CB19-N-002 – Relay Box Inspection – 2018-2019 Isuzu FTR & 2017-2019 N-Gas

September 9, 2019 NHTSA CAMPAIGN NUMBER: 19V647000

Loss of Electrical Power at Relay

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 is expected to begin October 25, 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


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

 

AFFECTED VEHICLES

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

 

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  

  1. Place the vehicle in park, apply the parking brake, and remove the key from the engine control switch.
  2. Disconnect the negative battery cable.
  3. 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.
driver side rear step

Figure 1

1.     Bolt
2.     Nut
3.     Rear Step

 

  1. Remove the fuse box lid to expose the relays and fuses. (See Figure 2.)
fuse box
Figure 2
  1. Remove the three (3) 12mm fuse box mounting bolts and set aside for later use. (See Figure 3.)
fuse box mounting bolts
Figure 3
  1. 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.)
inner cover inner cover
Figure 4 Figure 5
  1. 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.)
inner cover
Figure 6

 

grommet
Figure 7

 

locking tabs
Figure 8

 

  1. 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 [email protected]. 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.
  2. 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.
wire terminal
Figure 9

 

OK Condition Not OK Condition
Figure 10 – OK Condition Figure 11 – Not OK Condition
  1. 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.
  2. Torque the power supply terminal bolt to the specified torque.

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

  1. Reinstall the white inner fuse box cover.
  2. Reinstall the rubber grommet and tape as necessary.
  3. Reinstall the fuse box lower cover.
  4. 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).

  1. Reinstall the fuse box cover.
  2. 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).

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

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

  1. Proceed to Applying the Campaign Label.

 

APPLYING THE CAMPAIGN LABEL

  1. 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.
  2. Affix the campaign label onto the driver’s side B-pillar.

campaign label

 

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

*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.


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?

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.

 

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.

 


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

9 Associated Documents

Safety Bulletin

RCSB-19V647-1903.pdf 395.051KB

To View or Download this Document Click Here


Manufacturer Notices(to Dealers,etc)

RCMN-19V647-0639.pdf 67.048KB

Download (PDF, 65KB)


Manufacturer Notices(to Dealers,etc)

RCMN-19V647-3857.pdf 12.571KB

Download (PDF, 12KB)


Recall Acknowledgement

RCAK-19V647-5293.pdf 245.022KB

Download (PDF, 239KB)


Manufacturer Notices(to Dealers,etc)

RCMN-19V647-0989.pdf 233.415KB

Download (PDF, 228KB)


Remedy Instructions and TSB

RCRIT-19V647-8277.pdf 982.506KB

Download (PDF, 959KB)


Defect Notice 573 Report

RCLRPT-19V647-8208.PDF 217.527KB

Download (PDF, 212KB)


Manufacturer Notices(to Dealers,etc)

RCMN-19V647-6182.pdf 33.988KB

Download (PDF, 33KB)


Manufacturer Notices(to Dealers,etc)

RCMN-19V647-3844.pdf 34.089KB

Download (PDF, 33KB)


Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V647&docType=RCL


 

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Last update on 2019-09-30 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-09-30 / Affiliate links / Images from Amazon Product Advertising API

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