IB12-J-003C
Service Bulletin Details
Public Details for: IB12-J-003C
Proper installation of the fuel injector pipes into a long block assembly. The fuel injection pipes should be installed onto the new long block assembly after first installing the common rail. When installing the fuel injection pipes, fol
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BULLETIN NUMBER: IB12-J-003C IMPORTANT SERVICE INFORMATION FOR: SERVICE MANAGER SERVICE ADVISOR TECHNICIAN PARTS DEPARTMENT WARRANTY PERSONNEL ISSUE DATE: AUGUST 2016 GROUP: ENGINE LONG BLOCK REPLACEMENT – FUEL INJECTOR PIPE INSTALLATION AFFECTED VEHICLES 2005MY - Current Isuzu N-Series 2005-2010MY GMC and Chevrolet W-Series Equipped with 4HK1 5.2L Diesel Engine 1999-2009MY Isuzu F/H Series 1999-2009MY GMC and Chevrolet C/T Series Equipped with 6HK1 7.8L Diesel Engine 2011MY -Current NPR/NPR Stripped Chassis (Reach) Equipped with 4JJ1 3.0L Diesel Engine This bulletin supersedes IB12-J-003B. This bulletin is being revised to update Model Years and Models. Please discard bulletin IB12-J-003B. INFORMATION Proper Installation of the Fuel Injector Pipes into a Long Block Assembly The fuel injection pipes should be installed onto the new long block assembly after first installing the common rail. When installing the fuel injection pipes, follow the procedure below to ensure proper mating of the fuel injector high pressure inlet, and the fuel injection pipes. NOTE: Fuel injector pipes must not be reused. New pipes must be installed anytime the fuel injector pipes are removed. Failing to replace pipes and/or follow the procedure below may cause severe engine damage. Program the fuel injector flow rates found on the cylinder head cover into the ECM using IDSS (if applicable). Remove the cylinder head cover taking care to avoid damage to the gasket. On 4HK1 and 6HK1 engines only: loosen and remove the fuel injector terminal nuts. On 4HK1 and 6HK1 engines only: loosen and remove the fuel injector harness bracket bolts. Unclip the harness at the inside of the pass through connector. Remove the bracket and wire harness. On 4HK1 and 6HK1 engines only: remove the fuel injector leak off pipe. Discard the gaskets. Loosen but do not remove the fuel injector clamp fixing bolts. Ensure there is clearance between the fuel injector and the fuel injector clamp by gently rotating the fuel injector side to side. Apply engine oil to the outer diameter of the threads of the fuel injectors and the common rail pipe fittings. Loosely thread the fuel injection pipe sleeve nuts to the correct fuel injector and the correct location on the common rail. On 4HK1 and 6HK1 engines only: loosely install the fuel injection pipe clips. HAND TIGHTEN the fuel injector and common rail sleeve nuts until contact is felt between the pipe and the fuel injector, and pipe and common rail fitting. NOTE: Pay close attention to ensure the fuel injection pipe is positioned correctly into the fuel injector high pressure inlet. Torque the fuel injection piping in the following order. Refer to the appropriate service manual for detailed torque specifications. o Fuel injector clamp bolts. o Fuel injector pipe sleeve nuts to the fuel injectors. o Fuel injector pipe to the common rail. o On 4HK1 and 6HK1 engines only: install the fuel injector leak off pipe with new gaskets and tighten the banjo bolts. o On 4HK1 and 6HK1 engines only: clip the fuel injector harness passthrough connector on and install the harness bracket. o On 4HK1 and 6HK1 engines only: install the fuel injector terminal nuts. o On 4HK1 and 6HK1 engines only: torque the fuel injection pipe clips. NOTE: On 4HK1 and 6HK1 engines install the cylinder head cover from the original engine to ensure the correct engine emission label and information will be retained with the vehicle. Because 4JJ1 equipped vehicles have the emissions labels installed on the body of the vehicle, switching the cylinder head cover is not necessary. 2