NHTSA ID Number: 10189088
Manufacturer Communication Number: 0801-17
TSB/Document Date: 2021-03-15
Summary
0801-17 Symptom Diagnostics: Coolant Loss
08 01-17
1
08 01-17
SUBJECT
DATE
Symptom Diagnostics
August 2017
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0084
DDC-SVC-MAN-0191
Platform
Section Title
Change
DD Heavy
Duty
Coolant Loss
Updated HD diagnostic procedures.
All information subject to change without notice.
08 01-17
Copyright © 2017 DETROIT DIESEL CORPORATION
3
2 Symptom Diagnostics - Coolant Loss
2
Symptom Diagnostics - 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. No coolant needs 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.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Are any Original Equipment Manufacturer (OEM) components leaking coolant externally?
a. Yes; inspect the vehicle for the source of the coolant loss and consult OEM procedures for repair instructions.
b. No; Go to step 2.
2. Inspect the vehicle for any aftermarket components plumbed into the cooling system. Are there any aftermarket
components plumbed into the cooling system on the vehicle?
a. Yes; Go to step 3.
b. No; Go to step 4.
3. Inspect the aftermarket components; refer to OEM guidelines. Are aftermarket components the source of coolant loss?
a. Yes; repair as necessary.
b. No; Go to step 4.
4. Pressure test the surge tank cap(s). Do the cap(s) hold the correct rated pressure?
a. Yes; Go to step 5.
b. No; repair as necessary.
5. Check engine coolant fan operation. Does the fan function correctly?
a. Yes; Go to step 6.
b. No; repair as necessary.
4
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 01-17
08 01-17
6. Pressure test the cooling system and inspect for coolant leaks. Is the engine leaking coolant externally?
a. Yes; Go to step 7.
b. No; Go to step 10.
7. Is the external leak at the cylinder head to cylinder block joint?
a. Yes; remove the cylinder head.
For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly"
For DD15/16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly"
Go to step 8.
b. No; inspect the engine for the source for the coolant leak and make the repair.
8. Is the vehicle equipped with a GHG14 engine?
a. Yes; Go to step 9.
b. No; Go to step 11.
9. Inspect the cylinder head gasket coolant grommet(s) for damage. Are the grommet(s) damaged?
a. Yes; replace the cylinder head gasket.
b. No; Go to step 10.
10. Inspect the cylinder liner for cracks that would lead to coolant loss. Refer to section "Inspection of the Cylinder
Liner". Are the liners cracked?
a. Yes; replace the cracked liner(s). Refer to section "Removal of the Cylinder Liner".
b. No; test the cylinder liner upper O-ring. Refer to section "Testing of the Cylinder Liner Upper O-Ring".
11. Inspect the cylinder head gasket coolant grommet(s) for damage. Are the grommet(s) damaged?
a. Yes; replace the cylinder head gasket. Go to step 12.
b. No; Go to step 12.
12. Inspect the cylinder liner for cracks that would lead to coolant loss. Refer to section "Inspection of the Cylinder
Liner". Are the liners cracked?
a. Yes; replace the cracked liner(s), Refer to section "Removal of the Cylinder Liner" and test the cylinder liner
upper O-ring, Refer to section "Testing of the Cylinder Liner Upper O-Ring".
b. No; test the cylinder liner upper O-ring, Refer to section "Testing of the Cylinder Liner Upper O-Ring".
13. Is the vehicle equipped with an EPA07 engine?
a. Yes; Go to step 15.
b. No; Go to step 14.
14. Is there coolant contamination in the Diesel Exhaust Fluid (DEF)?
a. Yes; replace the DEF tank header assembly. Select the proper tank:
Refer to section "Removal of the EPA10 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit"
Refer to section "Removal of the GHG14 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit"
Refer to section "Removal of the GHG14 Six-Gallon Diesel Exhaust Fluid Tank Header"
b. No; Go to step 15.
15. Is there coolant contamination in the oil?
a. Yes; Refer to section "Coolant in Oil".
b. No; Go to step 16.
16. Is there coolant contamination in the fuel?
a. Yes; Refer to section "Fuel in Coolant/Coolant in Fuel".
b. No; Go to step 17.
17. Pressurize the cooling system; refer to OEM guidelines. Does the cooling system pass the pressure test?
a. Yes; Go to step 19.
b. No; Go to step 18.
18. Remove the EGR hot pipe and inspect for signs of coolant contamination. Is coolant contamination present?
a. Yes; replace the EGR cooler. Verify repairs.
Refer to section "Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly"
Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler"
b. No; Go to step 19.
19. Pressure test the Exhaust Gas Recirculation (EGR) cooler. Does the EGR cooler pass testing and inspection?
Refer to section "Testing of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly - In Chassis"
Refer to section "Testing of the DD15 and DD16 Exhaust Gas Recirculation Cooler - In Chassis"
All information subject to change without notice.
08 01-17
Copyright © 2017 DETROIT DIESEL CORPORATION
5
2 Symptom Diagnostics - Coolant Loss
a. Yes; Go to step 20.
b. No; replace the EGR cooler.
