Product Emission - Engine Horsepower Specifications - Reprogram ECM

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2004 and 2005 Chevrolet T-Series / Kodiak and GMC T-Series / TopKick T/C 6500, 7500 and 8500; and Isuzu FTR, FVR and FXR Medium Duty Trucks, equipped with a 7.8L L6 (RPO LG4 - VIN 3) Diesel engine. The Engine Control Module (ECM) in these vehicles may have been configured without certain calibration information because of missing Injector Trim Programming values. When the ECM does not have this information, the engine may not meet horsepower specifications.

Dealers are to reprogram the Injector Trim into the Engine Control Module (ECM).

Involved are certain 2004 and 2005 Chevrolet T / Kodiak and GMC T / TopKick T/C 6500, 7500 and 8500 Series; and Isuzu FTR, FVR and FXR Medium Duty Trucks, equipped with a 7.8L L6 (RPO LG4 - VIN 3) Diesel engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Important: Ensure you are using GM NAO TIS Data Version 6.0 for 2005, or later, with Application 5.2, broadcast to dealers on May 31, 2005; or CD ROM mailed to dealers beginning June 9, 2005; or Isuzu Technical Communication System (ITCS) CD 19 or later.

ECM Reprogramming for Injector Trim

Notice: Before reprogramming, please check the battery condition to prevent a reprogram error of the engine control module (ECM) due to battery discharge. If the vehicle battery is not fully charged, ensure that it is fully charged prior to performing the reprogramming procedure.

Use the Technical Information System (TIS) Service Programming System (SPS) to program the "Injector Trim" values into the ECM, using GM NAO TIS Data Version 6.0 for 2005, or later, with Application 5.2; or Isuzu ITCS CD 19, or later. The three characters displayed on the fuel injector flow rate ID label located on the valve cover are already stored in TIS. As long as the correct recall vehicle identification number (VIN) is entered, the correct Injector Trim values will be correctly downloaded.

Pass-Thru Programming

1. Connect the Tech 2 to the TIS terminal and the vehicle in preparation for Pass Thru programming. Turn on the Tech 2.
2. Select Pass-Thru from the "Select Diagnostic Tool" window.
3. Select Reprogram ECU from the "Select Programming Process" window.
4. Select Vehicle from the "Select ECU Location" window.
5. Select Next to go to the "Preparing for Communication" screen.
6. Select Salesmake, Model Year, Vehicle Type and Engine from the "Vehicle Data" window.
7. Select Next to continue to the "Preparing for Communication" instruction screen.
8. Select Next to verify vehicle identification number (VIN).
9. Select Next to view the "Supported Controllers" screen.
10. Select ITP Injector Trim Programming from the "Select Controller" window.
11. Select Normal from the "Select Programming Type" window.
12. Select Next to view the "Calibration Selection" screen.
13. Verify that the following information is displayed on the "Calibration Selection" screen: Your Part Number must begin with 1700**** "Injector Trim Programming."
14. Select Next to view "Summary" screen.
15. Select Next to program "Injector Trim values" to the controller.
16. Make sure to turn OFF the ignition for 30 seconds after the "Programming is Complete" screen is displayed. Clear diagnostic trouble codes (DTCs), if required

Tech 2 Remote Programming

1. Use normal "request method" through "Service Programming System" to request information from vehicle.
2. At Techline Terminal enter TIS SPS programming system.
3. Select Tech 2 from the "Select Diagnostic Tool" window.
4. Select Reprogram ECU from the "Select Programming Process" window.
5. Select Vehicle from the "Select ECU Location" window.
6. Select Next to go to the "Preparing for Communication" instruction Screen.
7. Select Next to verify vehicle identification number (VIN).
8. Select Next to view the "Supported Controllers" screen.
9. Select ITP Injector Trim Programming from the "Select Controller" window.
10. Select Normal from the "Select Programming Type" window.
11. Select Next to view the "Calibration Selection" screen.
12. Verify that the following information is displayed on the "Calibration Selection" screen: Your Part Number must begin with 1700**** "Injector Trim Programming."
13. Select Next to view "Summary" screen.
14. Select Next to download the "Injector Trim" values to the Tech 2.
15. Back at the vehicle enter "Service Programming Systems."
16. Select "Program ECU" and follow on screen instructions.
17. Make sure to turn OFF the ignition for 30 seconds after the "Programming is Complete" screen is displayed. Clear diagnostic trouble codes (DTCs), if required.

Important: FOR 2004-05 CALIFORNIA AND 2005 MASSACHUSETTS MAINE, & VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering.

Using a ballpoint pen, fill out the following information on a recall label (Part Number: 2-90028-700-0).

Affix the recall label adjacent to the manufacturer’s identification label located on the driver’s side B-pillar.

Submit a Product Recall Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***

When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.

Additional Certificates can be obtained, at no charge, from Dealer Support Materials by calling 1-866-700-0001 (Monday through Friday, 8:00 am to 5:00 pm EST). Ask for GM Item Number 1825 when ordering.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

Your 2004 or 2005 Chevrolet T-Series or Kodiak, GMC T-Series or TopKick T/C 6500, 7500, 8500 or Isuzu FTR, FVR and FXR Medium Duty Truck, equipped with a 7.8L L6 Diesel engine, has an Engine Control Module (ECM) that may not have been configured with certain calibration information. When the ECM does not have this information, the engine may not meet horsepower specifications.

Your dealer will reprogram the ECM. This service will be performed for you at no charge.

This service correction will take approximately 30 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Please contact your GM or Isuzu dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the card and mailing it back to us.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof Of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To get the most personalized information for your vehicle, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

General Motors Corporation

Enclosure

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