6/13/24, 1:36 PM Diesel Repair

Detroit Diesel - Engine - 2019 - DD15 - Coolant Loss

Coolant Loss

NOTE: Prior to diagnosing a coolant loss complaint, make sure that the coolant is not being unnecessarily
overfilled. The min/low and max/full marks on the coolant surge tank represent the acceptable operating
range of the coolant level. During normal operation, the coolant level will expand and contract between the
two lines, depending on temperature. Coolant does not need to be added if the coolant level is at the
number two line. Overfilling the coolant reservoir will cause the surge tank to push coolant out.

Step 1. Pressure test the cooling system and check the OEM components for leaks. Were any leaks found?

Yes. Repair or replace the leaking component as necessary.

No. Go to step 2.

Step 2. Pressure test the system and check any aftermarket components that have been added for leaks.
Were any leaks found?

Yes. Repair or replace the leaking component as necessary.

No. Go to step 3.

Step 3. Pressure test the surge tank cap. Does the cap hold the correct pressure?

Yes. Go to step 4.
No. Replace the cap as necessary.

Step 4. Check the operation of the engine cooling fan and related components. Does the cooling fan
operate properly?

Yes. Go to step 5.
No. Repair or replace the cooling fan or related components as necessary.

Step 5. Pressure test the cooling system and check the engine components for signs of leaks. Are any
leaks found?

Yes. Go to step 6.
No. Go to step 9.

Step 6. Is the external leak found between the cylinder block and the cylinder head joint?

Yes. Remove the cylinder head and go to step 7.

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6/13/24, 1:36 PM Diesel Repair

No. Find the source of the leak and repair or replace the component as necessary.

Step 7. Check the cylinder head gasket grommets for damage. Are the grommets damaged?

Yes. Replace the cylinder head gasket as necessary.

No. Go to step 8.

Step 8. Inspect the cylinder liners for scuffs. Are any liners scuffed?

Yes. Replace the liner as necessary.

No. Pressure test the cylinder block to check the cylinder liner upper O-rings and replace the liner or
O-rings if leakage is found.

Step 9. Check the Diesel Exhaust Fluid (DEF) for contamination. Is the DEF contaminated with coolant?

Yes. Replace the DEF tank header assembly and flush the tank and system.
No. Go to step 10.

Step 10. Check the oil for contamination. Is there coolant in the lubricating oil?

Yes. Perform troubleshooting steps for coolant in lubricating oil.

No. Go to step 11.

Step 11. Check the fuel for contamination. Is there coolant in the fuel?

Yes. Perform troubleshooting steps for coolant in fuel.

No. Go to step 12.

Step 12. Pressure test the Exhaust Gas Recirculation (EGR) cooler. Is the cooler leaking coolant?

Yes. Replace the EGR cooler as necessary.

No. Release the vehicle if all other steps have been taken with no resolution. Monitor the coolant
consumption and verify the system is not being overfilled.

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