SB-10045719-2298

IMPORTANT SERVICE
INFORMATION FOR:

BULLETIN NUMBER:
CB12-J-001

 SERVICE MANAGER
 SERVICE ADVISOR
 TECHNICIAN
 PARTS DEPARTMENT
 WARRANTY PERSONNEL

ISSUE DATE:
AUGUST 2012
GROUP:
ENGINE

VOLUNTARY EMISSION RECALL
TURBOCHARGER LOOSE HOUSING – #V1202

CV

AFFECTED VEHICLES
 2007-2010MY Isuzu N-Series
 2007-2010MY GMC/Chevrolet W-Series
Equipped with Diesel Particulate Filter (DPF)
INFORMATION
CONDITION
Isuzu Motors Limited has identified the potential failure of turbochargers produced from
March 2009 through November 2011, at the turbocharger supplier. During that production
period, improper process control occurred during the assembly of the turbocharger. As a
result, during engine operation, the turbocharger housing can become loose. The engine
malfunction indicator lamp is illuminated and vehicle operation will revert to a limp home
mode (reduced power mode).
The affected turbochargers were installed in 2009-2010MY vehicle produced from March
2009 through February 2010. In addition, the affected turbochargers were also shipped as
service parts as late as November 2011. This turbocharger is also used in certain 20072009MY vehicles. Therefore, certain 2007-2009MY vehicles are also affected if they had the
turbocharger replaced with one in that production period.
CORRECTION
Dealers are to inspect the serial number of the turbocharger and determine if the
turbocharger will need to be replaced, based upon the serial number’s production range. This
service will be performed for the customer at no charge.
NOTE: California dealers must issue a “Proof of Correction Certificate” to owners of
the affected vehicles after completing the work specified below. Instruct the Isuzu
owner to keep the certificate as the California Department of Motor Vehicles (DMV)
may ask for proof of completion of this campaign before permitting renewal of the of
the registration.
IMPORTANT: Dealers must fill out every field of the Proof of Correction Certificate.

VEHICLES INVOLVED
Involved are 2007-2010 model year Isuzu N-Series and 2007-2010 model year
GMC/Chevrolet W-Series vehicles equipped with Diesel Particulate Filter (DPF).
Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the
Isuzu Vehicle Inquiry System (IVIS).
For dealers with involved vehicles, a listing of involved vehicles containing the complete
vehicle identification number has been or will be provided. Dealers will not have a report
available if they have no involved vehicles currently assigned.
INSPECTION PROCEDURE
1. Lift the cab of the truck.
2. Locate the turbocharger on the passenger side of the engine.
3. Locate the turbocharger’s serial number located on the top of the turbocharger
compressor housing. Write the serial number on the Repair Order as it will be required for
warranty submission.

Figure 1 – Location of Serial Number Plate

Figure 2 – Serial Number – 110106470E
1. Top Row: Year, Month (ex: 2011, January)
th
2. Middle Row: Day, Sequence (6 day, #470 built
on that day)

4. Is the serial number within the production range of this emissions recall? Refer to the
Turbocharger Serial Number Production Range provided below.
Turbocharger Serial Number Production Range
090304183E through 111109240E
VIFH 0903
RHF55V 04 183E
898027-7735

through

VIFH 1111
RHF55V 09 240E
898027-7735



If the turbocharger is NOT within the production range above, the turbocharger is not
affected by the condition described in this campaign bulletin. Apply the campaign
label and return the vehicle to the customer.



If the turbocharger is within the production range of this emissions recall, continue
with the service procedure provided in this campaign bulletin.
SERVICE PROCEDURE

TURBOCHARGER REMOVAL
1. Disconnect the battery.
2. Drain engine coolant.
3. Remove the front exhaust pipe/exhaust brake assembly (see Figure 3).
 Remove the three clamping nuts from the front exhaust pipe at the turbocharger.
 Remove the four clamping nuts from the front exhaust pipe at the exhaust brake
assembly.
 Remove the two bolts from the front exhaust pipe bracket at the right side of the
transmission.
 Disconnect the vacuum line from the exhaust brake valve.
4. Remove the oil return pipe (see Figure 4).

Figure 3 – Front Exhaust Pipe/Exhaust
Brake Assembly

Figure 4
1. Oil Return Pipe

5. Disconnect the water feed pipe (see Figure 5).
 Remove the bolt from the pipe mounting clip.
 Remove the eye bolt at the cylinder block.
6. Remove the two turbocharger clamping nuts (4) (see Figure 6).

