Recall on record for this model family
- NHTSA 11V207000 (ENGINE): C15 combustion-tube weld may burn through — fire (Cat 11E-006) confirmed — official notice
- NHTSA 09V366000 (ENGINE): C15 variable-valve-actuation oil line may rub P-clips → oil leak → fire (Cat 09E-020) confirmed — official notice
Verify the unit's serial number against the official notice before purchase.
Last verified against the primary source on Sep 11, 2026.
The C15 regularly exceeds 800,000 miles before overhaul when maintained — but Caterpillar stopped building on-highway engines in 2009, so every C15 in a used truck is pre-2010 and NOT California-registerable without a DPF retrofit/engine replacement. The big-ticket repairs: injectors $4k–$6k, turbo $3k–$5k, and an overheat that cracks a head can run $15k–$25k. Two C15-specific NHTSA fire recalls are on record.
Confidence 60%Comparable set not yet verified
As of Not yet verifiedWhat can make the cheap machine expensive?
| Component | Severity | Documented repair cost |
|---|---|---|
| Fuel injectors | high | $4,000–$6,000 |
| Turbocharger bearing | high | $3,000–$5,000 |
| EGR valve clogging | medium | not yet verified |
Contaminated fuel destroys injectors — a set of eight costs $4,000–$6,000. Check fuel-system service history and injector condition.
$4,000–$6,000Turbo bearing damage costs $3,000–$5,000 to repair. Check for boost lag, oil in the charge pipe, and shaft play; boost should read 25–30 PSI under load.
$3,000–$5,000Overheating a Cat C15 or C13 can crack cylinder heads or warp the block — repairs that cost $15,000–$25,000. Cooling hoses should have no soft spots or cracks; the temp gauge should not read above 210°F consistently; watch for coolant leaks or white smoke at startup.
$15,000–$25,000Clean or replace the EGR valve every 150,000 miles to prevent performance problems on ACERT units.
Cost not yet verifiedCommon questions
What fails on the Caterpillar C15?
The most cited concerns in our evidence record: Fuel injectors, Turbocharger bearing, Overheating → cracked head / warped block. See the risk breakdown above for details and sources.
Is the Caterpillar C15 under recall?
A safety recall exists for this model family — verify the unit's serial number against the official notice linked on this page before buying.
From the research record
- REPAIR PART (Cat C15 injectors, set of 8): $4,000–$6,000. "Contaminated fuel destroys injectors - a set of eight injectors costs $4,000–$6,000." (Skyliner Cat legacy guide, fetched 2026-09-11) https://skylinerrepaircenter.com/blog/caterpillar-truck-engines-legacy-maintenance-guide
- REPAIR PART (Cat C15 turbocharger bearing repair): $3,000–$5,000. "This prevents turbo bearing damage that costs $3,000–$5,000 to repair." (same guide)
- REPAIR PART (Cat C15 cracked head / warped block from overheat): $15,000–$25,000. "Overheating a Cat C15 or C13 can crack cylinder heads or warp the block - repairs that cost $15,000–$25,000." (same guide)
- REPAIR PART (Cat C15 water pump): $800–$1,200. "A water pump replacement runs $800–$1,200 in parts and labor." (same guide)
- LIFE: "Properly maintained Cat C15 and C13 engines regularly exceed 800,000 miles before major overhaul." (same guide)
- RECALL (PRIMARY, NHTSA, verbatim): 11V207000 — "MODEL YEAR 2008-2010 WESTERN STAR 4900 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINES... DEGRADATION OF A COMBUSTION TUBE WELD... MAY BURN THROUGH CERTAIN BODIES USED ON C15 ENGINES." 09V366000 — "MODEL YEAR 2004-2010 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINE. THE VARIABLE VALVE ACTUATION OIL LINE MAY RUB AGAINST THE P-CLIPS RETAINING THE OIL LINE, CAUSING AN OIL LEAK." Both consequence: fire. https://api.nhtsa.gov/recalls/recallsByVehicle?make=western%20star&model=4900&modelYear=2010
- CARB (SECONDARY): "Caterpillar stopped building on-highway truck engines in 2009." Every used-truck C15 is pre-2010 → not CARB-registerable in CA without retrofit/replacement; C15s are the classic glider-kit engine ("strictest requirements regardless of chassis year"). https://www.skylinerrepaircenter.com/blog/carb-regulations-for-trucks-even-if-you-don-t-drive-in-california
Sources
- Caterpillar Truck Engines Legacy Maintenance Guideweb · research-cited · accessed 2026-09-11
- NHTSA recalls by vehicle — Western Star 4900official · verified-official · accessed 2026-09-11
- CARB Regulations for Trucksweb · research-cited · accessed 2026-09-11
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