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August 10, 2023 NHTSA CAMPAIGN NUMBER: 23V564000
Loss of Engine Power from Electrical Corrosion
Corrosion of the ignition coil pack fuses can cause a misfire and loss of engine power, increasing the risk of a crash.
NHTSA Campaign Number: 23V564
Manufacturer Isuzu Motors Limited
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 19,479
Summary
Isuzu Motors Limited (Isuzu) is recalling certain 2023-2024 NPR Gas, NPR HD Gas, 2024 NQR Gas, NRR Gas, 2023-2024 Chevrolet LCF 3500HG, Chevrolet LCF 4500HG, 2024 Chevrolet LCF 5500HG, and Chevrolet LCF 5500XG vehicles. The chassis harness may have an incorrectly sized wire seal for the 2 externally mounted engine ignition coil pack fuse holders, which can allow water intrusion and cause the fuses to corrode.
Remedy
Dealers will replace both engine ignition coil pack fuse holder assemblies, free of charge. Owner notification letters are expected to be mailed September 29, 2023. Owners may contact Isuzu customer service at 1-866-441-9638. Isuzu’s number for this recall is V2305.
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
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 2023-2024MY N-Series vehicles equipped with 6.6L (L8T) gasoline engines. In the affected vehicles, an incorrectly sized wire seal was selected for the 2 externally mounted engine ignition coil pack fuse holders. This results in the potential for water intrusion into the fuse holders and eventual corrosion or failure of the fuses.
If the ignition coil pack fuses corrode or fail, one or more of the following events may occur, in each case increasing the risk of a crash: (1) the Check Engine Malfunction Indicator Light (MIL) may illuminate and the engine may misfire and result in reduced power output and slower than normal acceleration; (2) the vehicle may derate and limit maximum vehicle speed to 5 MPH (power steering and power brake assist will still function normally); and (3) if you shut off the engine, it may stall when you try to start it and not restart.
WHAT WE WILL DO
We are preparing a new service procedure and procuring parts to repair these vehicles. You will receive another notice regarding owner notification and campaign bulletin release as soon as the schedule is available.
WHAT YOU SHOULD DO
Confirm the affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and hold the vehicles until further notification is received.
BULLETIN NUMBER:
CB23-N-001
ISSUE DATE:
SEPTEMBER 2023
GROUP:
ELECTRICAL
IMPORTANT SAFETY RECALL
IGNITION COIL PACK FUSE
(New Dealer Inventory Only) – 23V-564
(Transport Canada 2023-444)
AFFECTED VEHICLES
- 2023 – 2024MY Isuzu N-Series Vehicles Equipped with 6.6L (L8T) Gasoline Engines
INFORMATION
CONDITION
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2023-2024MY N-Series vehicles equipped with 6.6L (L8T) gasoline engines. In the affected vehicles, an incorrectly sized wire seal was selected for the 2 externally mounted engine ignition coil pack fuse holders. This results in the potential for water intrusion into the fuse holders and eventual corrosion or failure of the fuses.
If the ignition coil pack fuses corrode or fail, one or more of the following events may occur, in each case increasing the risk of a crash: (1) the Check Engine Malfunction Indicator Light (MIL) may illuminate and the engine may misfire and result in reduced power output and slower than normal acceleration; (2) the vehicle may derate and limit maximum vehicle speed to 5 MPH (power steering and power brake assist will still function normally); and (3) if you shut off the engine, it may stall when you try to start it and not restart.
CORRECTION
For New Vehicle Dealer Inventory Only: Isuzu dealers will apply a silicone sealant to the rear of the existing fuse holder plug.
Note: A separate campaign bulletin will be published which will include sample owner letters and a different service procedure applicable to affected customer-owned and used vehicles.
VEHICLES INVOLVED
Involved are certain 2023 – 2024MY Isuzu N-Series vehicles equipped with 6.6L (L8T) gasoline engines.
Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using IVIS (Isuzu Vehicle Information System).
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
Dealers will each be shipped one tube of Super X silicone in order to complete immediate repairs to affected new vehicle inventory. Most dealers will NOT REQUIRE additional orders. However, if needed, additional orders may be placed with American Isuzu Parts Distribution Network (AIPDN). Please refer to your “involved vehicles listing” before ordering additional parts.