Figure 5
1. Water Feed Pipe

Figure 6
1. Turbocharger Clamping Nuts
2. Exhaust Adapter
3. Exhaust Adapter Mounting Bolt

4. Turbocharger Clamping Nuts

7. Disconnect the connector from the turbocharger actuator.
8. Disconnect the air intake duct from the turbocharger (see Figure 7).
NOTICE: Do not remove the tamper proof bolts that clamp the PCV hose from
the intake duct.
9. Remove the charge air hose from the turbocharger and the charge air cooler (see
Figure 7).
10. Disconnect the water return pipe and bracket from the turbocharger and the cylinder
head (see Figure 8).
 Remove the eye bolt from the turbocharger.
 Remove the bolts from the pipe mounting clips.
 Remove the fan guide bracket nuts.
 Disconnect the “U”-shaped rubber hose from the water return pipe.

Figure 7
1. Air Intake Duct
2. Charge Air Hose
3. Clamp
4. Clamp
5. Clamp

Figure 8
1. Mounting Bolt
2. Water Return Pipe & Bracket

11. Remove the oil feed pipe (see Figure 9).
 Remove the eye bolt from the turbocharger.
 Remove the bolts from the pipe mounting clips.
12. Remove the turbocharger with the exhaust adapter (see Figures 6 and 10).
 Remove the turbocharger clamping nuts (1).
 Remove the exhaust adapter heat protector.
 Remove the exhaust adapter mounting bolts (3).

Figure 9
1. Oil Feed Pipe

Figure 10
1. Exhaust Adapter
2. Heat Protector
3. Exhaust Adapter Gaskets

TURBOCHARGER INSTALLATION
NOTE: All necessary new gaskets and mounting hardware are provided in the
service kit.
1. Install the exhaust adapter.
 Install the three new exhaust adapter studs into the new turbocharger.
 Install the new gasket and the exhaust adapter to the exhaust manifold.
Tighten the new nuts to the specified torque.
Tightening Torque: 32 Nm (24 lb ft)



Install the exhaust adapter heat protector. Tighten the bolts to the
specified torque.
Tightening Torque: 8 Nm (69 lb ft)
Install the turbocharger heat protector. Tighten the bolts to the specified torque.
Tightening Torque: 8 Nm (69 lb ft)

2. Install the two new studs onto the turbocharger mounting flange for the exhaust
manifold.
3. Install the new turbo gasket and the turbocharger to the exhaust manifold. Tighten
the new nuts and the exhaust adapter new bolt to the specified torque.
Turbocharger to Exhaust Manifold nuts: 52 Nm (38 lb ft)
Exhaust Adapter to Exhaust Manifold bolt: 24 Nm (17 lb ft)
4. Install the water feed pipe with new packing.
 Install the pipe mounting clip bolt and tighten to the specified torques.
Tightening Torque:
- Eye bolt to the cylinder block: 41 Nm (30 lb ft)
- Eye bolt to the turbocharger: 27 Nm (20 lb ft)
5. Install the oil feed pipe with new packing to the turbocharger. Tighten the eye bolt to
the specified torque.
Tightening Torque: 17 Nm (12 lb ft)
6. Install the water return pipe and bracket.
 Install the “U”-shaped rubber hose between the water return pipe and the
thermostat housing.
 Install the fan guide bracket bolt.
 Install the pipe mounting clip bolts.
 Tighten the eye bolt with new packing to the specified torque.
Tightening Torque: 27 Nm (20 lb ft)
7. Connect the connector to the turbocharger actuator.
8. Connect the air intake duct to the turbocharger and tighten the clamp to the specified
torque.
Tightening Torque: 8 Nm (69 lb in)
9.

Install the charge air hose and tighten the clamps to the specified torque.
Tightening Torque: 6 Nm (52 lb in)

10. Install the oil return pipe.
 Install the new O-rings and the oil return pipe.



Tighten the bolts to the specified torque.
Tightening Torque:
- Bolt to the turbocharger: 9 Nm (78 lb in)
- Bolt to the cylinder block: 22 Nm (16 lb ft)
11. Install the front exhaust pipe/exhaust brake assembly.
 Install a new gasket at the exhaust manifold.
 Install two new gaskets at the exhaust brake.
 Connect the vacuum line to the exhaust brake valve.
 Tighten the nuts and bolts.
Tightening Torque:
- Nut (turbocharger side): 67 Nm (49 lb ft)
- Bolt (exhaust pipe bracket): 18 Nm (13 lb ft)
- Nut (exhaust brake side): 27 Nm (20 lb ft)
12. Reconnect the battery.
13. Replenish the engine coolant. Refer to the “Coolant Refill Procedure” in the “Engine
Cooling System” section of the service manual.
14. Check to make sure the engine oil level is OK, start the engine and let idle for 30
seconds. After 30 seconds, fully accelerate the engine while in Park several times to
get oil flowing to the turbocharger bushings. Check the installation for any leaks and
clear any DTC that may have been present as a result of this condition.
15. Apply the campaign label.
APPLYING THE CAMPAIGN LABEL
1. Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign
Number V1202, Isuzu dealer code and repair date.
2. Affix the campaign label onto the driver's side B-pillar.

