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NHTSA ID Number: 10201100
Manufacturer Communication Number: 08-06-04-003D
Summary
New Tool Availability – EN-48974-EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber
133 Affected Products
Vehicles
MAKE | MODEL | YEAR |
CHEVROLET | C4500 | 2004-2009 |
CHEVROLET | C5500 | 2004-2008 |
CHEVROLET | EXPRESS | 2006-2016 |
CHEVROLET | SILVERADO 1500 | 2002-2016 |
CHEVROLET | SILVERADO 2500 | 2002-2016 |
CHEVROLET | SILVERADO 3500 | 2002-2016 |
GMC | SAVANA | 2006-2016 |
GMC | SIERRA 1500 | 2002-2016 |
GMC | SIERRA 2500 | 2002-2016 |
GMC | SIERRA 3500 | 2002-2016 |
GMC | TOPKICK | 2004-2013 |
An EGR Cooler Pressure Tester Adapter Set, EN-48974, was shipped essential to dealers in December 2007 to diagnose EGR cooler engine coolant leaks on all Duramax™ engines equipped with an EGR system. This adapter set is designed to be used with J-46091-1 – Charge Air Cooler Tester Regulator to pressurize the EGR cooler with shop air and monitor it for leakage.
Important: Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers on the right bank cylinders. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for coolant in the combustion chamber.
SEOCONTENT-START
Bulletin No.: 08-06-04-003D
Date: Dec-2015
Subject: New Tool Availability — EN-48974 – EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax®
Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber
Models: 2002-2016 Chevrolet Silverado
2004-2009 Chevrolet Kodiak C4500-C5500 Series
2006-2016 Chevrolet Express Vans
2002-2016 GMC Sierra
2004-2009 GMC TopKick C4500-C5500 Series
2006-2016 GMC Savana Vans
Equipped with 6.6L Duramax™ Diesel Engine (VINs 1, 2, D, 6, L, 8 – RPOs LB7 (CA Emissions), LLY, LBZ,
LMM, LML, LGH)
Please Refer to GWM/IVH
Attention: The graphics contained in this bulletin for clarity show the EGR cooler connections to J-46091 and EN-
48974 on a workbench. The connections are the same with on-vehicle service. This Bulletin also applies to
any of the above models that may be Export vehicles.
This Bulletin has been revised to add the 2016 Model Year. Please discard Corporate Bulletin Number 08-06-04-003C.
An EGR Cooler Pressure Tester Adapter Set, EN-48974, was shipped essential to dealers in December 2007 to diagnose EGR cooler engine coolant leaks on
all Duramax™ engines equipped with an EGR system. This adapter set is designed to be used with J-46091-1 – Charge Air Cooler Tester Regulator to
pressurize the EGR cooler with shop air and monitor it for leakage.
Important: Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers on the right
bank cylinders. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for coolant in the combustion chamber.
EN-48974 — EGR Cooler Pressure Tester Adapter Set
1. 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps
2. EN-48974–3 (Qty 1) 19 mm (3/4 Inch) EGR Cooler Hose Adapter
3. EN-48974–4 (Qty 1) 19 mm (3/4 Inch) Cap Plug
1
4. EN-48974–1 (Qty 1) 15.9 mm (5/8 Inch) EGR Cooler Hose Adapter
5. EN-48974–2 (Qty 1) 15.9 mm (5/8 Inch) Cap Plug
6. 544258 (Qty 2) 15.9 mm (5/8 Inch) Hose Clamps
In December 2010 another supplement to the EGR Cooler Pressure Tester Adapter Set, EN-48974-20, was shipped essential to dealers to diagnose EGR
cooler engine coolant leaks on all 2010-2011 Duramax™ 6.6L engines equipped with multiple cooler EGR system. This supplement gives the test adapter set a
larger variety of sizes to accommodate the newer style coolers that have multiple ports.
