Product Safety - Accessory-Dual Fuel Tank System

Isuzu Motors Limited has decided, and General Motors concurs, that a defect, which relates to motor vehicle safety, exists in certain 2003-2004 Chevrolet and GMC W3500/4500/5500 Series, and Isuzu NPR and NQR vehicles equipped with a diesel engine and a dual fuel tank system. On some of these vehicles, water and/or salt intrusion into the fuel switching manifold solenoid could cause the internal coil to fail. If one or more solenoid valves fail, the fuel system will exhibit fuel overflow from the fuel filler neck, and fuel may spill onto the ground. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur.

Dealers are to replace the solenoid valve manifold assembly and add a fault indicator light.

Involved are certain 2003-2004 Chevrolet and GMC W3500/4500/5500 Series, and Isuzu NPR and NQR vehicles equipped with a diesel engine and a dual fuel tank system 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.

For U.S. Dealers

Parts required to complete this recall are to be obtained from General Motors Service Parts Operation (GMSPO) or American Isuzu Parts Distribution Network (AIPDN), whichever is applicable. Immediately after placing the order, dealers are to call ParTech at 1-888-866-4272, 8:00 am - 5:00 pm EST. Dealers must provide the complete VIN when calling. The orders will be released when the VIN is verified. Orders placed for inventory parts will not be released. Parts should only be ordered when the inspection procedure determines that the kit is required.

For Canadian Dealers

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Due to the small number of vehicles involved in this recall, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when the inspection procedure determines that the kit is required.

Important: Fuel may spill during manifold removal. Ensure that all necessary safety precautions are taken when handling diesel fuel.

1. Park the vehicle and block the tires.
2. Disconnect the negative battery cable from the battery.
3. Place a drain pan under the solenoid valve manifold assembly.




Important: Make a note of the hose locations during removal. These hoses will be installed onto the new manifold in the same locations.

4. Using an open end wrench, disconnect the fuel hose fittings from the solenoid valve manifold assembly where shown.



5. Using two open end wrenches in the locations shown (1), remove the two hose swivel adapters from the tube unions connected to the return tubes. Be sure not to loosen the compression nut connected to the tube.
6. Disconnect the solenoid valve manifold wiring harness from the vehicle chassis wiring harness.
7. Remove the two mounting bolts/nuts that secure the manifold to the frame rail. Remove the old manifold assembly from the vehicle.



8. Carefully measure the hose sections 3 and 4 as shown.



9. Measure the hose provided on the replacement manifold assembly. If necessary, cut the provided hose shorter to meet the same dimensions as measured for 3 and 4 on the old manifold as measured in the previous step. Be sure to cut the hose ends square and smooth.



10. Install the provided clamps (5) onto the hoses and then insert the provided new swivel adapters (6) into the hoses as shown. Ensure that the hoses are completely seated onto the fittings and then position the clamps to secure the hoses to the fittings.
11. Install the new manifold assembly at the same mounting location as the old manifold assembly. Using the new nuts provided in the kit, secure the manifold to the frame rail.

Tighten
Tighten the nuts to 15 N·m(11 lb ft).




12. Install the new hoses with the swivel adapters to the existing tube unions from Step 5. Use two open end wrenches in the location shown (1) to secure this connection. Do not allow the compression nut to turn.

Tighten
Tighten fittings to 19 N·m (14 lb ft).




13. Connect the remaining hose fittings to the new manifold assembly. Ensure that the hoses are installed in the same locations as noted earlier when removed.

Tighten
Tighten fittings to 27 N·m(20 lb ft).

14. Connect the solenoid valve manifold wiring harness connector to the chassis wiring harness.
15. Inspect the installation. Ensure that all connections are secure.




Notice: Be sure to check behind the dash panel before drilling to ensure that other components or wires are not damaged.

Notice: The pilot hole must be used to ensure proper location of the caution light. The 0.500 drill bit alone may walk on the dash panel without a pilot hole. This may cause damage or an incorrect hole.

16. Carefully align the label (7) on the lower right side of the dash panel. Using a punch or scribe, mark the center hole position (8) on the dash panel. Remove the label and drill a 0.250 inch pilot hole; then drill a 0.500 inch hole. Using a small round file, remove any burrs created when drilling.



17. Position the caution label (9) on the dash panel as shown. Take care to properly align the hole in the label with the hole in the dash panel.
18. Route the fault indicator wiring harness (10) under the dash panel and through the new hole. Connect the harness to the fault indicator light assembly (11). Install the fault indicator light assembly into the dash bezel. The fault indicator light assembly should snap into the dash panel.

Automatic Transmission





Manual Transmission




19. Attach the ground wire in the fault indicator wiring harness (12) to the bolt under the steering column.
20. Fit the remainder of the fault indicator wiring harness through the cab grommet in the same location as the current dual tank wiring harness.
21. Route the fault indicator wiring harness along the frame rail toward the solenoid valve manifold assembly next to the current dual tank harness. Secure the fault indicator wiring harness to the current dual tank wiring harness every six to eight inches (150 to 200 mm) using the zip ties provided. Use diagonal cutters to remove any excess ends from the zip ties as required.
22. Connect the fault indicator harness to the solenoid valve manifold assembly connector.
23. Connect the negative battery cable to the battery.
24. Set the dual tank selector switch to the "Main" position and start the vehicle.
25. Inspect the solenoid valve manifold assembly and connections for any leaks. Make corrections as required.
26. While observing the fault indicator light, switch the dual tank selector switch to the "AUX" position. The fault indicator light should illuminate for 3 to 5 seconds. Additionally, a clicking sound may also be heard from the solenoid valve manifold assembly.

•	If the light fails to illuminate or does not go out after 5 seconds, there may a system malfunction. Shut off the engine and review the installation for any missed steps and make corrections as required, then repeat the procedure starting at Step 24.

•	If the issue is not resolved and additional diagnostic support is needed, contact Medium Duty Truck Technical Assistance at 1-800-633-4863, prompt #3.

27. With the dual tank selector switch still in the "AUX" position and the engine running, check all fuel line connections again for leaks and make corrections as required.

All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs to correct the recall condition are to be submitted by October 31, 2006.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims 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).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. 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, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Isuzu Motors Limited has decided, and General Motors concurs, that a defect, which relates to motor vehicle safety, exists in certain 2003-2004 Chevrolet and GMC W3500/4500 Series, and Isuzu NPR and NQR vehicles equipped with a diesel engine and a dual fuel tank system. On some of these vehicles, water and/or salt intrusion into the fuel switching manifold solenoid could cause the internal coil to fail. If one or more solenoid valves fail, the fuel system will exhibit fuel overflow from the fuel filler neck, and fuel may spill onto the ground. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur.

Your dealer will replace the solenoid valve manifold assembly and install a fault indicator light. This service will be performed for you at no charge .

This service correction will take approximately 1 1/2 hours. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

If, after contacting the Customer Assistance Center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 40990; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://safercar.gov.

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 form and mailing it back to us.

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

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

General Motors Isuzu Commercial Truck, LLC

Enclosure

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