California Vehicles Only
When a California emissions campaign is completed by an Isuzu dealer, the dealers must
provide the vehicle owner a “Proof of Correction Certificate”, 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. As set forth in the sample owner notification letter below, the owner will
need to submit the correction certificate to the DMV only if the DMV requests it. Otherwise,
we recommend that owners keep the certificate for their records.

 CUT OUT AND COMPLETE – FOR CALIFORNIA VEHICLES ONLY

Proof of Correction Certificate

CUT OUT AND COMPLETE – FOR CALIFORNIA VEHICLES ONLY 
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from American Isuzu Parts
Distribution Network (AIPDN).
Please confirm the serial number from the suspect
turbocharger is within the affected serial number production range before ordering
replacement parts. Normal orders should be placed on a Daily Order.
PART NUMBER
8-98209-652-0

DESCRIPTION
Turbocharger Assembly

QTY
1

8-98222-115-0

Service Kit

1

Comments
May substitute with part
number 8-98027-773-5 if the
serial number is outside of the
affected production range

NOTE: Dealer inventory of part number 8-98027-773-5 should be inspected for affected
serial numbers. Turbochargers outside of the affected serial number range may be used to
complete this recall. Turbochargers found to be within the affected serial number range can
be returned to AIPDN for full credit.
CLAIM INFORMATION
Submit a Campaign Claim with the information indicated below:
LABOR CODE
V1202

V1203

REPAIR PERFORMED

LABOR
TIME

Emission Recall V1202 – Inspection Tilt Cab

0.3

ADD: for Crew Cab

0.1

Emission Recall V1202 – Replace Tilt Cab

2.5

ADD: for Crew Cab

1.3

IMPORTANT: Dealers must include the turbocharger serial number in the customer
complaint comment field. Failure to provide this information may result in a delay in
claim reimbursement and possible denial.
Refer to the Isuzu Claims Processing Manual for details on Campaign Claim Submission.
OWNER NOTIFICATION
Notification letters will be sent to owners of affected vehicles already retailed in the United
States of America and Canada. (See enclosed copies).
DEALER RESPONSIBILITY
All unsold new vehicles in dealers’ possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for
which there is no customer information indicated o 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 owners. Program follow-up cards should not be used for this
purpose, since the owner may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in
your dealership for service, you must take the steps necessary to be sure the program
correction has been made before selling or releasing the vehicle.

OWNER LETTER – UNITED STATES (Produced with affected turbocharger)

VOLUNTARY EMISSION RECALL CAMPAIGN #V1202
Dear Customer:
This notice is sent to inform you that Isuzu Motors Limited is conducting a voluntary emission recall
that includes your vehicle VIN .
Reason For This Recall?
Your model year vehicle may have been manufactured with a turbo
charger that may, over time, develop a loose compressor housing. If this condition were to occur, it
could result in the illumination for the Check Engine Malfunction Indicator Light (MIL) with DTC P003A
and reduced engine power.
What Will Be Done?
The turbocharger assembly will be inspected for the suspect turbocharger serial number. If the
turbocharger on your vehicle is found to be within the affected range, it will be replaced. This service
will be performed for you at no charge.
What You Should Do?
We recommend that you contact your local Isuzu dealer as soon as possible to schedule an
appointment. Instructions for replacing the turbocharger have been sent to your dealer. Isuzu
estimates that the inspection and, if required, repair will take approximately three hours to perform.
However, additional time may be necessary depending on how appointments are scheduled and
processed at your dealership. To locate the nearest Isuzu dealer you can visit our website at
www.isuzucv.com and click on the dealer locator icon and enter your zip code or state. Should you
not have access to the internet please contact our Customer Relations department by calling 1-866441-9638.
Emission Warranty Information:
In order to ensure your full protection under the emission warranty made applicable to your vehicle by
State and 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. In addition, in some states participation in an emission recall
may be necessary to renew the vehicle registration.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of
your continued satisfaction with our products.
Sincerely,
Isuzu Commercial Truck of America
Important: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known, on the
attached "Change of Information" postcard, tear off at both perforations, and drop it in the mail. Postage has already
been paid. We will contact the new owner.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to
the lessee within ten days. Lessor means a person or entity that is the owner, as reflected on the vehicle title,
of any five or more leased vehicles.

