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Product Emission - Post O2 Sensors Cross Wiring - Install Wiring Extension Harness

Subject:01069 -- Post O2 Sensors Cross Wiring - Install Wiring Extension Harness

Models:Certain 2001 Chevrolet and GMC W3500 and W4500
And Isuzu NPR and NPR HD Series Vehicles
Equipped with 5.7L (RPO L31 - VIN Code R) Engine



Condition

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2001 Chevrolet and GMC W3500 and W4500; and Isuzu NPR and NPR HD series vehicles equipped with 5.7L (RPO L31 - VIN Code R). The chassis harness connectors for the left and right post catalytic converter oxygen (O2) sensors at the engine harness are crossed-wired.

Correction

Dealers are to install a wiring extension harness between the post O2 sensor harness and connectors.

Vehicles Involved

Involved are certain 2001 Chevrolet and GMC W3500 and W4500; and Isuzu NPR and NPR HD series vehicles equipped with 5.7L (RPO L31 - VIN Code R) engine and built within these VIN breakpoints:

Year

Division

Model

Plant

From

Through

2001

Chevrolet

W3500

Janesville

1J800039

1J804686

2001

Chevrolet

W4500

Janesville

1J800017

1J804552

2001

GMC

W3500

Janesville

1J800029

1J840737

2001

GMC

W4500

Janesville

1J800014

1J804550

2001

Isuzu

NPR

Janesville

1J800003

1J804740

2001

Isuzu

NPR HD

Janesville

1J800001

1J804645

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]

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 Information

For Chevrolet and GMC models:

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

Part Number

Description

Qty/ Vehicle

97728584

Harness (Kit), Da Wrg Harn Extn

1

For Isuzu models:

Parts required to complete this recall are to be obtained from AIPDN. Please refer to your "involved vehicles listing" prior to ordering requirements.

Part Number

Description

Qty/ Vehicle

2-90000-922-0

Kit, O2 Ext Harness

1

Service Procedure

  1. Park and secure the vehicle.
  2. Incorrect O2 Sensor Installation


    Object Number: 826988  Size: SH
    (1)Rear O2 Connector
    (2)Front O2 Connector
    (3)Left O2 Sensor Harness
    (4)Right O2 Sensor Harness
  3. Disconnect both right and left O2 sensor harnesses from the front and rear O2 sensor connectors (at the connector support on the frame). Refer to Figure 1.
  4. Correct Installation of Left O2 Sensor Harness to Rear Connector


    Object Number: 826990  Size: SH
    (1)Left O2 Sensor Harness
    (2)Rear O2 Connector Attached to Left O2 Sensor Harness
    (3)Install and Secure Harness with Tie Straps
  5. Install the rear O2 connector to the left O2 sensor harness. Secure the harness with the supplied tie wraps (cable clip) and trim off excess. Refer to Figure 2.
  6. Correct Installation of Right O2 Sensor to Front Connector (with Extension Harness)


    Object Number: 826992  Size: SH
    (1)Front O2 Connector with Extension Harness Attached to Right O2 Sensor Harness
    (2)Install and Secure Harness with Tie Wraps
    (3)Right O2 Sensor Harness

    Important: Remove the existing harness labels on the O2 sensor frame harness.

  7. Install the new extension harness to the front O2 connector, then to the right O2 sensor harness. Secure the harness with the supplied tie wraps (cable clip) and trim off excess. Refer to Figure 3.
  8. Important: Remove the existing harness labels on the O2 sensor frame harness.

  9. Start the engine and install the Tech 2. Scroll to the HO2S screen and verify O2 sensor operation by observing fluctuating mV output on all bank and sensor locations.
  10. Clear any related O2 sensor trouble codes.
  11. CALIFORNIA VEHICLES ONLY: Complete a "Proof of Correction Certificate" upon recall/campaign completion. (Refer to Figure 4 at the end of this recall.)
  12. Install the Recall Identification or Campaign Label.

Recall Identification Label

For Chevrolet and GMC models:

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. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

For Isuzu models:

 

  1. Using a ball point pen, fill out the following information on a campaign label (part number 2-90028-700-0).
  2. • This emission campaign number: 01069
    • Dealer code
    • Repair date: (month/date/year)
  3. Affix the campaign label adjacent to the manufacturer's identification label located on the driver's side B-pillar.

Claim Information

Submit a Product Recall Claim with the information indicated below.

Repair Performed

Part Count

Part No.

Parts Allow

CC-FC

Labor Op

Labor Hours*

Install Post O2 Wiring Extension Harness Kit

1

--

**

MA-96

V0799

0.2

* -- For Recall Administrative Allowance, add 0.1 hours to the "Labor Hours".

** -- The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus applicable Mark-Up for the extension harness kit needed to complete the repair.

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

Customer Notification

Customers will be notified of this recall on their vehicles by General Motors or General Motors Isuzu Commercial Truck LLC (see copy 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.

Dealer Recall Responsibility

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.

When a California emissions recall is completed by a GM or Isuzu dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" (refer to Figure 4) 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.

California Proof of Correction Certificate


Object Number: 826994  Size: SF
December, 2001

Dear General Motors/Isuzu Customer:

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

Reason For This Recall

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2001 Chevrolet and GMC W3500 and W4500; and Isuzu NPR and NPR HD series vehicles equipped with 5.7L V8 gasoline engines. The chassis harness connectors for the left and right post catalytic converter oxygen (O2) sensors at the engine harness are crossed-wired.

What Will Be Done

Your dealer will install a wiring extension harness between the post O2 sensor and connectors. This service will be performed for you at no charge .

Contacting Your Dealer

Please contact your Commercial Truck dealer as soon as possible to arrange a service date and to assure parts availability. 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 assistance, just contact your dealer or the Medium Duty Truck Customer Assistance Center at 1-800-862-4389.

Customer Reply Card

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 card and returning it to us in the postage paid envelope.

Emission Law Information

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.

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/General Motors Isuzu Commercial Truck LLC

Enclosure