SERVICE BULLETIN 16 January 2015 Bulletin Code: S2015-07

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Isuzu D-MAX & MU-X Center Glove Box Lid Return Spring - Service Campaign S201507

To: Dealer Principals, General Managers, Sales Managers, Service Managers and Warranty Managers. AFFECTED MODELS: Isuzu D-MAX & MU-X 2015MY (refer to the attached VIN list – for the details of affected units). CONCERN: A concern has been identified whereby the center glove box lid may not open automatically once the release button has been depressed. CAUSE: The root cause of the phenomena has been identified as glove box lid return springs with an incorrect torsional value fitted to a limited number of center glove box assemblies. CORRECTION: The attached rework instruction contained in this bulletin must be followed to rectify the potential concern. Make sure the procedure is read through thoroughly before commencing the rework procedure and ensure all Cautions and Warnings outlined in the procedure are adhered to, to prevent any damage to the trim or components.

At the time of this bulletin, all potentially affected units are identified as being in Dealer’s stock.

Please ensure any affected vehicles are rectified before delivery to the end user.

Should an affected vehicle be delivered to the customer before the service campaign has been completed, the selling Dealer should contact the customer and schedule an appointment to have the necessary rework completed.

PARTS INFORMATION:

a) Due to the limited availability of campaign parts, IUA can only provide the necessary parts to those

Dealer’s identified as holding potentially affected units in stock.

b) Parts will be sent FOC directly from IUA, marked for the attention of the Dealer Service manager on

Friday 16 January 2015.

c) The external packaging will be labelled “D-MAX SERVICE CAMPAIGN S201507” for ease of

identification.

d) Should additional parts be required, please contact IUA at service@iua.net.au and request

additional parts as necessary.

Part Number Part Description Quantity required

8982986780 SPRING; Upper Lid, RH 1

8982986790 SPRING; Upper Lid, LH 1

8981941761 HINGE; Lid 2

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CLAIM INFORMATION:

IDS Bulk Campaign

Code (Menu DC603) Operation

Code Operation Code Description Fault Code

Time (Hr.)

S201507 W9926 Bezel Lid Spring Replacement 96 0.6

a) Ensure that a warranty claim for any vehicle reworked is submitted via Dealer Connect (IDS) Menu

DC603 “Warranty Bulk Campaign Entry” within 24 hours of the rework being completed. b) For further information on claim submission; please refer to the Warranty System Manual.

If you have any questions regarding this rework procedure please contact your assigned Regional Service Manager. A copy of this bulletin can be found on the IUA Xnet under Dealer Bulletins / Service / Campaigns Regards,

Andy Gibson General Manager - Service

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Additional Information Required Tools

Screw driver (Philips head and Flat head).

Protective tape. Service campaign outstanding vehicle checking process Checking Step 1: In Dealer Connect (IDS) go to menu DC611 “Warranty Unit Enquiry” and input the VIN.

If the vehicle is outstanding as shown below (figure 1 & 2), proceed to Checking Step 2.

If the VIN is not listed as outstanding in IDS, no rework required.

Figure 1

LH Spring RH Spring

Plastic hinge

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Checking Step 2: After confirmation that the vehicle is still outstanding, check the tyre placard label located on the RH B pillar (figure 3),

If there is NO “Circle” mark (O) on the tyre placard label (figure 4), proceed to the rework process.

If there is a “Circle” mark (O) present on the tyre placard label (figure 5), no rework required. Please contact IUA.

Figure 2

Figure 3

Figure 4 Figure 5

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Rework procedure Read this instruction carefully and thoroughly before conducting the rework process. CAUTION: - Use extreme care when removing and installing parts to avoid any scratches or damage. - Ensure every function on the AC control panel and Audio unit is working after installation. Step 1 Ensure the ignition is OFF.

For AT transmission, press and hold “Shift Lock” button then move the shift lever to “N” position to allow sufficient space for the AC control panel removal (figure 6).

For MT transmission, there is no need to move the shift lever. Step 2 Turn all 3 knobs in the direction as shown below until they reach their steps. This is to ease the reinstallation of the cable in case it is disconnected during the AC control panel removal (figure 7).

Figure 6

Figure 7

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Step 3 Remove the AC control panel by gently pulling it away from the console. Starting from the bottom part (figure 8 & 9) then continue on both sides (figure 10 & 11) until all clips are unlocked.

