Recall - ISZS004 Rear Heater Fuel/Brake Line Wear
89isuzu01BULLETIN NUMBER SB89-12-001
ISSUE DATE January 5, 1989
GROUF HEATING & A/C
1987-1988 TROOPER AND TROOPER II (KT) REAR HEATER CAMPAIGN
CAMPAIGN IDENTIFICATION NUMBER
Number ISZ-S-004 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with this campaign.
VEHICLES AFFECTED
1987-1988 Trooper and Trooper II (KT) models equipped with rear heater with the following VINs:
H5400109 J7811562 J7830541
H5400107 J7811563 J7830552
H5405264 J7830628 J7830561
H5405467 J7830404 J7830579
H5405468 J7830434 J7830589
H5405624 J7830439 J7830604
H1405625 J7830444 J7830619
H5405829 J7830455 J7830642
H5405830 J7830461 J7830645
H5405926 J7830476 J7830648
H5406048 J7830488 J7830657
H5406049 J7830497 J7830658
J7811558 J7830512 J7830665
J7811559 J7830514 J7930666
J7811560 J7830526 J7830667
J7811561 J7830527
FIGURE 1:
SERVICE INFORMATION
Trooper and Trooper II vehicles equipped with rear heater units may experience a failure in the brake, fuel delivery or fuel evaporative lines caused by contact with the rear heater attachment bolts and/or hose clamp, (See Figure 1.) Continuous contact of the rear heater attachment bolts and hose clamp with the brake and fuel lines could result in wear and leakage of any of the lines. Leakage of the brake and/or fuel lines could lead to a partial loss of braking power and/or fuel, respectively.
This Campaign Bulletin contains the procedure for installing the new lines and clips.
OWNER NOTIFICATION
All owners of affected vehicles will be notified by letter from American Isuzu Motors Inc. (copy enclosed). Each Isuzu dealer will be supplied with a detailed list of affected vehicles originally allotted to that dealership. The list will contain VIN and detailed owner information. If none of the affected vehicles were shipped to a dealership, no list will be sent.
PARTS INFORMATION
The following parts are required to service each affected vehicle.
For 1987 models:
Part No. Description
5-87830-979-0 Rear Heater Campaign Kit
Each kit contains:
Part No. Description Qty.
8-94294-367-0 Pipe Clip 6
8-94222-878-2 Pipe Clip 3
8-94359-236-0 Fuel Delivery Pipe 1
For 1988 models:
Part No. Description
5-87830-981-0 Rear Heater Campaign Kit
Each kit contains:
Part No. Description Qty.
8-94484-688-1 Pipe Clip 8
8-94492-600-1 Pipe Clip 1
8-94358-751-0 Fuel Evaporator Pipe 1
8-94358-034-0 Brake Pipe 1
8-94358-151-0 Fuel Delivery Pipe 1
8-94358-154-0 Fuel Return Pipe 1
Parts are now available. Order as required, using normal parts ordering procedures.
FIGURE 2:
FIGURE 3:
SERVICE PROCEDURE
Refer to Figure 2 for 1987 models; refer to Figure 3 for 1988 models.
1. Remove transfer case protector
2. Disconnect rear brake line near rear axle cross member. After removal, install a cap to the brake line to prevent fluid leakage.
3. Disconnect brake line from rear of union. Remove brake line from pipe clips on frame rail.
4. Remove bolt securing black rubber pipe clip near the rear axle. Remove the black rubber pipe clip.
5 . Remove pipe clip above rear axle.
6. For 1987 models: Remove 6 grey pipe clips and 3 black pipe clips from frame rail.
For 1988 models: Remove 8 white pipe clips and one black pipe clip from frame rail.
CAUTION Use care when disconnecting fuel hoses, as fuel may spray out. After removal, install a cap to hose to prevent fuel leakage.
7. Disconnect rear main fuel hose (in front of fuel filter) from fuel delivery line.
8. Remove fuel filter band clip from the bracket and move it aside to allow room for fuel return line removal.
9. Disconnect fuel return line from fuel return line hose. Disconnect fuel evaporator hose from fuel tank rear line.
10. Disconnect fuel delivery line and fuel return line from front fuel hoses.
11. Disconnect fuel evaporator hose from fuel evaporator line, below check valve at side of canister.
12. Remove fuel return line as follows: Pull it forward to clear rear axle cross member. Then pull it out from the rear, between the leaf spring and the frame rail.
Remove the brake line and the fuel delivery line in the same manner.
13. Remove the fuel evaporator line as follows:
Pull it toward the rear, to clear the transmission cross member. Then pull it forward, between the suspension cross member and the transmission cross member.
