V2204 – ECM Software Programmed Without Braking Function – 2022 Isuzu FTR & FVR

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July 15, 2022 NHTSA CAMPAIGN NUMBER: 22V508000

ECM Software Programmed Without Braking Function

Without engine braking, a driver may experience longer stopping distances than expected, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V508

Manufacturer Isuzu Motors Limited

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 11

 

Summary

Isuzu Motors Limited (Isuzu) is recalling certain 2022 FTR and FVR trucks. A programming error in the ECM software calibration, resulted in the vehicles not having engine braking functionality.

 

Remedy

Dealers will reprogram the ECM with the corrected calibration, free of charge. Owner notification letters are expected to be mailed on September 1, 2022. Owners may contact Isuzu’s customer service at 1-866- 441-9638. Isuzu’s number for this recall is V2204.

 

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.nhtsa.gov.

 

Check if your Isuzu Truck has a Recall

 


BULLETIN NUMBER:
CB22-J-002A

ISSUE DATE:
AUGUST 2022

ENGINE EXHAUST BRAKE REPROGRAMMING – 22V-508

 

AFFECTED VEHICLES

  • 2022MY Isuzu F-Series Vehicles

 

CONDITION

Isuzu Motors Limited has decided that a defect exists in certain 2022 model year Isuzu F-Series vehicles. Due to a software calibration error, the affected vehicles were built without engine exhaust braking functionality. Without engine braking, a driver may experience longer stopping distances than expected, increasing the risk of a crash.

 

CORRECTION

Isuzu dealers will have the Cummins Engine Control Module (ECM) reprogrammed with the correct calibration setting for the engine exhaust brake. This service will be performed free of charge.

 

VEHICLES INVOLVED

Involved are certain 2022MY Isuzu F-Series vehicles

 

SERVICE PROCEDURE

1. Confirm the VIN is an affected vehicle in IVIS.

2. Contact the local Cummins Certified Service location to have the ECM reprogrammed per the procedure below.

a. If you (the Isuzu dealer) are also a Cummins Certified Service location, this procedure should be performed at your location, as you are the closest Cummins Certified Service location.

b. If you (the Isuzu dealer) are not a Cummins Certified Service location, you should arrange to have this procedure performed at the closest Cummins Certified Service location; you can find the closest Cummins Certified Service location on the web at https://www.cummins.com/locations.

3. Provide the “Procedure” section of this bulletin to the Cummins location to have a Cummins trained technician reprogram the ECM with the correct Engine Exhaust Brake settings using the Cummins INSITE tool.
PROCEDURE (to be performed by a Cummins Certified Service location using INSITE)

4. Using the Cummins INSITE tool (version 8.7.1.99 or later), from the Main Screen select Connect to ECM to establish communication with ECU, and then select Connect.

 

5. Select Features and Parameters.

 

6. Select Engine Brake Control and confirm it is “Enabled”.

 

7. If it is not Enabled, select Enable for Engine Brake Control at the drop-down menu.

 

8. Expand “ENGINE BRAKE CONTROL” by selecting the “+” and ensure “ENGINE BRAKE LAMP” is DISABLED.

 

9. Select FILE and select Send to ECM. Select OK from the Confirm ECM Adjustment pop up.

 

10. Follow the following Cummins INSITE instructions to complete download.

a. Key switch off, then click OK.
b. Wait 100 seconds.
c. Key switch on, then click OK.

11. Confirm all parameters were written successfully.

 


DET-22-089

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:

On April 20, 2022, an end of assembly line final inspection team at the factory noticed that the engine brake telltale on an F-Series truck did not illuminate when the engine brake switch was activated. That same day, Cummins (the supplier of the F-Series engine) was contacted. Cummins reviewed Isuzu Technical Center of America, Inc.’s (ITCA) flash station calibration Action Authorization Sheet (AAS) for the engine brake switch in effect at that time and found it to be in error.

On April 21, 2022, the production line updated the software calibration per Cummins’ instructions and the engine brake flashing station once again began to function properly.

