SB-12-L-003-A

SB-10050120-6224
BULLETIN NUMBER:
SB12-L-003A
IMPORTANT SERVICE
INFORMATION FOR:
 SERVICE MANAGER
 SERVICE ADVISOR
 TECHNICIAN
 PARTS DEPARTMENT
 WARRANTY PERSONNEL
ISSUE DATE:
DECEMBER 2012
GROUP:
FUEL & EXHAUST
NPR FROZEN DIESEL EXHAUST FLUID (DEF) LINE – DTC P1490
AFFECTED VEHICLES

2011-2012MY Isuzu NPR (3.0L 4JJ1)
With production dates prior to 12/12/2011

2011-2012MY Isuzu NPRHD/NQR/NRR (5.2L 4HK1)
With production dates prior to 1/2/2012
This bulletin supersedes SB12-L-003. This bulletin is being updated to include
updated affected vehicle information. Please discard bulletin SB12-L-003.
CONDITION
The customer may be experiencing the check engine light illuminated, and the engine
may also be in reduced power mode.
CAUSE
This condition may be caused due to Diesel Exhaust Fluid (DEF) freezing during
extremely cold weather. This is a normal characteristic of DEF. A 32.5% solution of DEF
mixed with water will begin to crystallize and freeze at 12°F (-11°C). Under this
extremely cold weather condition, the DEF system may not inject fluid into the SRC
Chamber in order to maintain the required NOx level. Therefore, the dealer may find the
DTC P1490, “DEF System NOx Trap Low Efficiency” appearing in the DTC list.
CORRECTION
IMPORTANT: It is necessary to retrieve a current Isuzu Health Report before
clearing any DTCs or attempting any reprogramming.
New DCU calibration is needed to improve DEF tank defrosting/heating time. Additional
insulation and heating to the outside of the DEF tank lines are outlined in this bulletin’s
instruction. Also follow the service manual for this and any other DTC diagnostic aid.
SERVICE PROCEDURE
1. Retrieve current Isuzu Health Report Data.
IMPORTANT: Be sure your IDSS is updated to the latest release before
programming the DCU.
2. Using IDSS, program the DCU to the latest available calibration.
3. Replace the DEF tube lines and other required parts as per the following
procedure.
REMOVAL (4HK1)
CAUTION: Diesel Exhaust Fluid (DEF) is highly corrosive to electrical connectors
and rubber used in electrical wiring. If any of these components come in contact
with DEF, wash the area thoroughly with warm water and allow to completely dry
before reconnection. Make a visual inspection for damage if the connection has
been exposed to DEF.
1. Remove the DEF injector cover.
Figure 1
Figure 1a
2. Using a clean cloth/rag, clean the following connections:
a. Engine coolant tube connector at DEF injector.
b. DEF tube connector at DEF injector.
c. Engine coolant hoses at frame connection.
d. DEF tube connector at frame connection.
3. Clamp the flexible engine coolant hoses at frame connection.
4. Disconnect the coolant lines at the frame connections and at the DEF injector.
NOTE: Use a drain pan to catch any coolant that may drain out during this
process.
2
Figure 2
Figure 2a
5. Disconnect the DEF tubes at the frame connections and at the DEF injector.
6. Remove the DEF tube/engine coolant hoses bracket bolts. Save the mounting
bolts since they will be reused to install a new bracket.
7. Remove the DEF tube/engine coolant hoses assembly and mounting bracket
from the vehicle.
INSTALLATION (4HK1)
1. Using a clean cloth/rag, clean the following connections:
a. Engine coolant tube connector at DEF injector.
b. DEF tube connector at DEF injector.
c. Engine coolant hoses at frame connection.
d. DEF tube connector at frame connection.
2. Install the DEF tube/engine cooling hoses bracket. Reuse the mounting
hardware from Step 6 of the removal procedure.
