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September 9, 2019 NHTSA CAMPAIGN NUMBER: 19V647000

A stall can increase the risk of a crash.

NHTSA Campaign Number: 19V647

Manufacturer Isuzu Technical Center of America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 16,766

Summary

Isuzu Technical Center of America, Inc. (Isuzu) is recalling certain 2017-2019 N-GAS HD and Chevrolet Low Cab Forward 3500 and 4500 vehicles and 2018-2019 Isuzu FTR and Chevrolet Low Cab Forward 6500XD vehicles. The power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to a stall.

Remedy

Isuzu will notify owners, and dealers will inspect the relay box power supply bolt, tightening it as necessary. If the harness or relay box is found to be damaged, it will be replaced or repaired, free of charge. The recall began October 24, 2019. Owners may contact Isuzu customer service at 1-866-441-9638. Isuzu’s number for this recall is V1905.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Check if your Isuzu Truck has a Recall

BULLETIN NUMBER:
CB19-N-002B

ISSUE DATE:
SEPTEMBER 2019

GROUP:
ELECTRICAL

IMPORTANT SAFETY RECALL
RELAY BOX INSPECTION – 19V-647
(Transport Canada 2019-452)

AFFECTED VEHICLES

2018-2019MY Isuzu FTR Vehicles
2017-2019MY Isuzu N-Gas Vehicles Wholesaled on or before 9/9/2019

This bulletin supersedes campaign bulletin CB19-N-002A. This bulletin is being revised to include the sample owner letters for US and Canada. Please discard previous campaign bulletin CB19-N-002A.

INFORMATION

CONDITION

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.

CORRECTION

Isuzu dealers are to inspect and torque the power supply bolt in all affected vehicles. During the inspection, the harness and relay box will be checked for damage and any excess insulation. If there is any excessive insulation, the bolt will be removed, the excess insulation will be trimmed away and the bolt will then be torqued to the appropriate specification. If the harness or relay box is found to be damaged it will be repaired or replaced. This service will be performed free of charge.

VEHICLES INVOLVED

Involved are certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles.

NOTE: It is not necessary to generate a health report in order to submit a warranty claim.

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 report of involved vehicles containing the complete vehicle identification numbers has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.

PARTS INFORMATION

If the result of the technician’s inspection done in Step 8 of the Service Procedure below directs them to send a photo to the Technical Assistance Line (TAL), additional parts (e.g., harness) may be required to complete this recall. Additional parts may not be ordered without direction and approval from TAL. Dealers are responsible to ensure parts are ordered using the correct affected VIN number. Harnesses mistakenly ordered by a dealer may not be returned.

All harnesses are E MAC coded. After placing a part order for this recall as directed by TAL, please contact TAL to update the TAL case with the appropriate order reference number to have your parts released.

SERVICE PROCEDURE

Place the vehicle in park, apply the parking brake, and remove the key from the engine control switch.
Disconnect the negative battery cable.
If the vehicle is a crew cab model, remove the driver side rear step. (See Figure 1.) If the vehicle is a standard cab, proceed to the next step.

Figure 1

1.     Bolt
2.     Nut
3.     Rear Step

Remove the fuse box lid to expose the relays and fuses. (See Figure 2.)

Figure 2

Remove the three (3) 12mm fuse box mounting bolts and set aside for later use. (See Figure 3.)

Figure 3

Flip the fuse box over and remove the lower cover using a flat blade screwdriver to release the five (5) locking tabs. Set the lower cover aside for later use. (See Figures 4 and 5.)


Figure 4	Figure 5

Remove the inner cover by removing the PVC tape, pulling the grommet off the end of the fuse box halves and using the same process to release the locking tabs as in Step 4. Set the cover to the side. (See Figures 6, 7 and 8.)

Figure 6

Figure 7

Figure 8

Inspect the condition of the relay box power wire. (See Figures 9 and 10 for OK condition.). Determine if there is any damage to the power wire and/or relay box:
1. If there is any damage, take a photo similar to Figure 9 and email it to isuzuta@icta-us.com. Then call the Isuzu Technical Assistance Line at 1-877-4783828, Prompt 3 for further instructions. Document the TAL case number on the repair order. This will be required for claim submission.
2. If there is no evidence of damage from heat, continue to Step 9.
Inspect the wire terminal for excessive insulation. (See Figures 10 and 11.) If the insulation is OK, proceed to Step 11. If the insulation is Not OK, proceed to Step 10.

Figure 9


Figure 10 – OK Condition	Figure 11 – Not OK Condition

Remove the terminal bolt and lift the terminal away from the fuse box. Using a razor blade, carefully trim away any excess insulation as necessary. Then reinstall the bolt.
Torque the power supply terminal bolt to the specified torque.