EN-48974-20 — EGR Cooler Pressure Tester Adapter Set
1. EN-48974–21 (Qty 1) 12.7 mm (1/2 Inch) EGR Cooler Hose Adapter
2. EN-48974–22 (Qty 1) 8 mm (5/16 Inch) EGR Cooler Hose Adapter
3. 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps
4. 553016 (Qty 1) 12.7 mm (1/2 Inch) Cap Plug
5. 544258 (Qty 3) 15.9 mm (5/8 Inch) Hose Clamps
6. 553015 (Qty 1) 8 mm (5/16 Inch) Cap Plug
7. 553017 (Qty 1) 22.2 mm (7/8 Inch) Cap Plug
Important: If an investigation of loss of engine coolant leads to coolant found in one or multiple cylinders on the right bank, YOU MUST test the EGR cooler
for leakage BEFORE attempting any engine repair. The cylinders affected will depend on which exhaust valves were open at the time of engine shutdown.
1. Partially drain the engine coolant to allow removal of the EGR cooler coolant hoses. Refer to Cooling System Draining and Filling in SI.
2. Select the appropriate size EGR Cooler Hose Adapter from the EN-48974 – EGR Cooler Pressure Tester Adapter Set.
3. Install the EGR Cooler Hose Adapter (1) and tighten the clamp (2) on the EGR cooler hose barb as shown.
4. Select the appropriate size Cap Plug(s) from the EN-48974 – EGR Cooler Pressure Tester Adapter Set.
2
5. Install the Cap Plug(s) (1) and tighten the clamp(s) (2) on the EGR cooler hose barb(s) as shown.
6. Connect the hose fitting (1) of pressure tester J-46091-1 Charge Air Cooler Tester Regulator to the EGR Cooler Hose Adapter (2) on the EGR cooler
as shown.
Important: SOME J-46091-1 REGULATORS MAY BE PRESET AT 30 PSI WITH THE ADJUSTING KNOB RIVETED IN PLACE. THE RIVET HEAD
MUST BE DRILLED OUT WITH A 5/16” DRILL BIT BEFORE ADJUSTMENT. DO NOT DRILL MORE THAN 1/8” IN DEPTH, OR JUST ENOUGH TO
REMOVE THE RIVET HEAD. THE RIVET SHAFT DOES NOT HAVE TO BE REMOVED FROM THE REGULATOR.
7. Back off the regulator on J-46091-1 – Charge Air Cooler Tester Regulator by turning counterclockwise until it stops.
8. Connect J-46091-1 – Charge Air Cooler Tester Regulator to the shop air supply.
9. Open the shutoff valve, then slowly turn the regulator on J-46091-1 clockwise until the gauge reads 42 psi.
10. Close the shutoff valve on J-46091-1 and monitor the gauge for pressure decay for 5 minutes.
⇒ If the gauge indicates pressure decay, replace the EGR cooler.
⇒ If the gauge does not indicate pressure decay, proceed to Step 11.
11. Continue performing the engine diagnosis to determine the source of the coolant leak.
12. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve and Cooler Installation in SI.
13. Fill the engine coolant to the proper level. Refer to Cooling System Draining and Filling in SI.
SEOCONTENT-END
1 Associated Document
Manufacturer Communications
Bulletin No.: 08-06-04-003D
Date: Dec-2015
https://www.nhtsa.gov/recalls?nhtsaId=10201100
MC-10201100-9999.pdf 668.174KB
NHTSA ID Number: 10190379
Manufacturer Communication Number: 08-06-04-003D
Summary
New Tool Availability EN-48974 EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax® Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber
NHTSA ID Number: 10056354
Manufacturer Communication Number: SB-080604003-C
Summary
GMC/CHEVROLET: ENGINES, WITH EGR SYSTEM, HAS LEAKAGE FROM EGR COOLER ENGINE COOLANT INTO THE COMBUSTION CHAMBER. MODEL 2002-15 SILVERADO, SIERRA, 2004-09 KODIAK C4500-C5500, TOPKICK C4500-C5500, 2006-15 EXPRESS, SAVANA. *PE
1 Associated Document
Service Bulletin Document
Bulletin No.: 08-06-04-003C
Date: September, 2014
https://www.nhtsa.gov/recalls?nhtsaId=10056354
SB-10056354-3195.pdf 685.405KB
NHTSA ID Number: 10138703
Manufacturer Communication Number: 08-06-04-003C
Summary
This informational bulletin advises of a new testing tool for EGR cooling pressure tester.
