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Cummins Internal Evans Coolant leak.

I have a coolant leak on a cummins ISX485 in a 2009 KW T660. The leak started in january of last year.

It was going through a qt a day at first. I would top it off in the morning after setting all night with the eng. off. As it got worse I took it to the local cummins dealer on 3/29/12. They could not get it to leak so we tried enj. cup o-rings this did not fix the problem. I p/u the truck on 4/6/12 went 45 miles to the house. Got up the next day and it was low on coolant. Took it back to get the EGR cooler replaced. I pick it up on 4/9/12 left the shop on a run. I got up the next day and had low coolant level. So far nothing has changed the coolant problem. I drove the truck for a another ten days. Took it off the road hoping it was a blown head gasket. I got the head off on 5/16/12. It was sent to a machine shop were they found two crack enj. cups. The head was checked for cracks and recon'd. After the head was put back on around 5/24/12 I drove the truck for a total of 400 miles over a weeks time around the house. I had no singes of a leak. The truck set till 10/1/12 then it was drove 70 miles and parked every thing was still good. The truck was drove a cuppel of times for a total of 30 miles still know problems. I went to pick the truck up on 3/7/13. I called 1hr head so the truck would be warmed up when I got there. They said that it was low on coolant. I left with the truck and drove it 70 miles. the next day it was 3/4 of a gallon low on coolant and the crank case breather filter light was going off. I pulled the filter out and it was covered with coolant. This was not the first time for this. I had to change it thru this whole process. This one was new when the head was put back on. I put a knew one on the truck. I left the house on 3/10/12 bob tailing. Then 350 miles later the crank case filter light was going off. This one was in the same shape as the last one. It was also low on coolant about a QT. I went about 75 miles more packed for the night. Got up the next morning and it was about a 1/2 gal. low. Drove for another 350 mils that day adding 2QT of water. Parked the truck over night. The next morning it was at least 1gal. or more low. Put it in a shop in the area. They have pulled a oil sample and found the there is 150 to 200 ppm of sodium in the oil. This oil only has 1300 miles on it. It had 2456 ppm sodium when I pulled the head off with 71443 miles on the oil. The sample before that was 33 ppm with 45801 miles on it. The shop has pulled the pan off and pressurized the cooling system looking for a liner leaking with no luck. They pressurized the cooling system up to 15psi and let it set for 24 hours with know leak found. I should say that I had the coolant conversion done in cookeville TN. on 7/5/09. Up till 1/2012 I had no problems.

Any help would be great

Answer this question I have this problem too

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It's not the coolants fault. Like I said I ran Evans for 2 1/2 years with no leaks.

Besides I'v had eng. with coolant leaks that never had Evans in them. I'm looking for help finding the leak not running down the coolant.

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I wish I could tell you where the problem is but I had the same problem with a Detroit running Evans Coolant by time they got the problem fix the Evans coolant ended up costing me total of 24,000 dollars in repairs. Needless to say I don't have Evans coolant in motor anymore.

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I also ran the Evans for about 23 months and it was the cause of my problems I replaced 4 cracked heads 2 EGR Coolers and 1 Air Compressor head that cracked and since then went back to running Antifreeze 9 months ago I haven't even been in the shop. That cracked air compressor head was the hard one to find cause there was no signs of a problem other than using about quart of coolant every 2 days and no signs of it.

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Where was the coolant going in the air compressor did you find out. It would help me to know.

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What it was doing was letting just enough air pressure into the cooling system that it would push it out the over flow tube and never could find a trace of it sense it was such a small amount of coolant. I had talk to Bendix and they said that it could do this but normally you would find some coolant in the air tanks which I never did find any and that was a year ago and I finally got tired of spending money on trying to find the problem and putting a quart coolant in every 2 days and I was fairly sure it was the air compressor sense everything else had been replaced even though Detroit shop didn't think it was the air compressor but I had them change it out anyway and sure enough that took care of the problem I haven't added any coolant.

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Ok,

Well I'm still getting it in the oil.

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I know you've replaced the head and EGR cooler but I had replaced these same parts and took it out on a trip and stilled lost coolant I got back home and had to put another head on it cracked that fast. Those heads and EGR coolers that had to replaced didn't start having a problem till I had the Evans in the motor for 16 months then with in 7 months time frame I put 4 heads 2 EGR coolers on this motor I am guessing either the EGR cooler or the head is your problem again. Have you checked to see if you have combustion gases in the coolant?

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With that kind of coolant loss if it was coming from a oil cooler I would expect the oil to have a white tint to it plus the oil level would be rising and if its coming from EGR cooler or head it would be burning the coolant so the oil would look normal and the level would be normal.

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I found out the head was cracked on CYL. #4. AIS the head shop in MI. retested the head for warranty prepossess on the work they did last year. They found the crack a 1/4 to 3/8 of a inch in from the intake seat and it went half way around the intake port. They do 4-6 cummins heads a week and only came across this same type of crack once and it was last weak. I got a full refund on the work they did and on the head gasket set I bought. Cummins in the Twin Cities in MN. found the leak and R/R the head under warranty.

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You will get all the informations that you need here: https://www.tradebit.com/filedetail.php/...

Will help you a lot because there you will find all wiring diagrams, and repair procedures that you need.

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