Part Number | Description | Quantity |
2-90008-008-0 | Super X Silicone | 1 tube for up to 30 vehicles* |
N/A | 8” Black Zip Tie | 2 |
*Super X silicone should be utilized within one (1) year of the manufacture date.
Make sure to keep the cap on the adhesive any time it is not actually being applied.
Store the adhesive in a cool, dry location out of direct sunlight.
SERVICE PROCEDURE
FOR NEW VEHICLE INVENTORY ONLY
- Disconnect the negative battery cable.
- (For NPR/NPRHD ONLY) – Remove three (3) nuts and bolts (14mm) securing the transmission cooler lines and release one (1) chassis harness clip. (See Figure 1.)
- (For NPR/NPRHD ONLY) – Gently pull the transmission cooler lines away from the frame rail to create access to the inline ignition fuse holders.
- If a body mounting bolt or other upfitter modification interferes with access to these fuse holders, loosen and move those parts out of the way to access this location.
- Locate the inline ignition fuse holders J-432 and J-433. Cut and remove two (2) zip ties and tape securing the fuse holders. (See Figures 2 & 3.)
- Gently pull back the corrugated tube and PVC tape away from the fuse holder. (See Figure 4.)
- Clean the harness side of the fuse holder with electrical contact cleaner. (See Figure 5.)
- Use plastic bristle brush. Spray cleaner onto the brush and remove debris.
- Wipe dry with clean paper towel or cloth.
- Wrap the base of the fuse holder with PVC electrical tape (any PVC tape is acceptable). This will create a small cavity or cup to retain the Super X silicone. (See Figure 6.)
- Prepare the Super X silicone by cutting the very tip of the applicator nozzle off. (See Figure 7.)
NOTE: Wear latex/disposable gloves while using Super X silicone to reduce clean up.
- Apply the Super X silicone onto the fuse holder where the wires pass through the connector insulation. (See Figure 8.)
- After ensuring each wire is covered where it exits the connector, fill the remaining area of the cup with the Super X silicone. Allow the Super X silicone to “set” (about 5 minutes @ 73°F / 23°C) so it will not run out of the cup. (See Figure 9.)
- Secure each fuse holder back into position onto the chassis harness with a zip tie.
- (NPR NPRHD ONLY) – Secure the chassis harness to the frame by pushing the one (1) clip removed in Step 2 back into the frame. (See Figure 1.)
- (NPR NPRHD ONLY) – Install the transmission cooler line mounting bracket bolts and nuts and torque to specification. (See Figure 1.) Torque specification 40 Nm (30 ft lb)
- (NPR NPRHD ONLY) – Check the transmission cooler line position. Be sure the white tape mark on the cooler line lines up with the clip on the mounting bracket. (See Figure 12.)
- Reinstall any upfitter components that were removed to access the fuse holders. Refer to the upfitter for any necessary torque specifications and guidance in resecuring these parts.
- Connect the negative battery cable.
- Proceed to Applying the Campaign Label.
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 IVIS (Isuzu Vehicle Information System). 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
Sample recall letters that will be sent to owners of affected vehicles already retailed in the United States and Canada will be added in a future bulletin revision.
August 10, 2023
DET-23-101
ISUZU Campaign: V2305
Chronology of Defect Determination
573.6(c)(6)
Describe the chronology of events leading up to the defect determination decision.
On December 27, 2022, Isuzu North America Corporation (INAC) QA was made aware of a Technical Assistance (TAL) Case from Isuzu Commercial Truck of America (ICTA) in which a technician reported corrosion on one of the externally mounted ignition coil pack fuses on a 2023MY NPRHD gasoline vehicle. The field report indicated that the vehicle exhibited a Check Engine MIL and reduced engine power. INAC QA was unable to recover any parts from this case.
Between December 27, 2022 and January 8, 2023, INAC QA received 2 additional reports of corroded fuses. One case stated that the driver experienced a crank no start condition while the other stated that the driver experienced a Check Engine MIL and engine misfire.
On January 11, 2023, Isuzu Technical Center of America (ITCA) and Isuzu North America Corporation (INAC) QA, together with Isuzu Motors Limited (IML) and Isuzu Technical Center of America (ITCA), Inc. (collectively, Isuzu), promptly launched an investigation.
