NHTSA ID Number: 10186932
Manufacturer Communication Number: SB09-J-002F
Summary
AN EGR COOLER TESTER WAS PROVIDED TO DEALERS IN JUNE 2009 TO DIAGNOSE EGR COOLER LEAKS ON ALL ISUZU
DIESEL ENGINES EQUIPPED WITH AN EGR COOLER. THIS TESTER CONSISTS OF A PRESSURE REGULATOR ASSEMBLY J-46091-1 AND ADAPTERS EN-48974-5, EN-48974-15, AND EN-48974-30.
IMPORTANT: LEAKS FROM THE EGR COOLER MAY ALLOW COOLANT OT PASS THROUGH THE EXHAUST SYSTEM AND ENTER THE COMBUSTION CHAMBERS. FAILURE TO INSPECT THE EGR COOLER FOR LEAKS MAY LEAD TO A MISDIAGNOSIS FOR ENGINE COOLANT IN THE COMBUSTION CHAMBER.
IMPORTANT: LEAKS FROM THE EGR COOLER MAY ALLOW EXHAUST GAS AIR TO PASS TO THE ENGINE COOLANT PASSAGE WITHIN THE EGR COOLER. FAILURE TO INSPECT HTE EGR COOLER FOR LEAKS MAY LEAD TO A MISDIAGNOSIS OF AIR IN THE ENGINE COOLING SYSTEM
BULLETIN NUMBER:
SB09-J-002F
ISSUE DATE:
DECEMBER 2020
GROUP:
EGR COOLER PRESSURE TESTER TO DIAGNOSE ISUZU DIESEL ENGINE EGR COOLER LEAKS
AFFECTED VEHICLES
- 2005MY- Current Isuzu N-Series
- 2011-2018MY NPR Stripped Chassis (Reach)
- 2005-2010MY GMC and Chevrolet W-Series
- 2007i-2009MY Isuzu F-Series
- 2018MY-Current Isuzu F-Series
- 2007i-2009MY GMC and Chevrolet T and C-Series 6HK1 Equipped with Diesel Engines with an EGR Cooler
This bulletin supersedes SB09-J-002E. This bulletin is being revised to update model years and content. Please discard previous bulletin SB09-J-002E.
INFORMATION
An EGR cooler tester was provided to dealers in June 2009 to diagnose EGR cooler leaks on all Isuzu diesel engines equipped with an EGR cooler. This tester consists of a pressure regulator assembly J-46091-1 and adapters EN-48974-5, EN-48974-15, and EN-48974-30.
Important: Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for engine coolant in the combustion chamber.
Important: Leaks from the EGR cooler may allow exhaust gas air to pass to the engine coolant passage within the EGR cooler. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis of air in the engine cooling system.
EGR Cooler Pressure Tester
J-46091-1 – EGR Cooler Tester Pressure Regulator Assembly
EN-48974-5 – EGR Cooler Tester Adapter (5/8 inch for 2005-2007 5.2L, 2007-2009 7.8L, 2011-2018 3.0L)
EN-48974-15 – EGR Cooler Tester Adapter (17 mm for 2007i-2010 5.2L)
EN-48974-30 – EGR Cooler Tester Adapter (1 inch for 2011-Current 5.2L)
SERVICE PROCEDURE
EGR Cooler Testing
- Partially drain the engine coolant and remove the EGR cooler hoses.
- With the cooler on the engine, install the end cap and clamp of EN-48974 (EGR cooler tester adapter) on one of the EGR cooler hose barbs and install the pressure tester adapter hose and clamp to the other EGR cooler hose barb.
- Back off the regulator on the J-46091-1 (EGR cooler pressure regulator assembly) by turning the knob counterclockwise until it stops.
- Connect J-46091-1 to EN-48974, and connect 90 PSI shop air to J-46091-1.
- Open the shutoff valve, and then slowly turn the regulator on J-46091-1 clockwise until the gauge reads 30 psi.
- Shut off the valve on J-46091-1 and monitor the gauge for leak down. Remove the EGR cooler if it does not hold pressure.
- If the EGR cooler does not hold pressure, redo Steps 5 and 6 with the EGR cooler submerged in very warm water (which allows the EGR cooler to expand). After placing the EGR cooler under very warm water, shake and rotate the cooler for approximately 1 minute to ensure all air bubbles escape from the exhaust gas passage before testing. With the pressure set to 30 psi watch for air bubbles. Watch for at least 1 minute. This is done to ensure the EGR cooler is leaking and not the EGR cooler tester.
Note: Not removing this trapped air may result in missed diagnosis.