Tightening Torque: 30.1 lb in. (3.4 Nm).

Reinstall the white inner fuse box cover.
Reinstall the rubber grommet and tape as necessary.
Reinstall the fuse box lower cover.
Mount the fuse box onto the vehicle using the three (3) 12mm mounting bolts removed in Step 5. Tighten the bolts to the specified torque.

Tightening Torque: 5.3 lb ft. (7.1Nm).

Reinstall the fuse box cover.
If the vehicle is a crew cab model, reinstall the driver side rear step and torque to the specified torque. (See Figure 1.) For standard cab, proceed to the next step.

Tightening Torque: 13 lb ft. (18 Nm).

Reinstall the negative battery cable. Tighten the bolts to the specified torque.

Tightening Torque: 53 lb in. (6 Nm).

Proceed to Applying the Campaign Label.

APPLYING THE CAMPAIGN LABEL

Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number V1905, Isuzu dealer code, and repair date.
Affix the campaign label onto the driver’s side B-pillar.

CLAIM INFORMATION

Refer to the Isuzu ICS Claims Processing Manual for details on Campaign Claim Submission. Submit only one claim as indicated below.

If you are seeking reimbursement for completed and unclaimed inspection for the Fuse Box Bolt Dealer Service Campaign (V1904) please use labor code V1905. Submitting for reimbursement will also close this safety recall. The fuse box bolt inspection is only required once and may only be claimed once.

NOTE: It is not necessary generate a health report in order to submit a warranty claim.

Labor Code	Description	Vehicle Off Road (VOR) Order	Labor Hours
V1905	Fuse Box Bolt Inspection* (Includes necessary time to trim harness insulation) ADD: For Crew Cab Vehicles	N/A	0.5
V1905T	Fuse Box Harness Replacement Per TAL**	Overnight	0.3 ST

Labor Code

Description

Vehicle Off Road (VOR) Order

Labor Hours

V1905

Fuse Box Bolt Inspection*

(Includes necessary time to trim harness insulation)

ADD: For Crew Cab Vehicles

N/A

0.5

V1905T

Fuse Box Harness Replacement Per TAL**

Overnight

0.3 ST

*Includes 0.1 hours for administrative allowance

**This requires pre-approval from Isuzu TAL. Ensure Step 8 of the service procedure was completed properly by the technician. Failure to receive approval from TAL may result in delayed or no reimbursement.

DEALER RESPONSIBILITY

Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of the vehicle, or ownership. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to perform the required correction according to the instructions contained in this bulletin. Program followup cards should not be used for this purpose, since the customers 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 ensure the recall remedy has been implemented before selling or releasing the vehicle.

Important:

As required by Federal law, dealers are not to deliver any new vehicle in their inventory, which is covered by a Safety Recall, until the necessary remedy has been performed.

Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry Systems (IVIS). Not all vehicles may be involved.

For dealers with involved vehicles, a listing of involved vehicles containing the complete vehicle identification numbers has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.

OWNER NOTIFICATION

Notification letters will be sent to owners of affected vehicles already retailed in the United States and Canada.

[SAMPLE OWNER LETTER – US]

IMPORTANT SAFETY RECALL
NHTSA Recall 19V-647
This notice applies to your vehicle, <VIN>

OCTOBER 2019

Dear Customer,

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Your vehicle <VIN> <MY> model year Isuzu <SERIES> is involved in safety recall NHTSA 19V-647.

WHAT IS THE CONDITION?

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.

WHAT WE WILL DO

WHAT YOU SHOULD DO

We recommend that you contact your Isuzu dealer to schedule an appointment. Although not necessary, please present this Owner Notification Letter at the time of your appointment or refer to Campaign Service Bulletin CB19-N-002B. Isuzu estimates that the repair may take up to 48 minutes to perform, but additional time may be necessary. To locate the nearest Isuzu dealer you can visit our website at www.isuzucv.com, click on the dealer locator link and enter your zip code or state. If you do not have access to a computer terminal please contact our Customer Relations Department at the number listed below.

Isuzu Commercial Truck of America
Customer Relations
1-866-441-9638

If you have any difficulty having this recall performed, we recommend that you call Isuzu customer relations at 1-866-441-9638. If you are still not satisfied that we have remedied this situation without charge, and within a reasonable amount of time, you may wish to write to the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the agency’s toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov. We regret any inconvenience which this action may cause you.

Sincerely,

Isuzu Commercial Truck of America, Inc.

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.

