5.2L 4HK1 Diesel Engine Quality Monitor/Parts Technical MAC Code/Exchange Program
| Subject: | 5.2L 4HK1 Diesel Engine Quality Monitor/Parts Technical MAC Code/Exchange Program |
| Models: | 2005 Chevrolet W-Series Medium Duty Tilt Cab Models |
| 2005 GMC W-Series Medium Duty Tilt Cab Models |
| 2005 Isuzu N-Series Commercial Models |
| with 5.2L 4HK1 Diesel Engine (VIN Code 6) |
This bulletin is being revised to extend the engineering evaluation period to December 31, 2004. Please discard Corporate Bulletin Number 04-06-01-005 (Section 06 -- Engine/Propulsion System).
Important: This service bulletin is not applicable to 'GM of Canada' dealers.
Product teams continually seek valuable information for product engineering improvements. For the new 2005 5.2L 4HK1 Diesel Engine in the models listed above, Isuzu Motors will be strictly monitoring Engine Performance until December 31, 2004.
During the 2005 model year evaluation period (start of sale through December 31, 2004), the following components will be under study:
| • | Engine Assembly |
| • | Fuel Injector |
| • | Engine Control Module |
| • | Fuel Supply Pump |
| • | Common Rail |
To monitor this engine, the list of parts will be on Technical Manual Allocation Control (MAC) code. Dealers will be contacted based on the ordering of the parts listed below. When contacted, dealers will be required to provide detailed failure information regarding the component failure before parts will be released.
A Technical MAC coding will be placed on the following part numbers for the evaluation period.
Item | Description | Isuzu P/N | GM P/N | Qty for Repair |
|---|---|---|---|---|
1 | Partial Engine | 5-87310-716-0 | 97761519 | 1 |
2 | Cylinder Head | 8-97383-041-0 | 97383041 | 1 |
3 | Fuel Supply Pump | 8-97328-886-1 | 97328886 | 1 |
4 | Injectors, Fuel | 8-97329-703-1 | 97329703 | 4 |
5 | Common Rail | 8-97306-063-2 | 97306063 | 1 |
6 | Turbo Assembly | 8-97310-502-0 | 97310502 | 1 |
7 | Engine Gasket Set | 5-87814-688-0 | 97769180 | 1 |
5-87814-689-0 | 97769181 | 1 | ||
5-87814-690-0 | 97769182 | 1 | ||
8 | Cylinder Head Gasket Set | 5-87814-691-0 | 97769183 | 1 |
5-87814-692-0 | 97769184 | 1 | ||
5-87814-578-0 | 97761525 | 1 |
Based on information provided to Isuzu Motors America, at the time of the order, it may be decided to exchange the failed part for engineering evaluation. In this situation, the new part will be provided at no cost and the dealer should use the following parts mark-up allowance
Labor Operation | Part | Allowance |
|---|---|---|
J1820 J1840 | Engine Assembly | $900.00 |
J5926 | Fuel injector | $50.00 each |
J6360 | Engine Control Unit | $50.00 |
J5950 | Fuel Supply Pump | $150.00 |
J5929 | Common Rail | $50.00 |
Replaced failed parts will be collected by Isuzu Motors America through a dedicated shipping company pick up and returned directly to Isuzu Motors America. Dealers must be ready to have the failed parts picked up 2-3 days after the repair. The dealer will not be required to arrange for shipping or pick up. Shipping arrangements will be scheduled by Isuzu Motors America after completion of the repair.
Detailed Failure information
A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements. Isuzu Motors America will verify that proper diagnosis has been performed. Isuzu Motors America may request the dealer to perform additional work in order to accurately understand the failure and validate the necessity for component replacement. Upon review of the diagnosis, Isuzu Motors America will either provide parts directly or release the current pending MAC coded part.
Warranty Submission Parts Amount
Engineering part is supplied at No Charge. Submit for normal labor hours and parts allowance as described above PLUS 0.2 hr for administrative time and form preparation.
Check Sheets for Common Rail and 4HK1T Partial Engine, Cylinder Head and Turbo
The following sheet is to be filled out by the dealer and faxed to 562-623-0800.