1 Associated Document
Manufacturer Communications
Bulletin No.: 08-06-04-003C
Date: September, 2014
https://www.nhtsa.gov/recalls?nhtsaId=10138703
MC-10138703-9999.pdf 598.182KB
“This site contains affiliate links for which OEMDTC may be compensated” |
- PULL HARDER , IMPROVE MPG & KEEP YOUR MOTOR HEALTHY --BY ELIMINATING TURBO BOOST LEAKS! It is good practice to pressure test any new CAC before install to ensure it is leak free and avoiding removal and re-installation. INCLUDES THE SIZES YOU REALLY NEED FOR TESTING HD TRUCKS CAC INTERCOOLERS 4", 3.5" AND 3". ANTI-SLIP GROOVES AND BEAD SOLID 6061 BILLET ALUMINUM 5FT EXTENSION LINE W 150 PSI REGULATOR PREMIUM COMPONENTS
- TOW WITH CONFIDENCE AND SAVE ON FUEL! Avoid a Test your truck for leaks the correct way, fix any boost leaks, and keep the motor running healthy. Even picking up 1/2 or 1 MPG over thousands of miles can convert to significant savings every week and keep the motor happier
- DESIGNED FOR YOUR SAFETY - Each step has grooved rings to grip the intercooler hoses better when clamped down. Also an Integrated pressure relief valve for accidental excessive pressure. Premium AR2000 150 PSI Air pressure Regulator
- ENGINEERED FOR PRECISION TESTING - This Charge Air Cooler tester kit is designed to fit into the flexible hoses on each side of your CAC and isolate it for a pressure test up to 60 PSI. The two billet end caps have 4", 3.5", and 3" steps. The 5 ft. extension line kit comes with an air pressure on/off valve, 150 pressure regulator to safely and accurately drop the source pressure down to a reasonable level, and allow you to check the intercooler for leaks
- Comprehensive Kit for HD Trucks: What's included in this kit: (2) 6061 CNC machined end caps with 4", 3.5", and 3" steps that will fit a variety of class 7 and class 8 HD Trucks. Includes 60 PSI mounted boost gauges, 5ft Extension hose Stainless Steel shut-off Ball Valve and 150 PSI air pressure regulator - Uses 1/8" and 1/4" NPT on all connections. M-type compressor fittings.
- Plugs the output of the turbo and the intake inlet.
- Air and smoke are applied through one adapter to show the presence of leaks within the system.
- Features a pressure gauge, Shu off valve and pressure regulator and includes six pairs of stepped adapters to fit most turbo systems on cars and light trucks
- Can also be used on some cooling system hoses.
- OTC's Charged Air Cooler Tester is the easy way to find air leaks in charged air cooler systems
- For use on class 7 and 8 truck engines
- Large, easy to read 2-1/2 inch pressure gauge reads 0-60 PSI
- Kit includes regulator, relief valve, and two safety cables
- Quick disconnect air fittings attach to 3 inch, 3-1/2 inch, or 4 inch cooler hoses
- 【Operating Principle】 - The turbocharger leak detector kit is used to diagnose air leaks in the turbocharger system by blocking the outlet and inlet ports of the turbocharger.
- 【4 Pairs of Stepped Adapters】 -Our air pressure leakage tester comes with 4 pairs of stepped adapters, including 35, 40, 45 mm (1.38'', 1.57'', 1.77''), 50, 55, 60 mm (1.97'', 2.17'', 2.36''), 65, 70, 75 mm (2.56'', 2.76'', 2.95''), 80, 85, 90 mm (3.15'', 3.35'', 3.54''). Fits for turbo chargers of most vehicles.
- 【Convinient to Use】 - Connect the tool to the adapter and your workshop air. It is easy to find the leaks position. The tester should be used with your workshop air and smoke machine.
- 【 Warm Note】 - View the manual about the maximum air pressure of the turbo charger or other system being tested. Over pressurisation may damage the turbo components. The pressure gauge with shut off valve & regulator to help prevent over pressurisation.