Rotate Cooler to release trapped air
Shake Cooler to release trapped air
20 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| GMC | C SERIES | 2007-2009 |
| GMC | T6500 | 2007-2009 |
| GMC | T7500 | 2007-2009 |
| GMC | T8500 | 2007-2009 |
| ISUZU | F-SERIES | 2021 |
| ISUZU | N SERIES | 9999 |
| ISUZU | N-SERIES | 2021 |
| ISUZU | W-SERIES | 2005-2009 |
1 Associated Document
Manufacturer Communications
BULLETIN NUMBER:
SB09-J-002F
ISSUE DATE:
DECEMBER 2020
https://www.nhtsa.gov/recalls?nhtsaId=10186932
MC-10186932-9999.pdf 285.429KB
- Comprehensive Tool Set: Orion Motor Tech's 19 pcs coolant pressure tester kit makes detecting internal & external pressure leaks in your vehicle's cooling system easy, including 15 adapters, a manual vacuum pump, a probe thermometer, a wrench, and O-rings
- 15 Adapters for Most Cars: With 15 different radiator adapters, this coolant pressure tester kit is compatible with numerous vehicle makes and models such as BMW, Ford, Fiat, VW, Porsche, Mercedes-Benz, Nissan, Peugeot, Chrysler, and more
- Accurate Readings: This cooling system pressure tester kit features a 2.5 in. (6.4 cm) easy-to-read pressure gauge with protective rubber coating, ideal for testing automotive pressurized cooling systems up to 35 psi (2.5 bar)
- Hassle-Free Organization: The color-coated adapters and molded size markings make it easy to quick identify the appropriate tool for the job. The custom molded carrying case keeps everything organized and ready for transport
- Built to Withstand Everyday Use: Constructed with quality aluminum alloy, nylon, rubber, and brass, this coolant system pressure tester kit is designed for enhanced strength and consistent performance for years to come
- 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
- Comprehensive Tool Set: Orion Motor Tech's 33 pcs coolant pressure tester kit includes 22 adapters, a universal adapter, a vacuum pump, a vacuum purge & refill tool, a probe thermometer, a wrench, EU & US air intake joints, O-rings, and hoses
- Versatile Application: This cooling system pressure tester kit identifies leaks from the header and expansion tanks, head gasket, radiator core, heater matrix, and water pump & pipes, and ensures air pocket-free coolant refilling for radiators
- 23 Adapters for Most Cars: With 23 different radiator adapters, this coolant pressure tester kit is compatible with numerous vehicle makes and models such as BMW, Ford, Opel, Fiat, VW, Porsche, Mercedes-Benz, Nissan, Peugeot, Chrysler, and more
- Hassle-Free Organization: The color-coated adapters and molded size markings make it easy to quick identify the appropriate tool for the job. The custom molded carrying case keeps everything organized and ready for transport
- Built to Withstand Everyday Use: Constructed with quality aluminum alloy, nylon, rubber, and brass, this vacuum coolant fill kit is designed for enhanced strength and consistent performance for years to come
- 【TROUBLESHOOTING & SAVING MONEY】32pcs universal radiator pressure tester and vacuum refill kit with functions of leak detection, temperature measurement, liquid filling, etc. If you use the coolant pressure tester, the tester can quickly and easily solve any problems related to radiator pressure, making your job easier and faster.Note: Please select the corresponding adapter according to the user manual; otherwise, leakage may occur. If a suitable adapter is not available, please use a universal adapter, which is suitable for all vehicle models.
- 【ALL-IN-ONE TOOL KIT】1 x Radiator manual pressure tester(0-35psi/0-2.5 bar); 1 x Pneumatic vacuum coolant refiller(-30 to 0inHg/ -76 to 0cmHg); 1 x 19" Rubber nylon resin hose; 1 x Thermometer(32 - 400 ℉); 3 x Radiator cap test adapters; 1 x Universal tapered rubber adapter; 17 x Adapters; 1 x Adapter handle; 2 x Connectors; 1 x Storage case.
- 【TOP QUALITY MATERIAL】Radiator manual pump pressure detector adopts a premium aluminum cylinder and accurate shock-proof gauge design. A vacuum-type coolant refiller uses reliable brass and plastic material—a rubber hose with brass parts, anti-corrosive and waterproof. American & European style air plugs are provided for various air hoses.
- 【KEY EASE-OF-USE FEATURES】Color-coded caps help you quickly choose the right adapter without confusion.All-in-one design eliminates need for multiple separate tools.Clear instructions guide you through pressure testing and vacuum filling.Quality gauge provides accurate, easy-to-read pressure measurements,that even if you're new to cooling system work, the comprehensive kit and straightforward process make it accessible for DIY mechanics.
- 【APPLICATION】The kit includes 3 radiator cap test adapters for common cap styles.Look at your expansion tank: Most adapters are designed for expansion tank necks.Color-coded system: Each adapter has a colored cap to help you quickly identify the right fit.Universal tapered adapter: Included as a backup option for unusual fittings.Compatible with: Mercedes-Benz, BMW, Audi, VW, Ford, GM, Toyota, Honda, Nissan, Mazda, Subaru, and many more brands.The comprehensive adapter selection means you'll likely have the right fit, and if one doesn't work perfectly, you can try others in the set.
- Universal Compatibility: Our 30-piece radiator coolant pressure tester and refill kit is engineered for maximum versatility. Featuring 17 color-coded test caps and 3 test covers, it easily adapts to a wide range of Japanese, European, and American car models. Quickly identify the right adapter for your vehicle and get the job done efficiently.
- Precision Engineering: Built with a durable aluminum hand pump and dual rubber rings for superior airtightness, our pressure tester ensures reliability and longevity. With a testing pressure range of 0-35 psi, you can trust that every measurement is accurate, allowing for confident diagnosis of cooling system leaks.
- Upgraded Vacuum Refill System: Our advanced filling valve features high-quality metal construction, enhancing stability and suction power. The integrated vacuum refiller includes an easy-to-read gauge marked in both psi and bar, making it straightforward to monitor pressure levels during use.
- Effortless Operation: Designed for user-friendliness, this kit allows you to test cooling system integrity and replace coolant without hassle. With a testing range of 0 to -30 inHg for the Vacuum Filler Gauge and 0-35 PSI for the Vacuum Pump, it's perfect for both professionals and DIY enthusiasts.
- Quality Assurance and Customer Support: Our products are crafted from high-quality materials, ensuring durability and performance you can rely on. We also offer robust after-sales support, with 24/7 customer service available. If you have any questions or concerns, feel free to reach out to us, and we will do our utmost to ensure your satisfaction.
Last update on 2026-05-25 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.