BULLETIN NUMBER:
SB19-J-001

IMPORTANT SERVICE
INFORMATION FOR:

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SERVICE MANAGER

ISSUE DATE:
JANUARY 2019

SERVICE ADVISOR
WARRANTY PERSONNEL

GROUP:
ENGINE

TECHNICIAN
PARTS DEPARTMENT

OIL IN THE AIR CLEANER – UPDATED AIR INTAKE DUCT (SERVICE PART)
AFFECTED VEHICLES
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2011-2019MY Isuzu N-Series Vehicles Produced prior to May
28, 2018
Equipped with 5.2L (4HK1) Diesel Engines
INFORMATION

Some customers may experience issues with oil dripping from the air cleaner or an oil
soaked filter element, along with illuminated Check Engine (CEL) and Check Air Filter
warning lamps.
The purpose of this bulletin is to announce the availability of a new air inlet duct that will
reduce the PCV oil remnants entering the air cleaner and an updated drain plate that will
prevent gear train oil splash from entering the PCV system.
See the Service Procedure in this bulletin for parts and installation information.
SERVICE PROCEDURE

Figure 1 – Original Inlet Pipe

Figure 2 – Updated Inlet Pipe

INLET PIPE REMOVAL & INSTALLATION
1. Remove three (3) 10mm bolts from the PCV flange pipe and loosen the PCV flange
from inlet pipe. (See Figure 3.)

Figure 3

2. Loosen the air duct clamp at the air filter housing (using a 10mm socket).
3. Loosen the air duct clamp at the turbo charger (using a 7mm socket).
4. Remove the air duct as an assembly while also removing the PCV flange from the
inlet pipe.
5. Assemble the new duct using the new inlet pipe, new connector hose, and new
clamp (see Figure 4) and torque clamp to 6.4 N·m (57 lb·in). Transfer air filter
housing clamp to the updated air duct.

Figure 4 – New clamp location

6. Remove PCV flange from the new inlet pipe and remove the “O”-ring from the PCV
flange to use in Step 7. (See Figure 5.)
7. Replace the “O”-ring for PCV flange on the truck with the “O”-ring removed from
the new inlet pipe in Step 6. (See Figure 6.)

Figure 5 – PCV flange from new Figure 6 – PCV flange left on truck
inlet pipe
8. Ensure the air filter housing and turbocharger clamps are in place on the air duct
assembly and install first onto the turbocharger inlet side. Guide the PCV flange
into place during installation being careful not to pinch the “O”-ring during
assembly. Then install duct onto the air cleaner.
9. Insert and torque the three (3) PCV flange mounting bolts to 9 N·m (78 lb·in).
10. Torque the air duct assembly turbocharger clamp to 6.4 N·m (57 lb·in). Then
torque the air filter housing clamp to 4 N·m (35.5 lb·in).
DRAIN PLATE REMOVAL & INSTALLATION

Figure 8 – Original drain plate

Figure 9 – Updated drain plate

11. For single cab vehicles tilt the cab forward following the instructions found in the
applicable Workshop Manual (WSM). For crew cab vehicles remove engine cover
and then remove the transmission oil fill tube. (See Figure 10.)

Figure 10
12. Using a flat blade screwdriver remove the lower clip (Oetiker clamp) from the PCV
drain hose and disconnect the hose. (See Figure 11.)
13. Remove the two (2) tamper proof bolts (Figure 11) from drain plate using
Special Tool EN-48711. (See Figure 12.)
14. Remove old drain plate. (See Figure 11.)

Figure 11

Figure 12

15. Wipe the installation surface of drain adaptor (engine side) with a clean rag to
remove oil and foreign matter.
16. Install rubber packing onto the new drain plate.
17. Place a new clip on the PCV drain hose and connect the hose to the drain plate.
Install new lower clip (Oetiker clamp). (See Figure 13.)

Oetiker clamp
Figure 13
18. Install the drain plate using new bolts and torque the bolts to 23.5 N·m (17.5 lb·in).
19. Check engine oil level. Adjust as necessary.
20. Check air filter and Mass Air Flow (MAF) sensor for oil contamination. If
contamination is found, refer to the applicable WSM for repair procedure.
21. Perform MAF sensor relearning procedure as shown in the Installation Procedure
for the Mass Air Flow (MAF) sensor in the applicable WSM.
22. For single cab, lower the cab and lock it in place in accordance with the instructions
found in the WSM. For crew cab, install the transmission oil fill tube, torque the bolt
to 47 N·m (35 lb ft). Install the engine cover.
23. Start vehicle and check drain plate for leaks.
24. If there are leaks in the drain plate return to Step 12. If there are no leaks, this
service procedure is complete.

PARTS INFORMATION
The following new parts are now available from AIPDN.
Part Number

Description

QTY

8-98399-910-0

Inlet Pipe

1

8-98399-909-0

Connector Hose

1

1-09707-138-0

Duct Clamp (Clamp C)

1

8-97501-245-0

Drain Plate

1

8-98142-378-0

Rubber Hose, Oil Clip

1

8-98165-143-0

Drain Plate Bolts

2

8-94394-671-0

Drain Plate Packing

1

WARRANTY INFORMATION

The following labor operation information is provided for warranty claim submission (if
the vehicle or replacement part is still under warranty).
Labor Operation

Description

J6040

Updated Air Duct Installation – Oil in the
Air Cleaner

Labor Time

Single Cab

1.0

Double Cab

1.4