On February 16, 2023, INAC QA, after receiving returned warranty ignition coil pack fuse holders from the field, contacted American Furukawa (the vehicle chassis harness supplier) and requested them to study the returned warranty parts in order to determine the water leak path.
On March 8, 2023, American Furukawa reported to INAC QA that it was unable to determine the exact water intrusion entry point.
On March 23, 2023, ITCA completed its preliminary analysis and discovered that the incorrect seal part number was used on both ignition coil pack fuse holders. This incorrect seal did not create a proper interference fit on the smaller of the two wires at the rear of the fuse holder, resulting in a potential water intrusion path into the fuse holder cavity and fuse.
On March 24, 2023, INAC QA reviewed the current field cases and confirmed that the rate of reported cases from the field was low (Incident Rate Per Thousand Vehicles was 3.75. Moreover, the rate of incoming claims from the field decreased month over month from the peak in January 2023. Of the reported cases, most reported a Check Engine MIL with either engine misfire or an engine derate (reduction to about 5 mph acceleration). Notwithstanding the low rate and declining number of field incidents, INAC QA requested ITCA to perform a risk assessment study and confirm the potential failure modes in the event the ignition coil pack fuse(s) becomes corroded or fails.
Between March 24 and May 25, 2023, ITCA also studied other potential leak paths into the fuse holder, and on May 25, 2023, ITCA confirmed that the only leak path was from the rear wire seal. During this period, the field incident rate of engine performance issues remained low.
In the meantime, on April 23, 2023, based on ITCA’s findings, ITCA submitted an Engineering Change Request (ECR) to the supplier to correct the ignition coil pack fuse holder seal/wire combination by increasing the smaller wire size from 2.1mm to 2.9mm.
Between May 31, 2023, and July 12, 2023, IML in conjunction with ITCA began studying an interim countermeasure.
- Throughout this period, Isuzu continued to monitor field incidents and confirmed that they remained low. ITCA completed the interim countermeasure study and confirmed that the application of Cemedaine Super X 8008 silicone sealant to the rear of the fuse holder plug will provide sufficient sealing performance for the connection.
- On July 12, 2023, the Charlotte production team began to apply silicone sealant to the rear of the ignition coil pack fuse holder plugs on production vehicles. All vehicles produced after this date have silicone applied.
On July 5, 2023, ITCA completed the risk assessment and concluded that corroded fuses could lead to a Check Engine MIL and an engine derate, and an engine stall while trying to start it.
On July 19, 2023, INAC QA obtained a vehicle and testing equipment in order to perform a duplication test to validate ITCA’s risk assessment.
On July 20, 2023, to July 31, 2023, after receiving ITCA’s risk assessment, INAC QA studied the consequences of a corroded ignition coil pack fuse on the functioning of an actual vehicle to validate ITCA’s risk assessment and to understand the warning signs to the driver as fuse corrosion progresses from light corrosion to a later stage of heavy corrosion. During this study INAC QA confirmed:
- When one fuse becomes lightly corroded (50 to 1000 ohm resistance), the vehicle illuminates the Check Engine MIL and an audible misfire is heard from the engine. These are accompanied by a very noticeable shake or vibration due to the engine misfire.
- The vehicle also exhibits reduced power with no engine derate, which was observed as slower than normal acceleration (roughly 30% increased acceleration times). In addition, drivers will notice a fuel smell from the exhaust.
- Drivers would be given multiple indications (sight, sound, smell, feel) that the engine was not operating properly.
- To evaluate the consequences should a driver ignore these warning signs, INAC QA tested this possibility by inducing a higher resistance (>1000 ohms) in one ignition coil pack circuit. This resulted in a flashing Check Engine MIL, engine derate, and a speed reduction to 5 MPH; however, power steering and power brake assist were still retained since the engine remained running.
- Based on this test, Isuzu concluded that if a driver had ignored the prior warnings, the vehicle could still be controlled with power assist brakes and power assist steering, but that accelerator function would be greatly reduced and the vehicle would be limited to a maximum speed of 5 MPH.
- To further evaluate the consequences of disregarding these warnings, INAC QA then induced resistance in both circuits, resulting in an engine stall and an inability to restart the engine.
On August 1, 2023, Isuzu reviewed the work done to date, the details of the field cases, and risk assessment findings.