[SAMPLE OWNER LETTER – CANADA]

IMPORTANT SAFETY RECALL
This notice applies to your vehicle, <VIN>
<MY> model year ISUZU <SERIES>

OCTOBER 2019

Dear Customer,

This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Safety Recall Transport Canada 2019-452.

WHAT IS THE CONDITION?

WHAT WE WILL DO

WHAT YOU SHOULD DO

We recommend that you contact your Isuzu dealer to schedule an appointment. Although not necessary, please present this Owner Notification Letter at the time of your appointment or refer to Campaign Service Bulletin CB19-N-002B. Isuzu estimates that the repair may take up to 48 minutes to perform, but additional time may be necessary. To locate the nearest Isuzu dealer you can visit our website at www.isuzutruck.ca or contact our Customer Relations Department at the number listed below.

Isuzu Commercial Truck of Canada
Customer Relations
1-866-441-9638

If you have questions or concerns that your Isuzu dealer is unable to answer, please contact our Customer Relations Department at 1-866-441-9638.

We regret any inconvenience which this action may cause you.

Sincerely,

Isuzu Commercial Truck of Canada, Inc.

OCTOBER 2019
Safety Recall 19V-647
Campaign Bulletin CB19-N-002B

IMPORTANT SAFETY RECALL
RELAY BOX INSPECTION 19V-647
(Transport Canada 2019-452)

To: Isuzu Commercial Truck Service Managers and Parts Managers

This notice, Campaign Bulletin CB19-N-002B with sample owner letters are being sent to update you about Safety Recall – Relay Box Inspection in certain Isuzu commercial vehicles.

AFFECTED VEHICLES

2018-2019MY Isuzu FTR Vehicles
2017-2019MY Isuzu N-Gas Vehicles Wholesaled on or before 9/9/2019

CONDITION

CORRECTION

VEHICLES INVOLVED

Involved are certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019.

OWNER NOTIFICATION

OWNER NOTIFICATION WILL BEGIN OCTOBER 25, 2019.

Please ensure that all appropriate personnel within your dealership are aware of this Safety Recall – Relay Box Inspection and that the necessary repairs are performed on all affected vehicles either in your inventory or brought into your dealership for repair per the above instructions.

Isuzu Commercial Truck of America, Inc.
Customer Relations Department
1400 S. Douglass Road, Suite 100, Anaheim, CA 92806 *1-866-441-9638

DOC ID: DN_19V647_20191018

STOP SALE AND DELIVERY – SAFETY RECALL

Date: September 09, 2019

Subject: Stop Sale and Delivery for Upcoming Safety Recall Affected Models:

2018-2019MY Isuzu FTR Vehicles
2017-2018MY Isuzu N-Gas Vehicles Wholesaled on or before 9/9/2019

To: Isuzu Dealer Principal, Sales Manager and Service Manager

Effective immediately, stop the sale and delivery of affected vehicles in your inventory, even if a customer has purchased an affected vehicle. We are in the process of taking steps to address a safety related defect in these vehicles. Federal law prohibits the sale and delivery to customers of any vehicle containing a safety defect. You must not deliver any covered vehicles to customers until after the vehicle has been remedied.

WHAT IS THE CONDITION?

WHAT WE WILL DO

Isuzu Commercial Truck of America, Inc. has issued this notice, an affected inventory report (for dealers with involved inventory) and Campaign Bulletin CB19-N-002. The bulletin provides recall remedy instructions. This recall also supersedes the Fuse Box Bolt Dealer Service Campaign (V1904). Vehicles with an “Open” status for campaign V1904 will be reassigned to this new safety recall (V1905).

WHAT YOU SHOULD DO

Confirm the affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and perform the procedure provided Campaign Bulletin CB19-N-002. Vehicles that were inspected as part of dealer service campaign V1904 do not require any further action. If you still need to submit for reimbursement for V1904, please follow the information provided in the Warranty Information section of bulletin CB19-N-002.

IMPORTANT: Always confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry System (IVIS).

You will receive another notice regarding owner notification as well as a version of the campaign bulletin containing a sample owner letter as soon as the owner notification schedule is available and owner letter has been approved by NHTSA.

We regret any inconvenience this action may cause you.

Sincerely,

Isuzu Commercial Truck of America, Inc.

DET-19-126 NHTSA 573- ISUZU RELAY FUSE BOX.
September 9, 2019

Chronology of Defect / Noncompliance Determination

573.6 (c) (6) (7)

Describe the chronology of events leading up to the defect decision or test data for the noncompliance decision*: (2000)

During the summer of 2018, Isuzu received reports of loose main power wire bolts, and/or melted wiring inside the external relay box, on N‐gas trucks. Parts were requested from the field and were then sent to the harness supplier for analysis. An internal investigation was opened under the U.S. field investigation process. As of that time, Isuzu had received a total of nine reports.

