Product Safety Recall - Battery Cable Routing

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 Chevrolet Kodiak and GMC TopKick C6500/7500/8500 vehicles equipped with the optional Caterpillar diesel engine (LG5). Some of these vehicles were built with a misrouted battery cable that could come in contact with the exhaust pipe. The conduit and the nylon cable coating could degrade to the point where the copper wire strands of the cable are exposed. If the cable strands contacted the exhaust pipe the short circuit could cause the battery cable coatings to ignite and possibly lead to an engine compartment fire.

Dealers are to inspect the battery cable for proper routing and reroute the cable if necessary.

Involved are certain 2003 Chevrolet Kodiak and GMC TopKick C6500/7500/8500 vehicles equipped with a diesel engine (LG5) and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

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

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

1. Open the hood.
2. Remove the retaining clips and remove the right wheelhouse panel.
3. Remove the nuts and the right wheelhouse splash shield.
4. Inspect the routing of the positive battery cable.

Improper Routing





•

If the positive battery cable (1) is routed BELOW the frame (2) as shown in the Improper Routing illustration (from under the vehicle you will also see that there is a harness retaining clip on the conduit on the battery cable that is not attached to anything), proceed to Step 5 to reroute the cable over the top of the frame.

Proper Routing





•	If the positive battery cable (1) is routed over the TOP of the frame (2) as shown in the Proper Routing illustration, it is routed correctly. Proceed to Step 21.

5. Remove the battery cover and disconnect the negative battery cable.
6. Inside the cab, flip the right front seat cushion rearward.
7. Release the latches attaching the engine cover (dog house).
8. Using the right door opening, remove the engine cover from the cab.
9. Remove the nut attaching the positive battery cable to the starter.

Important: Note the attaching locations of the wiring harness retainers at the rear of the engine when disconnecting them in the next step.

10. Disconnect the retainers that attach the positive battery cable at the rear of the engine. On vehicles equipped with a manual transmission, it will be necessary to cut off two plastic tie bands.
11. Pull the positive battery cable from across the rear of the engine compartment and route down below the frame.
12. Reroute the positive battery cable over the top of the frame as shown in the Proper Routing illustration.
13. Continue routing the positive battery cable across the rear of the engine compartment and over to the starter.
14. When in position, attach the wiring harness retainers.
15. Attach the one previously unattached retainer to the engine harness at the location shown (3) in the Proper Routing illustration.
16. On vehicles equipped with a manual transmission, install two new plastic tie bands at the locations where the originals were removed.
17. Connect the positive battery cable to the starter.

Tighten
Tighten the nut to 30 N·m (22 lb ft).

18. Install the engine cover inside the cab and secure the latches.
19. Fold the right seat cushion down.
20. Connect the negative battery cable and install the battery cover.
21. Install the wheelhouse splash shield and install the attaching nuts.

Tighten
Tighten the nuts to 9 N·m (79 lb in).

22. Install the right wheelhouse panel and install the retaining clips.
23. Install the GM Recall Identification Label.

FOR US AND IPC

Place a Program Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Program Bulletin. Each label provides a space to include the program number and the five (5) digit dealer code of the dealer performing the program service. This information may be inserted with a typewriter or a ball point pen.

Put the Program 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 Program Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Program 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 am to 5:00 pm EST). Request Item Number S-1015 when ordering.

Additional Program Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

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 (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point 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. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

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.

FOR US AND CANADA

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR IPC

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.

FOR US AND IPC (US STATES, TERRITORIES, AND POSSESSIONS)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which 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.

FOR ALL

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.

Dear General Motors Customer:

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

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 Chevrolet Kodiak and GMC TopKick C6500/7500/8500 vehicles equipped with the optional Caterpillar diesel engine. Some of these vehicles were built with a misrouted battery cable that could come in contact with the exhaust pipe. The conduit and the nylon cable coating could degrade to the point where the copper wire strands of the cable are exposed. If the cable strands contacted the exhaust pipe the short circuit could cause the battery cable coatings to ignite and possible lead to an engine compartment fire.

Your GM dealer will inspect the battery cable for proper routing, and reroute the cable if necessary. This service will be performed for you at no charge .

The length of time required to perform this inspection is approximately 15 minutes. If the cable requires rerouting, it will be another 35 minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer.

Your GM dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate 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 20590 or call 1-888-327-4236.

The attached customer reply card identifies your vehicle. Presentation of this card 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 attached and mailing it in the postage paid envelope.

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