

[Instructor]

hard to say by the pic but oil would be on top and diesel would be throughout. Looks like something has settled to the bottom. It may be settiment from the antifreeze if hasnt been changed and may have overheated at one time. If you are not the original owner someone may have put bars leak or some type of stop leak in it. That is what it looks like to me with a combo of other things.

[joshsill]

Yeah, its kinda weird, the deeper end of the coolant tank is pretty much full of "thick floaties" for lack of a better description.

[Instructor]

You might flush your system and put a good 50/50 mixture back in. You may need to flush several times before you get everything out of the coolant passages in the engine and radiator. Dont have to use radiator flush everytime except the first. Straight water a few times afterward adn then go back with you antifreeze mix. then fill to correct mark and see if it reappears.

[joshsill]

Yeah, I'm gonna flush it and then just watch it. I can't find any of the good coolants recommended right now in my area so I'm going to use either the zerex g-05 or Napa stuff and then change it later when I can get the good stuff. Is this Napa HD coolant any good:
Store Locator | NAPA Online

I can't find any reviews or recommendations on it.

[Instructor]

Its a good coolant. Key is to flush real good and add you coolant. and like you said once you have established if the system is clean then you can get the type of coolant you want to run. You may want to flush your system at that time as well. You should be fine.