Isuzu North America Corporation (INAC) QA, together with Isuzu Motors Limited (IML) and  Isuzu Technical Center of America, Inc. (collectively, Isuzu), promptly launched an investigation and determined that: (1) the engine brake flashing station had a problem that required its calibration to be reloaded on January 24, 2022; (2) the calibration reloading on that day followed the erroneous AAS mentioned above; (3) between the Start of Production in December 2021 and January 24, 2022, the F-Series vehicles produced had properly functioning engine brakes and engine brake switches and telltales; and (4) there were 745 F-Series vehicles still within Isuzu’s control that were produced between January 24 and April 21, 2022 and, thus, that had non-functioning engine brakes and engine brake switches and telltales. Those 745 vehicles within Isuzu’s control were re-flashed (such that their engine brake and engine brake switch and telltale would function properly) between April 25 and 28, 2022. There also were, however, and are eleven vehicles with improper calibration that already had been released from Isuzu’s control.

Between the end of April 2022 and the middle of June 2022, Isuzu studied the nature and effect of the improper engine brake calibration on the functioning of the vehicles. In a properly functioning vehicle, turning the engine brake switch on would cause the engine brake to function at speeds over 9.9 mph and cause the engine brake telltale to illuminate to show that the engine brake was on. Isuzu’s analysis determined that in the vehicles with the improper calibration, the telltale would not illuminate when the engine brake switch was turned on. In that respect, drivers would be given an indication that the engine brake would not function. And, of course, since generally one can feel the effect of a functioning engine brake slowing down the vehicle even without use of the service/foundation air brakes, the absence of engine braking would likely be noticed by the driver, who, presumably would not rely on the engine brake to assist in the stopping of the vehicle.

Although Isuzu is not aware of any crashes, property damage claims, warranty claims, injuries or deaths associated with this issue, in an abundance of caution, on July 8, 2022, Isuzu made a decision to conduct a safety-related defect recall to address this concern.

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
ISUZU FTR 2022
ISUZU FVR 2022

 


11 Associated Documents

Defect Notice 573 Report

RCLRPT-22V508-3198.PDF 215.598KB

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Recall Acknowledgement

RCAK-22V508-4685.pdf 646.438KB

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Miscellaneous Document- Chronology

RMISC-22V508-1536.pdf 89.334KB

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Remedy Instructions and TSB

RCRIT-22V508-1124.pdf 915.384KB

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Remedy Instructions and TSB

RCRIT-22V508-5492.pdf 2067.727KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V508-7377.pdf 131.055KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V508-2247.pdf 136.143KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V508-2078.pdf 237.202KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V508-0486.PDF 211.142KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V508-9484.PDF 211.239KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V508-3648.PDF 211.319KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V508&docType=RCL

 


 

Isuzu Truck Reprogramming

The Isuzu Diagnostic Service System (IDSS) is an all-in-one hardware and software solution for diagnosis and repair of Isuzu commercial vehicles.

This package contains service information (including electronic troubleshooting manual/wiring diagrams), full-featured scan tool, service programming, and bulletins to support all Isuzu manufactured products.

The IDSS software is designed for use with the IDSS interface module, included with this kit.

 

What is included with an IDSS subscription?

An IDSS subscription enables you to register your product and receive periodic web updates through the Internet to update your Interface module with new models, functionality and programming capabilities.

 

IDSS Diagnostic Service Tablet

The Isuzu Diagnostic Service System (IDSS) Tablet is Isuzu's next generation all-in-one hardware and software solution for diagnosis and repair of Isuzu commercial vehicles.

The IDSS II tablet arrives pre-installed with IDSS II software, which contains service information (including electronic troubleshooting manual/wiring diagrams), full-featured scan tool, service programming, and bulletins to support all Isuzu manufactured products.

The IDSS II tablet is compatible with the following protocols:

  1. J1939
  2. CAN
  3. J1708
  4. NRZ
  5. LIN
  6. KW2000
  7. FlexRay
  8. ISO 9141
  9. J1850 VPW, PWM
  10. ISO 15765

This product does not apply to Isuzu industrial engines. Only commercial vehicles in the U.S. and Canada are supported.

 

IDSS supports only U.S. or Canadian specification Isuzu vehicles at this time.

IDSS supports 1996-to-current model year Isuzu commercial vehicles.

 

https://www.isuzutruckservice.com/

 


 

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Last update on 2024-05-19 / Affiliate links / Images from Amazon Product Advertising API

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