For DD13, Refer to section "Installation of the DD13 EGR Cooler Water Manifold Assembly"
For DD15/16, Refer to section "Installation of the DD15 and DD16 Exhaust Gas Recirculation Cooler"
20. Inspect the air system for the presence of coolant. Is coolant present?
a. Yes; replace the air compressor.
b. No; release the vehicle and monitor coolant consumption During normal operation, the coolant level will
expand and contract. Overfilling the coolant reservoir will cause the surge tank to push coolant out.
6
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 01-17
08 01-17
3
Symptom Diagnostics - 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. No coolant needs 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.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Are any Original Equipment Manufacturer (OEM) components leaking coolant externally?
a. Yes; inspect the vehicle for the source of the coolant loss and consult OEM procedures for repair instructions.
b. No; Go to step 2.
2. Inspect the vehicle for any aftermarket components plumbed into the cooling system. Are there any aftermarket
components plumbed into the cooling system on the vehicle?
a. Yes; Go to step 3.
b. No; Go to step 4.
3. Inspect the aftermarket components; refer to OEM guidelines. Are aftermarket components the source of coolant loss?
a. Yes; repair as necessary.
b. No; Go to step 4.
4. Pressure test the surge tank cap(s). Do the cap(s) hold the correct rated pressure?
a. Yes; Go to step 5.
b. No; repair as necessary.
5. Check engine coolant fan operation. Does the fan function correctly?
a. Yes; Go to step 6.
b. No; repair as necessary.
All information subject to change without notice.
08 01-17
Copyright © 2017 DETROIT DIESEL CORPORATION
7
3 Symptom Diagnostics - Coolant Loss
6. Pressure test the cooling system and inspect for coolant leaks. Is the engine leaking coolant externally?
a. Yes; Go to step 7.
b. No; Go to step 10.
7. Is the external leak at the cylinder head to cylinder block joint?
a. Yes; remove the cylinder head.
For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly"
For DD15/16, Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly"
Go to step 8.
b. No; inspect the engine for the source for the coolant leak and make the repair.
8. Inspect the cylinder head gasket coolant grommet(s) for damage. Are the grommet(s) damaged?
a. Yes; replace the cylinder head gasket.
b. No; Go to step 9.
9. Inspect the cylinder liner for cracks that would lead to coolant loss. Refer to section "Inspection of the Cylinder
Liner". Are the liners cracked?
a. Yes; replace the cracked liner(s), Refer to section "Removal of the Cylinder Liner".
b. No; test the cylinder liner upper O-ring, Refer to section "Testing of the Cylinder Liner Upper O-Ring".
10. Is there coolant contamination in the Diesel Exhaust Fluid (DEF)?
a. Yes; replace the DEF tank header assembly. Select the proper tank:
Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit".
Refer to section "Removal of the Six-Gallon Diesel Exhaust Fluid Tank Header".
b. No; Go to step
11. Is there coolant contamination in the oil?
a. Yes; Refer to section "Coolant in Oil".
b. No; Go to step 12.
12. Is there coolant contamination in the fuel?
a. Yes; Refer to section "Fuel in Coolant/Coolant in Fuel".
b. No; Go to step 13.
13. Pressurize the cooling system; refer to OEM guidelines. Does the cooling system pass the pressure test?
a. Yes; Go to step 15.
b. No; Go to step 14.
14. Remove the EGR mixer pipe and inspect for signs of coolant contamination. Is coolant contamination present?
a. Yes; replace the EGR cooler. Verify repairs.
Refer to section "Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly".
Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler".
b. No; Go to step 15.
15. Pressure test the Exhaust Gas Recirculation (EGR) cooler. Does the EGR cooler pass testing and inspection?
Refer to section "Testing of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly - In Chassis"
Refer to section "Testing of the DD15 and DD16 Exhaust Gas Recirculation Cooler - In Chassis"
a. Yes; Refer to section "Testing the Upper Liner O-Ring".
b. No; replace the EGR cooler.
For DD13, Refer to section "Installation of the DD13 Exhaust Gas Recirculation Cooler Water Manifold
Assembly".
For DD15/16, Refer to section "Installation of the DD15 and DD16 Exhaust Gas Recirculation Cooler".
16. Inspect the air system for the presence of coolant. Is coolant present?
a. Yes; replace the air compressor.
b. No; release the vehicle and monitor coolant consumption During normal operation, the coolant level will
expand and contract. Overfilling the coolant reservoir will cause the surge tank to push coolant out.
8
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 01-17
- Formulated to replace the OEM fluid in Asian make vehicles...
- 5 year/150, 000 mile . Silicate-free, long-life, phosphate...
- The long life formula provides protection for all cooling...
- Meets the following OEM and industry specifications: JIS K...
- Note: Please check the vehicle specification before...
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: 0801-17
Replacement Service Bulletin Number:
MFR Communication Date: 2017-08-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln
. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase - OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.