Product Safety - Air Compressor Does Not Build Air Pressure

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2007 7500/8500 series Chevrolet Kodiak and T-Series; GMC TopKick and T-Series; and Isuzu F-Series and H-Series vehicles equipped with a 7.8L diesel engine (RPO LG4/LF8) and air brakes (RPO JE4). The air compressor in some of these vehicles may not build enough air pressure to support the air brake system. If this condition were to occur while the vehicle was stationary (brakes applied) the air brakes would remain applied and prevent the vehicle from moving.

If this condition were to occur while the vehicle was in motion, the dual system air pressure gauges would register the drop in pressure. If the pressure continued to drop, the low air pressure warning buzzer and warning lamp would activate as designed, warning the driver to move the vehicle to a safe location. If the driver ignores these warnings and continues to drive the vehicle, and if there was a continued loss of pressure, the rear spring parking brakes would automatically apply, preventing the truck from being driven.

Dealers are to replace the air compressor cylinder head, or in a few instances, the air compressor assembly.

Involved are certain 2007 7500/8500 series Chevrolet Kodiak and T-Series; GMC TopKick and T-Series; and Isuzu F-Series and H-Series vehicles with a 7.8L diesel engine (RPO LG4/LF8) equipped with air brakes (RPO JE4) and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

-- US dealers - GM DealerWorld Recall Information

-- Canadian dealers - GMinfoNet Recall Reports

-- Export dealers - sent directly to dealers

The listing 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.

Parts required to complete this recall are to be obtained from General Motors Service and 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.

Parts required to complete this recall are to be obtained from American Isuzu Parts Distribution Network (AIPDN). Please refer to your "involved vehicles listing" prior to ordering requirements.

Important: Refer to the information below.

Tools Required

Caution: 

1. Apply the parking brake.
2. Block the wheels.
3. C-Models: Open the hood.
4. Remove the right-side splash shield. Refer to Splash Shield Replacement -- Wheelhouse in SI.
5. Remove the engine cover. Refer to Engine Cover Replacement in SI.
6. T-Models: Tilt the cab forward according to the Owners Manual cab tilting and lowering instructions.
7. Drain all of the air reservoirs. Refer to Draining Reservoirs in Air Brakes in SI.
8. Drain the engine coolant to below the level of the air compressor. Refer to Cooling System Draining and Filling in SI.
9. Remove the air compressor discharge pipe at the air compressor.
10. Remove the air compressor governor line at the air compressor.
11. Remove the power steering pump. Refer to Power Steering Pump Replacement in SI.
12. Remove the air compressor inlet hose at the air compressor.
13. Remove the air compressor water inlet hose at the air compressor.
14. Remove the air compressor water outlet hose at the air compressor.
15. Remove the air compressor oil inlet hose at the engine block.
16. Remove the air compressor.

16.1.

Support the air compressor.

16.2.

Remove the air compressor mounting stud nuts.

16.3.

Remove the air compressor from the vehicle.




17. Use a bench vise to secure the air compressor.

Operational Checks

After repairs are completed and all of the air and coolant lines are properly connected, start the engine. Shut the engine off after the system pressure has reached its cut-out pressure. (This is typically noted by an audible purge at the air dryer.)

1. C-Models: Install engine cover. Refer to Engine Cover Replacement in SI.
2. Install the right-side splash shield. Refer to Splash Shield Replacement -- Wheelhouse in SI.
3. Close the hood.
4. T-Models: Lower the tilt cab according to Owners Manual cab tilting and lowering instructions.

Conditions Requiring Compressor Replacement

Refer to the text and illustrations above to determine if the air compressor must be replaced. Do not install a new cylinder head on an air compressor with a damaged piston or cylinder. If the piston or cylinder is damaged, the whole air compressor must be replaced. Inspect the piston and cylinder for the following conditions:

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).

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.

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 Commercial Truck 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 that relates to motor vehicle safety exists in certain 2007 model year 7500 and 8500 Series Chevrolet Kodiak and T-Series; GMC TopKick and T Series; and Isuzu F-Series and H-Series vehicles equipped with a 7.8L diesel engine and air brakes. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

Why is your vehicle being recalled?

The air compressor in your vehicle may not build enough air pressure to support the air brake system. If this condition were to occur while the vehicle was stationary (brakes applied) the air brakes would remain applied and prevent the vehicle from moving.

If this condition were to occur while the vehicle was in motion, the dual system air pressure gauges would register the drop in pressure. If the pressure continued to drop, the low air pressure warning buzzer and warning lamp would activate as designed, warning the driver to move the vehicle to a safe location. If the driver ignores these warnings and continues to drive the vehicle, and if there was a continued loss of pressure, the rear spring parking brakes would automatically apply, preventing the truck from being driven.

What will we do?

Your GM/Isuzu dealer will inspect and replace either the air compressor cylinder head or the air compressor assembly. This service will be performed for you at no charge . It is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 3½ hours because of service scheduling requirements.

What should you do?

You should contact your GM/Isuzu dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

Do you have questions?

If you have questions or concerns that your dealer is unable to resolve, please contact 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.

If after contacting your dealer and the Customer Assistance Center, you are still not satisfied 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 St., SW, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

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

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

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