In October, 2018, the supplier identified pinched insulation as being the likely cause of damage to the wiring harnesses. The investigation found that, in June, 2017, the supplier had changed the insulator tube heating process from individual heat lamps to a conveyer belt heat lamp system. In January, 2018, the supplier changed back to the individual heat lamp process because workers found that maintaining the proper insulator position was difficult with the conveyor belt heater lamp system.

Consistent with the supplier’s analysis, Isuzu contained the parts at the vehicle assembly plant in Charlotte, and the supplier and Isuzu jointly audited the part inventory at the plant to check for excessive insulation. As part of that inspection, any bolts found with pinched or excessive insulation were removed and reattached once the insulation was trimmed. In November, Isuzu and the supplier jointly inspected completed trucks at the Charlotte assembly plant and trimmed insulation when found out of specification. During this inspection, all relay box main power supply bolts were torqued to the proper specification.

In December, based on additional testing, the supplier determined that the pinched insulation was not causing the bolts to loosen. The investigation began to focus on finding the root cause of the loose bolts. Upon review, Isuzu Motors Limited also confirmed that, while the insulation will become hot and may melt the wiring, the thermal event is self‐extinguishing and would not result in smoke or open flame. The loose bolts could result in a no‐start condition or an intermittent loss of power. Isuzu opened an internal investigation in Japan corollary to the investigation in the U.S. to determine the root cause of the concern.

Between January and April, 2019, the supplier conducted extensive testing and evaluation, including a process history review, duplication analysis, a process comparison of the supplier’s different plants, as well as additional wire melting duplication tests. In May, the supplier provided Isuzu with its final report, which concluded that notwithstanding the potential for excessive insulation, the root cause of the issue was the supplier’s random failure to torque the bolt appropriately during initial harness production.

Upon reviewing the matter, Isuzu determined that a campaign to inspect the bolts was warranted. As of May/June, Isuzu had received 15 reports of loose bolts and/or melted wires with regard to the N‐gas trucks, and none with regard to the more limited population of FTR trucks or Chevrolet badged trucks. Nine of the 15 reported a no‐start condition. Others described intermittent loss of power, mostly with the ability to restart the vehicle and drive to a service station. One report alleged that the vehicle lost power while being driven but was able safely to reach the roadside. Most of the reports were early in the life of the vehicles both in terms of mileage and time‐in‐service. The last report had been received in March, 2019 and all of the vehicle’s production dates pre‐dated the Charlotte plant inspection. This led to the likelihood of an early life condition that had already been fully identified in the field.

After discussion with the agency, Isuzu initiated a service campaign/survey of vehicles in dealer inventory. Isuzu discussed with the agency that if Isuzu found no loose bolts in the survey, Isuzu would expand the service campaign to the remaining vehicles in the field. If loose bolts were found, Isuzu would conduct a safety recall to inspect the remaining vehicles in the field and to complete the campaign with regard to trucks still remaining in dealer inventory. While 391 vehicles were inspected, Isuzu received the survey reports with regard to 292 of those vehicles, with none indicating loose bolts when the inspection process was properly followed.

However, in late July/early August, Isuzu received two additional reports of relay box failures in N‐Gas vehicles in the field. These two vehicles experienced the relay box failures later in their “vehicle life” (more mileage and/or more months in service) than prior vehicles. The parts were collected and sent to the supplier for analysis. The supplier confirmed that on these two vehicles the relay box bolt had not been properly torqued during production.

Isuzu informed the agency of the results of the dealer survey as well as the new reports from the field. On August 30, 2019, Isuzu decided to conduct a safety recall to ensure the bolts are appropriately torqued.

13 Affected Products

Vehicles

MAKE	MODEL	YEAR

CHEVROLET	LOW CAB FORWARD 3500	2017-2019
CHEVROLET	LOW CAB FORWARD 4500	2017-2019
CHEVROLET	LOW CAB FORWARD 6500	2018-2019
ISUZU	FTR	2018-2019
ISUZU	N-SERIES	2017-2019

20 Associated Documents

Recall Quarterly Report #1, 2019-4

RCLQRT-19V647-4903.PDF 211.155KB

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Summary

Remedy

Notes

INFORMATION

CONDITION

CORRECTION

VEHICLES INVOLVED

PARTS INFORMATION

SERVICE PROCEDURE

APPLYING THE CAMPAIGN LABEL

CLAIM INFORMATION

DEALER RESPONSIBILITY

OWNER NOTIFICATION

Latest Recalls Documents

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