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Coolant in water/fuel separator and tanks, ISX

I have a 2011 KW T 660, Cumminns ISX, 450 HP. Bought the truck 4 months ago with 485,000 miles on it. A few months after buying it I noticed when I toped off the tanks, fuel would be leaking on the ground. Then I started getting water in the fuel code. The water separator was plug up with junk in the bottom, (dirt), cleaned it out. Ehen I got home, had the tanks pulled, both tanks were cracked around the pickup tubes and fuel heaters. Had the drained, and welded. Leaks are gone. 3 fill ups latter, get water in fuel code again. I thought this might happen, system cleaning itself out and all. Drain the separator, was a little dirt, but the water was red, like coolant.

Ive vey changed the filter 3 times in 9000 miles, still getting water in fuel code. I do notice the coolant is dropping slowly. Checked the bottom of the tanks, you can see the red at the bottom of the tank.

The only thing I can think of is the tank heaters might be leaking coolant into the tanks. They may have been damaged when the tanks were cracked, the cracks were so bad, you could almost pull the tank heater off the tank. Only other thing I can think of is a cracked injector, or injector cup.

Any thought or help would be appreciated.

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3 Answers

You pretty well have your bases covered. Start with isolating the fuel heaters then on to the injector sleeves.....

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I think so to. Fuel heaters have not work from when I bought the truck 4 months ago. Talk to a guy from another forum who is a Paccar/Cumminns tech, he didn't belive the injectors or cups to be bad, heater was what he suspects, if so, a fairly easy fix.

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You are probably on the right track but if you find the tank heaters are ok check and see if you have a heated davco filter housing? Some models run water through the case to keep the housing warm. These often crack internally and allow coolant into the fuel. If so just shut the water of to the filter housing and see if the problem persist. Much cheaper than injector cups.

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Anyone ever see this go the other way with a cracked Davco housing? I'm getting fuel in the coolant and I'm wondering if my Davco 380 is the culprit...

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john blink will be eternally grateful.
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