2016 cascadia coolant in fuel and fuel in cooling system

Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by devindell327, Nov 29, 2019.

  1. devindell327

    devindell327 Bobtail Member

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    I have a 2016 cascadia with a dd15 engine in it.
    This truck has 650,000 miles on it.
    Driver gets a light on dash for water in fuel.
    Had fuel and water fuel separator filters changed, ended with the same result again.
    Engine shut down and has since had injector cups replaced, and fuel system cleaned from tanks to lines and all.
    We get the truck running again and now it is getting fuel in the cooling system as well as coolant in the fuel.
    Any help would be greatly appreciated.
     
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  3. magoo68

    magoo68 Road Train Member

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    Does it have a heated fuel filter.. if so I’d bypass that for now to see if that’s the problem.
     
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  4. devindell327

    devindell327 Bobtail Member

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    How would i determine if it has heated fuel filter?.
     
  5. QUALITYTRUCK

    QUALITYTRUCK Road Train Member

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    Injector cup o rings. Common issue on DD15.
     
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  6. devindell327

    devindell327 Bobtail Member

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    Already replaced them, now the fuel is getting into the cooling system as well as coolant into the fuel.
    I have talked to several people who say that the filter housing could be cracked internally letting this happen.
     
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  7. QUALITYTRUCK

    QUALITYTRUCK Road Train Member

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    DD15 injector cup o rings are a PIA to replace correctly. The o ring has to be placed in the head and carefully tucked under a lip with a 90 degree pick tool. They are not placed on the cup prior to screwing or swedging the cup into the head. It is difficult every time we do it, especially on #5/#6 where it is hard to see what you are doing.
     
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  8. devindell327

    devindell327 Bobtail Member

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    We replaced them it took us 1 day to do the job, replaced all o-rings, cups and injector orings.
    Ran it two hours to see what happened.
    Truck ran fine until it sat for 2 days, then crank truck and it shuts down with wif light on again after sitting for 2 whole days engine off.
     
  9. QUALITYTRUCK

    QUALITYTRUCK Road Train Member

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    Same answer as before. I do this for a living and make mistakes while "fixing" stuff. If you are confident that there is no way that you made a mistake while installing then I am out of ideas and wish you the best of luck in getting your issue resolved.
     
    Last edited: Nov 30, 2019
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  10. devindell327

    devindell327 Bobtail Member

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    Could it possibly be bad o-rings or cracked fuel filter housing?.
     
  11. magoo68

    magoo68 Road Train Member

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    Maybe I’m wrong but I thought injector cups mostly leak into the oil ??
     
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