Recall - 00V253 Fuel Line Shield Installation
BULLETIN NUMBER:SB00-02-S004
ISSUE DATE:
SEPTEMBER 2000
GROUP:
FUEL SYSTEM
2000 TROOPER (UX) FUEL LINE SHIELD SAFETY CAMPAIGN 00V-253
CAMPAIGN IDENTIFICATION NUMBER
Number 00V-253 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with the campaign.
AFFECTED VEHICLES
All 2000 Trooper A/T with TOD (4WD) models.
NOTE:
This does not affect 2000 Trooper with M/T or 2WD models.
CONDITION
In certain high-speed frontal crashes, relative movement and abrasion of internal components can cause the potential for fuel leakage due to separation of fuel hose and fuel line.
CORRECTION
To correct this condition, install Fuel System Shields by following the procedures in this campaign bulletin.
DEALER RESPONSIBILITY
Isuzu dealers must service all affected vehicles at no charge to the owner, regardless of mileage, age of vehicle, or ownership.
NOTE:
All affected model year 2000 Troopers wholesaled to Isuzu dealers after September 6, 2000 will already have been repaired under this Safety Campaign, and will already have the campaign completion label affixed on the driver's side B-pillar adjacent to the manufacturer's identification label.
Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure that this campaign correction has been made before selling or releasing the vehicle.
All unsold new vehicles in dealer's possession and subject to this campaign must be held and repaired per the service procedure in this Campaign Bulletin before being retailed.
OWNER NOTIFICATION
American Isuzu Motors Inc. (AIMI) will begin notifying owners of affected vehicles already retailed by mail on September 21, 2000. Dealers should follow up with vehicle owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in the AIMI Campaign Report AWS 123-1A. Dealers may obtain these postcards from their Regional Office.
SERVICE PROCEDURE
1. Lift vehicle with a chassis/frame hoist. Shift the transmission into neutral and release the parking brake. This is to allow free movement to the propeller shaft during the removal and installation procedure.
CAUTION:
Do not touch the exhaust system, it may be hot when installing Fuel System Shields.
2. Apply alignment marks on the flanges of the following coupling points:
^ Front differential to front propeller shaft (Figure 1)
^ Front propeller shaft to front output flange of the transfer case (Figure 2)
3. Remove the (6) 8 mm Allen head bolts and the (6) 14 mm bolts from the front propeller shaft, and remove the front propeller shaft. (Figures 3, 4, and 5)
CAUTION:
Do not touch the exhaust system, it may be hot when installing Fuel System Shields.
4. Remove the 17 mm bolt and nut of the transmission housing. (Figure 6)
5. Install Fuel Hose Shield, 17 mm bolt and nut. Hold Fuel Hose Shield towards transmission while tightening bolt to specification. Apply torque of 56 lb ft.(Figure 8)
IMPORTANT:
Verify Fuel Hose Shield clearance from floor board or noise may occur. (Figure 8)
CAUTION:
Do not pinch the Breather Hose when installing Fuel Hose Shield.
Figure 9:
NOTE:
Attach the harness clip (facing the front of the vehicle) onto the Fuel Line Shield Assembly prior to installing the Assembly on the vehicle. (Figure 9)
6. Disconnect the Oxygen Sensor Harness from the retaining clip mounted on the fuel line.
7. Install the Fuel Line Shield Assembly (Figure 10).
IMPORTANT:
You must first align the Fuel Line Shield Assembly clips with the fuel line prior to pushing the Fuel Line Shield Assembly in place [all four (4) fuel clips must snap into place] Use mirror to verify that all the clips have snapped into place.
8. Install the oxygen Sensor Harness into the retaining clip mounted on the Fuel Line Shield Assembly.
9. Ensure the connecting surfaces of the front propeller shaft and the flange coupling on each end are clean so no foreign matter will be caught in between.
10. Install the Front Propeller Shaft:
^ Align the marks, which were applied prior to removal of the front propeller shaft.
^ Install the front propeller shaft and tighten all 12 bolts to the specified torque of 46 lb ft.
NOTE:
You must align the marks when installing the Front Propeller Shaft.
11. Lower the vehicle from the hoist.
12. Fill out and affix a campaign completion label using the procedure in the next section, and return the vehicle to the customer.
APPLYING THE CAMPAIGN LABEL
1. Using a ball-point pen, fill out the following information on a campaign label (Part 2-90028-700-0)
^ This Safety Campaign Number: 00V-253
^ Dealer Code
^ Repair Date: (Month/Day/Year)
^ Affix the campaign label adjacent to the manufacturer's identification label located on the driver's side B-pillar.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
Use the new labor operation as shown.
Use Trouble Code 07 for this Labor Operation.
Labor Time includes administrative time allowance.
WARRANTY CLAIM SUBMISSION INFORMATION
For your convenience please use the information when submitting your warranty claim as shown.