| |
|---|---|
Date:
Dealer Name:
Dealer Address/Code:
Service Contact Name:
Telephone Number:
Fax Number:
Suspected Failed Parts: Part Name:
Part Number:
Part Name:
Part Number:
Vehicle Information: Rear Body Type:
Engine Model/Number:
Engine Shutdown/Warning System:
VIN:
Mileage:
R.O. Date: | |
Customer Complaint (Summary of Failure Information) Complaint Description: _______Overheated _______Excessive Oil Consumption _______Engine Seized _______Oil Leak _______Coolant Leak _______Noise _______Knocking _______Other (Please Explain):
| |
Failure Conditions When? _______Since New _______Since Certain Mileage Date of Mileage____________________ Mileage:____________________ Indication Before Failure: _______None _______Yes Explain what kind of indication and when it happened:
Frequency: _______Regularly _______Occasionally _______Night Time _______Special Condition (Please Explain)
Weather: _______Fair _______Cloudy _______Rainy _______Snowy _______Other (Please Explain)
Ambient Temperature (°F) when failure condition occurred:
Failed Location: _______City _______Suburb _______Highway _______Hilly _______Other (Please Explain)
Driving Condition _______Climbing Hill _______High Speed _______Traffic Jam _______Idle _______At Start _______Acceleration _______At Certain Speed Please List Speed:____________________MPH Acceleration: _______Slight _______Heavy _______Off-Pedal _______Re-Acceleration _______Fixed Speed Please List Speed:____________________MPH T/M Position: _______M/T List Gear Position:____________________ _______A/T List Shift Position (D, 3, 2 or L):____________________ Bodybuilder Equipments: _______PTO _______Additional Pump/Compressor/Generator _______Other (Please Explain)
Engine Coolant Temperature: _______Cool _______Warming Up _______Hot _______Other List Coolant Temperature:____________________Deg. Exhaust Gas: _______Black Smoke _______White Smoke _______Blue Smoke _______Normal _______Other (Please Explain)
Vehicle Load: _______Loaded _______Empty _______Other (Please Explain)
Estimated GVW:____________________lbs. Towing:
Estimated GVCW:____________________lbs. | |
Technician Findings Related Repair or Service History: _______Yes _______No If there has been related repair or service history, please explain. Supply date and mileage and attach any ROs.
Duplication: _______Always duplicate _______Sometimes duplicate _______Cannot duplicate Fluid Level: Engine Oil:____________________ Coolant:____________________ Troubleshooting Comments (cylinder compression test, oil, coolant leak location, noise, visible damage, other):
Correction (repair content):
Root Cause: _______Known (Please Explain)
_______Unknown |
Check Sheet for Common Rail Related Part Exchange
The following sheet is to be filled out by the dealer.
| |
|---|---|
Date:
Dealer Name:
Dealer Address/Code:
Service Contact Name:
Telephone Number:
Fax Number:
Replaced Parts: Part Name:
Part Number:
Serial Number:
Quantity:
Part Name:
Part Number:
Serial Number:
Quantity:
Vehicle Information: Rear Body Type:
Engine Model/Number:
Retail Date:
VIN:
Mileage:
R.O. Date: | |
Customer Complaint (Summary of Failure Information) Complaint Description: _______Stall _______Lack of Power _______Check Engine Light _______Vibration _______Start Failure _______Idle Condition _______Noise _______Hesitation _______Knocking _______White Smoke _______Black Smoke _______Other (Please Explain):
| |
Failure Conditions When? _______Since New _______Since Certain Mileage Date of Mileage____________________ Mileage:____________________ Indication Before Failure: _______None _______Yes Explain what kind of indication and when it happened:
Frequency: _______Regularly _______Occasionally _______Night Time _______Special Condition (Please Explain)
Weather: _______Fair _______Cloudy _______Rainy _______Snowy _______Other (Please Explain)
Ambient Temperature (°F) when failure condition occurred:
Failed Location: _______City _______Suburb _______Highway _______Hilly _______Other (Please Explain)
Driving Condition _______All the Time _______At Re-Start _______Starting _______Climbing Hill _______High Speed _______Traffic Jam _______Idle _______At Start _______Acceleration _______At Certain Speed Please List Speed:____________________MPH Acceleration: _______Slight _______Heavy _______Off-Pedal _______Re-Acceleration _______Fixed Speed Please List Speed:____________________MPH T/M Position: _______M/T List Gear Position:____________________ _______A/T List Shift Position (D, 3, 2 or L):____________________ Accessories Used: _______PTO _______A/C _______Wireless Communication Device, 2-way radio, cell phone Engine Coolant Temperature: _______Cool _______Warming Up _______Hot _______Other List Coolant Temperature:____________________Deg. Exhaust Gas: _______Black Smoke _______White Smoke _______Blue Smoke _______Normal _______Other (Please Explain)
Vehicle Load: _______Loaded _______Empty _______Other (Please Explain) Fuel: _______Specific Brand List Brand:____________________ _______Generic _______Other (Please Explain and Provide Sample)
| |
Technician Findings Related Repair or Service History: _______Yes _______No If there has been related repair or service history, please explain. Supply date and mileage and attach any ROs.
Duplication: _______Always duplicate _______Sometimes duplicate _______Cannot duplicate Diagnostic Trouble Code: _______No _______Yes (currently failed) _______In History (Please List DTC:____________________) Troubleshooting Comments (Attach Tech 2 Snapshot if available):
Correction (repair content):
Root Cause: _______Known (Please Explain)
_______Unknown |