OWNER LETTER – UNITED STATES (May have received an affected turbocharger)

VOLUNTARY EMISSION RECALL CAMPAIGN #V1202
Dear Customer:
This notice is sent to inform you that Isuzu Motors Limited is conducting a voluntary emission recall
that includes your vehicle VIN .
Reason For This Recall?
Your model year vehicle, during a warranty repair, may have
received a turbocharger assembly which, over time, may develop a loose compressor housing. If this
condition were to occur, it could result in the illumination for the Check Engine Malfunction Indicator
Light (MIL) with DTC P003A and reduced engine power.
What Will Be Done?
The turbocharger assembly will be inspected for the suspect turbocharger serial number. If the
turbocharger on your vehicle is found to be within the affected range, it will be replaced. This service
will be performed for you at no charge.
What You Should Do?
We recommend that you contact your local Isuzu dealer as soon as possible to schedule an
appointment. Instructions for replacing the turbocharger have been sent to your dealer. Isuzu
estimates that the inspection and, if required, repair will take approximately three hours to perform.
However, additional time may be necessary depending on how appointments are scheduled and
processed at your dealership. To locate the nearest Isuzu dealer you can visit our website at
www.isuzucv.com and click on the dealer locator icon and enter your zip code or state. Should you
not have access to the internet please contact our Customer Relations department by calling 1-866441-9638.
Emission Warranty Information:
In order to ensure your full protection under the emission warranty made applicable to your vehicle by
State and 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. In addition, in some states participation in an emission recall
may be necessary to renew the vehicle registration.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of
your continued satisfaction with our products.
Sincerely,
Isuzu Commercial Truck of America
Important: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known, on the
attached "Change of Information" postcard, tear off at both perforations, and drop it in the mail. Postage has already
been paid. We will contact the new owner.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to
the lessee within ten days. Lessor means a person or entity that is the owner, as reflected on the vehicle title,
of any five or more leased vehicles.

OWNER LETTER – CANADA (Produced with affected turbocharger)

VOLUNTARY EMISSION RECALL CAMPAIGN #V1202
Dear Customer,
This notice is sent to inform you that Isuzu Motors Limited is conducting a voluntary emission recall
that includes your vehicle VIN .
Reason For This Recall?
Your model year vehicle may have been manufactured with a turbo
charger that may, over time, develop a loose compressor housing. If this condition were to occur, it
could result in the illumination for the Check Engine Malfunction Indicator Light (MIL) with DTC P003A
and reduced engine power.
What Will Be Done?
The turbocharger assembly will be inspected for the suspect turbocharger serial number. If the
turbocharger on your vehicle is found to be within the affected range, it will be replaced. This service
will be performed for you at no charge.
What You Should Do?
We recommend that you contact your local Isuzu dealer as soon as possible to schedule an
appointment. Instructions for replacing the turbocharger have been sent to your dealer. Isuzu
estimates that the inspection and, if required, repair will take approximately three hours to perform.
However, additional time may be necessary depending on how appointments are scheduled and
processed at your dealership. To locate the nearest Isuzu dealer you can visit our website at
www.isuzutruck.ca and click on the dealer locator icon and enter your province. Should you not have
access to the internet please contact our Customer Relations department by calling 1-866-441-9638.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of
your continued satisfaction with our products.
Sincerely,
Isuzu Commercial Truck of Canada
Important: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known, on the
attached "Change of Information" postcard, tear off at both perforations, and drop it in the mail. Postage has already
been paid. We will contact the new owner.

OWNER LETTER – CANADA (May have received an affected turbocharger)

VOLUNTARY EMISSION RECALL CAMPAIGN #V1202
Dear Customer,
This notice is sent to inform you that Isuzu Motors Limited is conducting a voluntary emission recall
that includes your vehicle VIN .
Reason For This Recall?
Your model year vehicle, during a warranty repair, may have
received a turbocharger assembly which, over time, may develop a loose compressor housing. If this
condition were to occur, it could result in the illumination for the Check Engine Malfunction Indicator
Light (MIL) with DTC P003A and reduced engine power.
What Will Be Done?
The turbocharger assembly will be inspected for the suspect turbocharger serial number. If the
turbocharger on your vehicle is found to be within the affected range, it will be replaced. This service
will be performed for you at no charge.
What You Should Do?
We recommend that you contact your local Isuzu dealer as soon as possible to schedule an
appointment. Instructions for replacing the turbocharger have been sent to your dealer. Isuzu
estimates that the inspection and, if required, repair will take approximately three hours to perform.
However, additional time may be necessary depending on how appointments are scheduled and
processed at your dealership. To locate the nearest Isuzu dealer you can visit our website at
www.isuzutruck.ca and click on the dealer locator icon and enter your province. Should you not have
access to the internet please contact our Customer Relations Department by calling 1-866-441-9638.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of
your continued satisfaction with our products.
Sincerely,
Isuzu Commercial Truck of Canada
Important: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known, on the
attached "Change of Information" postcard, tear off at both perforations, and drop it in the mail. Postage has already
been paid. We will contact the new owner.