- 【Packing List】 - The air leak tester kit includes pressure gauge with a shut off ball valve, a pressure release valve, air coupling and air inlet, 4 pairs of stepped adapters(35mm - 90mm), totally 9 pieces in a plastic suitcase.
- Troubleshooting Turbo Leaks: if you have a turbo-charged car, leaks can develop in the system. If you have any leaks in the turbo system, you will have a loss of boost pressure and a subsequent loss of power. and this turbo pressure testers kit are specially design to check turbo system leaks or cooling systems pipe, help you easy to troubleshoot turbo leak, and find the leak location
- Fit Most Turbo Vehicle: This turbo system leakage tester kit include 4 pairs stepped stoppers, use to block up intake hose and exhaust hose. The multiple sizes allows for fitting several size hoses, they can work on 1.38''-3.54'' diameter hose, the detail size are 35, 40, 45 mm (1.38'', 1.57'', 1.77''); 50, 55, 60 mm (1.97'', 2.17'', 2.36''); 65, 70, 75 mm (2.56'', 2.76'', 2.95''); 80, 85, 90 mm (3.15'', 3.35'', 3.54'')
- With Pressure Guage Tester: with a 0-6 bar(0-87 psi) pressure guage, it could precise measurement the pressure inside the hose, included pressure regulator, press down it means lock, when you need adjust pressure, you need pull up it and rotate. and a red manual valve to control air pressure on and off; you can pull the red excess pressure release valve to reduce air pressure if over pressurisation
- Easy To Check Turbo System Leaks: Make stoppers plugged hose intake and exhaust , use regulator connect stoppers and air compressor, pressurize the turbo system, once pressurized you can see the guage if holding pressure and hear any leaks
- Tips: Best to use with an air compressor with a holding tank; not over pressurization, because over pressurization can damage the components of the engine
- Restore power and lost fuel economy
- Premium Components including billet aluminum end caps
- 【Premium Quality】Made of quality silicone, the appearance is smooth and flat. It has excellent oxidation resistance, high temperature resistance, corrosion resistance, is not easy to wear and crack, and has a long service life. All items undergo strict quality inspection to ensure their integrity, quality stability, and reliability.
- 【Replaces The Following Part Number】DynaFlex: 202-36-2042, Flexfab: FLX7715-0002, Purosil: 367-400-060, Gav: 7715-0002. We kindly request that you verify the hose dimensions in order to assess compatibility.
- 【Specification】Temperature Range: -40 F to +392 F, Max Pressure: 100 psi, Layers: 4-Ply Polyester Reinforced, Thickness: 0.2'' (5 mm), Number of Rings: 3.
- 【Easy to Install】Standard size specifications, perfect fit and easy to install. Paired with 304 stainless steel T-bolt tension clamps for a secure, self-locking nuts to prevent any loosening.
- 【What You Get】ASKALL have friendly customer service and comprehensive after-sales service.
- The turbo system leakage tester helps locate air leaks in the components by plugging the output side of the turbo and plugging the intake inlet
- Air is applied through one end of the adapter to show the presence of leaks within the system
- Kit features a pressure gauge, shut off valve and pressure regulator
- Comes with 6 pairs of stepped adapters to fit most size hoses
- This setup can also be used on cooling system hoses. WARNING: Injury could occur if system is over pressurized - We Recommend NOT exceed 15 PS
- Pressure regulates shop air to test any cooling system or radiator cap for leaks
- Quick connector works on nearly all brands of cooling system testing caps and adapters
- Fills even large cooling system almost instantly, and provides constant pressure on leaks to trace their source
- Gauge displays the common pressures levels for different cooling systems and regulator will max at 30psi to prevent damage
- Allows you to quickly and easily diagnose leaks and other cooling system issues.Fit Type: Universal
- Includes 17color-coded adapters and 3 test caps to fit most import and domestic vehicles
- Includes vacuum purge and refill tools to prevent air intrusion and eliminate cooling system bleeding time
- Working pressure of 0-35 psi
- Mishimoto Lifetime Warranty
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