Have been getting fuel in coolant and have searched the forums and found that it is either cracked head or cracked inj.cup. I am now trying to isolate which head is the culprit. I have put 100 psi of air to each fuel rail individually, for 45 min and can get no pressure increase in the cooling system. Is there something else I am missing?

 

theres an update on the diag.
TSB
08-23-8 6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS

Publication Date: November 7, 2008

FORD: 2003-2005 Excursion
2003-2007 F-Super Duty
2004-2008 E-Series


ISSUE:
Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.0L engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle.

ACTION:
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics.

NOTE: IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR.



Drain coolant from cooling system.
Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C.
Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles)
Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant)
Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle.
NOTE: MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT.



Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3)
Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C.
Replace cylinder head if leaking through casting, refer to WSM 303-01C.
Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.


Figure 1 - Article 08-23-8




Figure 2 - Article 08-23-8




Figure 3 - Article 08-23-8



OTHER APPLICABLE ARTICLES:
08-23-01

WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB.

 

Thanks for your help I think I found the leaker.

 

np. the correct way to repair is to remove the head and replace the cup. the reason is the cups are made of stailess steel.

we have done them by request and singing of waviors of liability with the head on. if you opt for the head on approch make sure that the nozzel hole is pluged. we just use pice of metal cut down (maybe a penny will fit in the hole) and cover it in trans jell (aka vasillen)

 

I am removing the head but am having trouble removing the steel braided line from the oil pipe coming up. Do you pry the rubber up or down to release the line? Early built 04 with 03 motor.

 

they are a lil bit of a pain. you need to lift up on the bottom of the rubber and push up on it to release.
if you have something close to a 13mm collet wrench (they come with a die grinder) they work great... better then the oem special tool. then once its pushed up lightly tap it with a small hammer and it should pop up.
you should not have to force it

 

Thats what I will try. Thanks again.