3. Install the new DEF tubes. Pay close attention to the new routing positions and
be sure the tubes are secure.
4. Connect the DEF tubes at the frame connections and at the DEF injector. Be
sure an audible click sound is heard ensuring the connection is secure.
5. Install the engine coolant hoses at the DEF injector. Be sure an audible click
sound is heard insuring the connection is secure.
6. Install the engine coolant hoses at the frame connection. Properly secure the
two connections with hose clamps.
7. Remove the clamps from the engine coolant hoses installed in Step 3 of the
removal procedure.
8. Install the DEF injector cover. Be sure to install the new clip provided.
3
9. Start the engine then activate the DEF tank heater control valve with IDSS to
purge the air from the engine cooling hoses. Both hoses should be at same
temperature when air is removed.
Figure 3 -
Figure 3a -
132.5”, 150”, 176” Wheel Bases
109” Wheel Base
4
REMOVAL (4JJ1)
CAUTION: Diesel Exhaust Fluid (DEF) is highly corrosive to electrical connectors
and rubber used in electrical wiring. If any of these components come in contact
with DEF, wash the area thoroughly with warm water and allow to completely dry
before reconnection. Make a visual inspection for damage if the connection has
been exposed to DEF.
1. Remove the DEF supply pump cover.
Figure 4
NOTE: Use a drain pan to catch any coolant that may drain out during this process.
2. Disconnect the engine coolant and the DEF tube at the DEF supply pump.
3. Disconnect the DEF tube assembly from the bracket.
Figure 5
5
4. Disconnect the DEF tube at the DEF injector.
5. Clamp the flexible engine coolant hoses at frame connection.
6. Disconnect the engine coolant hose above the DEF injector. Remove the “P” clip
and mounting bracket installed at this location. Discard the mounting bracket. A new
bracket will be installed in the installation procedure.
NOTE: Use a drain pan to catch any coolant that may drain out during this process.
Figure 6
7. Disconnect the “P” clamp for the DEF tube assembly.
8. Disconnect the DEF tube assembly at the 5 mounting clips.
Figure 7
9. Remove the DEF tube clip bracket.
6
INSTALLATION (4JJ1)
1. Install the new DEF tube clip bracket.
2. Install the new DEF tube assembly across the frame at the 5 mounting clip
locations.
3. Install the “P” clamp for the DEF tube assembly.
4. Install the engine coolant hose above the DEF injector. Install the “P” clip and
mounting bracket at this location. Install the new mounting bracket.
5. Unclamp the flexible engine coolant hoses at the frame connection.
6. Install the DEF tube at the DEF injector.
7. Install the DEF tube assembly to the bracket.
8. Reconnect the engine coolant and DEF tube at the DEF supply pump.
9. Install the DEF supply pump cover.
PARTS INFORMATION
Eng
4HK1
4JJ1
Part Number
Description
Qty
8-98199-114-0
8-98204-966-0
8-98199-176-0
TUBE ASM; UREA LIQ DOSING
TUBE ASM; UREA LIQ DOSING
BRACKET; UREA LIQ DOSING TUBE
1
1
1
8-98199-178-0
1-09700-126-1
8-98201-060-0
8-98210-727-0
8-98137-046-0
8-98201-092-0
1-09700-608-2
0-95235-576-0
BRACKET; UREA LIQ DOSING TUBE
CLIP; UREA LIQ DOSING TUBE
TUBE ASM; UREA LIQ DOSING
BRACKET; UREA LIQ DOSING TUBE CLIP
CLIP; UREA LIQ DOSING TUBE
HOSE; UREA LIQ RSVR HTR RTN
CLIP; UREA LIQ DOSING TUBE
CLIP; UREA LIQ DOSING TUBE
1
1
1
1
1
1
1
1
Wheel
Base (in.)
132.5, 150,
176
109
WARRANTY INFORMATION
For vehicles repaired under warranty, use:
Labor
Operation
L3025
Description
Replace, NPR Frozen DEF Line (DTC P1490)
Add for Diagnosis
Labor Time
1.9 hrs
0.3 hrs
7