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High Pressure Oil Leaks

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I have now come across my second high pressure oil system leak. This one is a 2005 Econoline with 2700 miles on it that just quit running on the highway, no warning, no restart. I also discovered that you don't have to access the ICP sensor to put shop air into the system to diagnose the leak. I found an easily accessible plug on the top of the new oil pump cover. I put shop air into that puppy and with the engine cover off I could easily detect the leak was at the back of the right cylinder head.

 

Unfortunately, performing any under valve cover repairs on the right side requires removing the engine mounts. /forums/images/%%GRAEMLIN_URL%%/smhair.gif I never tell anyone how to do their job but I was never a fan of lifting cabs and bodies, neither is FORD for that matter. I gave in and removed the forward body bolts and jacked the body up 2" to allow the valve cover to come off as well as the "5 injector.

 

The oil inlet o-ring was split because the metal support ring and snap ring were broken. I can only assume they were broken during assembly of the injector. I only found one piece of the support ring that was not still in the injector.

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Kieth... I spent Friday at the Edmonton training centre. Ford Canada is pushing us diesel techs through 51S01T0 - 6.0 updates. There was a quality control issue with the top snap ring not being seated that would give your concern. We are told that this has been taken care of.

 

It was a battle to stay awake for part of it but there was some really good info and discussion. Got to take a good look at the 4.5 twin turbo at the same time... damn, that's a cute little thing.

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Thanks Keith for the informative post. Like you, I've never fancied the cab-lift route, but mostly because my service area cannot facilitate very much height. Even though the dealership was built in the early 80's, the service area is equipped to handle nothing much larger than a typical 350 pickup of that era. The SD's are just too big for my lifts, so I have to resort to over, under, and through, just like the old greasy-kid days. Once again I say, please NEVER let a 6l econo come my way!

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Quote:
6.0 updates. There was a quality control issue with the top snap ring not being seated that would give your concern. We are told that this has been taken care of.
Now, you see? THAT is the kind of information we need to hear about out in the field. I don't recall ever seeing anything about injector inlet o-rings as a service message. But all things considered, at least we aren't going though the o-ring failures we saw with the early 7.3L. We just need to be sure that the 6.0L hold down clamps are properly torqued. /forums/images/%%GRAEMLIN_URL%%/wink.gif
You do see service messages about that or other potential technician screw ups like installing injectors with air tools.

I got it! We can start our own message system and call them EWM's - "Engineering Warning Messages!"

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EMS #1000 - 2004 though 2006 Econoline vans equipped with diesel engines. Beware that engineers have a tendency to stuff things where they don't belong. Technicians performing repairs on the engine should wear their very short to avoid scalp damage from pulling hair.
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/forums/images/%%GRAEMLIN_URL%%/smirk.gif

Isn't this fun?

Now back to our regular technical banter.
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  • 2 weeks later...

Just FYI, I have two of these things in the shop right now, same thing, blown o-ring #5 injector. The Hotline guy said to me it was all 2004&5s built before Jan 15 05. Another hot tip: these things don't just explode, apparently they can fail gradually and if you have any in that have an extended crank after hot, that you can't find a cause for, look for a torn oring. /forums/images/%%GRAEMLIN_URL%%/drinkingdude.gif

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Yeah, but you know what, I have seen this on 03's too and they do just as you said. A truck might roll in and the customer will say "Don't turn it off because it won't restart for at least 8-10 hours!" That equates to a full day's work and no lunch for the poor guy. /forums/images/%%GRAEMLIN_URL%%/eek.gif Makes it a real pain to move the truck around the lot until it's repaired. At least I now know what to look for. Putting air into the system is the best way to find a high pressure leak. If it's an injector o-ring you will be able to identify which bank the leak is on. If the ICP is on the valve cover or it's an Econoline, you can determine which bank the leak is on BEFORE you remove the valve covers.

 

I used a discarded fuel port plug and made an adapter that fits the ICP hole and the port on the back of the new style HPOP for the Econoline. That way you don't have to remove any covers and install adapters to apply shop air. At least not for an initial test. /forums/images/%%GRAEMLIN_URL%%/banghead.gif

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