CAUTION: - Do not disconnect any connectors or cables from the AC control panel. Step 4 Attach the protective tape on both sides of the centre air vent grille to avoid scratching the surface (figure 12).

Figure 8 Figure 10

Figure 12

Figure 11 Figure 9

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Step 5 Remove the audio retaining screw(s). One screw for standard audio (figure 13) and two screws for Sat Nav audio (figure 14). Retain the screws for reinstallation. Step 6 Remove the audio by gently pulling it out from the bottom part (figure 15). Disconnect the connector of the Hazard switch (figure 16), antenna and other connectors connecting to the audio unit (figure 17).

Figure 13 Figure 14

Figure 15 Figure 16

Figure 17

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Step 7

Remove the two retaining screws for the centre glove box (figure 18). Then remove the centre glove box by gently pulling it away from the console (figure 19) until both clips are unlocked (figure 20).

Figure 18 Figure 19

Figure 20

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Step 8 Place the removed centre glove box on a soft surface to avoid scratches or damage. Carefully remove the plastic hinge pin from the glove by gently squeeze the clip’s wings then pull it away from the lid (figure 21). Discard both springs and plastic hinges.

Pull out

Gently squeeze to unlock

Figure 21

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Step 9 Install the new spring and new plastic hinge. CAUTION: - This step shows the correct way to install the new spring. Please read carefully. - This step only shows the LH side. Same procedure applies to the RH side. 9.1) Install the spring. Firstly, ensure that the “Outer spring hook” is rested on the lid as shown (figure 22).

9.2) While holding the spring in place, gently insert the plastic hinge through the slots and spring all the way until it locks (figure 23 & 24).

Figure 22

Figure 23 Figure 24

Gently push

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9.3) Adjust the “Inner Spring hook” to the correct position (figure 25 & 26). Ensure the spring and plastic hinge are in the correct position (figure 27 & 28).

Figure 25 Figure 26

Figure 27

Figure 28

Correct position of the Inner and Outer hook

Correct position of the Inner and Outer hook

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Step 10 Reinstall the centre glove box to the console. Gently press it down until both clips are locked (figure 29). Reinstall the two retaining screws (figure 30). Check the operation of the centre glove box. It must open smoothly and remain open after one gentle click on the button. And it must be firmly closed by a gentle downward push. Step 11 Reconnect the emergency switch connector, antenna and all connectors connecting to audio unit. Step 12 Reinstall the audio unit by gently pressing it until both clips are locked (figure 32). Then retighten the retaining screw(s). One screw for standard audio and two screws for Sat Nav audio (figure 33).

Figure 29 Figure 30

Figure 31

Figure 32 Figure 33

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Step 13

For Auto AC : Ensure the connector is firmly secured (figure 34) then move to step 14.

For Manual AC : Ensure all connectors and cables are still connected to AC control panel. If all of them are firmly secured, skip to step 14. If the connectors are disconnected, reconnect the connector. If the cables are disconnected, follow step 13.1 to 13.3.

13.1) To reinstall the cable, firstly remove the cable coupler and adjust the position as shown below (figure 37 & 38).

Figure 35 Figure 36

Figure 37 Figure 38

Correct position of the cable coupler: Cable is still firmly secured

Incorrect position of the cable coupler: Cable hasn’t been disconnected

Correct position of the cable coupler: Yellow marks are lined up

Correct position of the cable coupler: Yellow marks are NOT lined up

Figure 34

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13.2) Ensure the position of each control knob is still the same from step 2 as also shown below (figure 39). 13.3) Reconnect the cable coupler by gently inserting the cable coupler to the back of the knob. The knob might need to be slightly rotated for the coupler to engage (figure 40). Step 14 Remove the protective tape from both sides of the centre air vent grille. Then reinstall the audio unit, gently push it towards the console until all clips are locked (figure 41 & 42).

Figure 39

Figure 41 Figure 42

Figure 40

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Step 15 Ensure the shift lever is changed back to “P” (for AT transmission) and Neutral (for MT transmission) Step 16 Start the engine and confirm the following operations. 16.1) Reconfirm the operation of the centre glove box. It must open smoothly and remain open after one gentle click on the button. And it must be firmly closed by a gentle downward push. 16.2) Check the operation of the Hazard switch. 16.3) Check the operation of the audio. 16.4) Check the operation of all knobs and switches on the AC control panel. Step 17 Mark a circle on the bottom right corner of the tyre placard which is located on the RH B pillar. Ensure a warranty claim is submitted within 24 hours after the rework is completed.

Figure 43