NHTSA Complaint #10495681 — 2002 FORD F-250 SD

2002 FORD F250 SUPERDUTY. CONSUMER WRITES IN REGARDS TO A STRONG DIESEL FUEL ODOR AND FINDING FUEL ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT IN THE CAB OF THE VEHICLE. THE DEALER INFORMED THE CONSUMER, THE DIESEL ENGINE WAS DESIGNED WITH COPPER SLEEVES OR CUPS AROUND THE FUEL INJECTORS. THE PURPOSE OF THE CUPS WERE TO SEPARATE THE ENGINE COOLING SYSTEM FROM THE PRESSURIZED FUEL SYSTEM. OVER A PERIOD OF TIME, THE ENGINE COOLANT REACTED WITH THE COPPER CUPS AND CREATED SMALL PIN HOLES OR CRACKS IN THE INJECTOR CUPS. SINCE THE FUEL SYSTEM WAS PRESSURIZED IT INJECTED DIESEL FUEL INTO THE COOLANT CIRCULATING IN THE ENGINE. EVENTUALLY THE DIESEL FUEL CAME OUT OF THE RADIATOR OVERFLOW AND ALL OVER THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. SINCE THERE WAS NO WAY TO TELL, WHICH INJECTOR CUP WAS BAD, ALL OF THEM WOULD HAVE TO BE REPLACED ALONG WITH THE COOLANT HOSES AND THE RADIATOR WOULD NEED TO BE FLUSHED. THE ENGINE WOULD HAVE TO BE TAKEN APART, THE HEADS WOULD HAVE TO BE REMOVED AND THE INJECTOR CUPS REPLACE.*JB UPDATED 02/13/13