14. Disconnect the speedometer cable from the transmission.
15. Install new pipe clips as described below, at the locations of the old pipe clips.
FIGURE 4:
For 1987 models:
a. Install 6 new grey pipe clips (part no. 8-94294-367-0) vertically to frame rail.
b. Install 3 new black pipe clips (part no. 8-94222-878-2) horizontally to rear of frame rail.
For 1988 models:
a. Remove rear heater hose clip, rotate 90 degrees, then reinstall clip as shown in Figure 4.
b. Install 8 new white pipe clips (part no. 8-94484-688-1) to the frame rail.
c. Install one new black pipe clip (part no. 8-94492-600-1) to the frame rail.
16. For 1987 models: Reinstall fuel evaporator line. Do not connect line to hose at this time.
For 1988 models: Install new fuel evaporator line. Do not connect line to hose at this time.
17. For 1987 models: Reinstall brake line. Torque brake line connectors to 12 ft.lbs.
For 1988 models: Install new brake line. Torque brake line connectors to 12 ft.lbs.
18. For 1987 models: Install new fuel delivery line. Reinstall fuel return line.
For 1988 models: Install new fuel delivery line and new fuel return line.
19. Apply a thin coat of lubricant to the black rubber pipe clip before installation. Reinstall the black rubber pipe clip to the bracket above the rear axle, using the existing bolt.
20. Reinstall fuel filter.
21. Connect the following hoses:
a. Connect fuel evaporator hose to the fuel tank line.
b. Connect fuel return line hose to the fuel return line.
c. Connect fuel filter hose to the fuel delivery line.
d. Connect fuel delivery line hose to the fuel delivery line.
e. Connect fuel return hose to the fuel return line.
f. Connect fuel evaporator hose to the fuel evaporator line, below the canister check valve.
22. Reconnect speedometer cable to the transmission.
23. Reinstall transfer case protector. Torque bolts to 27 ft.lbs.
24. Bleed the brake system as outlined in the appropriate Workshop Manual.
25. Verify that there is no interference between rear heater mounting bolts and fuel lines or brake line. Clearance must be at least 0.5 inch (12 mm).
FLAT RATE MANUAL UPDATE INFORMATION
OPERATION OPERATION TASK TIME
NUMBER
Rear Heater 120168 Install 2.1
Campaign Kit
Use Trouble Code 07 for all Campaign operations.
DEALER RESPONSIBILITY
Isuzu dealers are responsible for repairing any affected vehicle regardless of date of purchase, mileage or selling dealer.
Dear Trooper or Trooper II Owner:
THIS NOTICE CONCERNS A SAFETY DEFECT THAT COULD RESULT IN A PARTIAL LOSS OF BRAKING POWER AND/OR FUEL.
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Isuzu Motors Limited has determined that a defect which relates to motor vehicle safety exists in some 1987 and 1988 TROOPER (II) vehicles.
WHAT IS THE DEFECT?
Trooper (II) vehicles equipped with a rear heater may experience a failure in the brake, fuel delivery or fuel evaporative lines caused by contact with the rear heater attaching bolts or hose clamps.
WHAT COULD HAPPEN?
Continued contact between the heater attaching bolts and hose clamps with the brake and fuel lines could result in wear and leakage of any of the lines. A leak in the brake line could result in a partial brake loss, whereas a leak in the fuel line could result in fuel spillage and fire could result.
WHAT SHOULD YOU DO?
Please make an appointment with your Isuzu Dealer who will replace the line(s) on your vehicle at no charge. It will take approximately two (2) hours to repair the vehicle.
WHAT IF YOU HAVE PROBLEMS?
If you believe that the defect has not been or cannot be remedied without charge within a reasonable time, you may contact the appropriate Isuzu Regional Office listed in the back of the Owners Manual; the National Consumer Affairs Office, American Isuzu Motors Inc., P.O. Box 2280, City of Industry, CA 91746; the Administrator of the National Highway Traffic Safety Administration, 400 7th St. S. W., Washington, DC 20590; or call the Auto Safety Hotline (800) 424-9393 (Washington, DC area residents may call 366-0123).
We apologize for any inconvenience and appreciate your cooperation in having this correction to your Isuzu vehicle completed as soon as possible.
IMPORTANT
If you have sold your vehicle, please enter the new owner's name and address, if known, on the enclosed "Change of Information" postcard and drop it in the mail. Postage has already been paid.
THE USE OF SEAT BELTS BY ALL VEHICLE PASSENGERS IS RECOMMENDED AT ALL TIMES. NATIONAL SAFETY COUNCIL STATISTICS CLEARLY INDICATE THAT THE USE OF SEAT BELTS REDUCES THE POSSIBILITY OF SERIOUS AND FATAL INJURIES IN ACCIDENTS OR SUDDEN STOPS.