Although Isuzu is not aware of any crashes, property damage claims, injuries or deaths associated with this issue, in an abundance of caution, on August 4, 2023, Isuzu decided to conduct a safety-related defect recall to address this concern.
8 Affected Products
Vehicles
MAKE | MODEL | YEAR |
ISUZU | CHEVROLET LCF 3500HG | 2023-2024 |
ISUZU | CHEVROLET LCF 4500HG | 2023-2024 |
ISUZU | CHEVROLET LCF 5500HG | 2024 |
ISUZU | CHEVROLET LCF 5500XG | 2024 |
ISUZU | N-SERIES | 2023-2024 |
8 Associated Documents
August 10, 2023 DET-23-101 ISUZU Campaign: V2305 Chronology of Defect Determination
RMISC-23V564-5585.pdf 119.403KB
Defect Notice 573 Report
RCLRPT-23V564-1404.PDF 220.511KB
Recall Acknowledgement
RCAK-23V564-6217.pdf 645.472KB
Manufacturer Notices(to Dealers,etc) – GM Date: August 10, 2023 Subject: Stop Delivery Order for Safety Recall N232419340
RCMN-23V564-2748.pdf 128.307KB
Manufacturer Notices(to Dealers,etc) – GM Frequently Asked Questions (FAQs) for Safety Recall N232419340 Ignition Coil Pack Fuse
RCMN-23V564-4846.pdf 104.947KB
Manufacturer Notices(to Dealers,etc) – STOP SALE AND DELIVERY – SAFETY RECALL Date: August 11, 2023 Subject: Stop Sale and Delivery for Upcoming Safety Recall
Manufacturer Notices(to Dealers,etc) – GM August 25, 2023 Subject: N232419340 – Safety Recall
RCMN-23V564-6812.pdf 185.003KB
Remedy Instructions and TSB
RCRIT-23V564-5740.pdf 1551.492KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V564&docType=RCL
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Last update on 2024-04-24 / Affiliate links / Images from Amazon Product Advertising API
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-564 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Isuzu Motors Limited Submission Date : AUG 10, 2023 NHTSA Recall No. : 23V-564 Manufacturer Recall No. : V2305 Manufacturer Information : Manufacturer Name : Isuzu Motors Limited Address : 46401 Commerce Center Drive Plymouth MI 48170-2473 Company phone : 866-441-9638 Population : Number of potentially involved : 19,479 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2023-2024 ISUZU NPR Gas Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [1,208] Production Dates : APR 12, 2022 – JUL 10, 2023 VIN Range 1 : Begin : 54DB4W1D4PS200018 End : 54DB4W1D1RS207589 ✔ Not sequential Vehicle 2 : 2023-2024 ISUZU NPR HD Gas Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [11,788] Production Dates : APR 11, 2022 – JUL 12, 2023 VIN Range 1 : Begin : 54DC4J1D9PS200006 End : 54DC4W1D2RS207718 ✔ Not sequential Part 573 Safety Recall Report 23V-564 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 3 : 2024-2024 ISUZU NQR Gas Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [146] Production Dates : APR 05, 2023 – JUL 09, 2023 VIN Range 1 : Begin : 54DE5W1D3RS500002 End : 54DE5W1D6RS500205 ✔ Not sequential Vehicle 4 : 2024-2024 ISUZU NRR Gas Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [921] Production Dates : APR 06, 2023 – JUL 10, 2023 VIN Range 1 : Begin : 54DE5W1DXRSR00008 End : 54DE5W1D8RSR01173 ✔ Not sequential Vehicle 5 : 2023-2024 CHEVROLET LCF 3500HG Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [662] Production Dates : APR 12, 2022 – JUL 07, 2023 VIN Range 1 : Begin : 54DBDW1D1PS200042 End : 54DBDW1D7RS207421 ✔ Not sequential Vehicle 6 : 2023-2024 CHEVROLET LCF 4500HG Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [4,692] Production Dates : APR 11, 2022 – JUL 12, 2023 VIN Range 1 : Begin : 54DCDJ1D4PS200012 End : 54DCDW1D5RS207745 ✔ Not sequential Part 573 Safety Recall Report 23V-564 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 7 : 2024-2024 CHEVROLET LCF 5500HG Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [18] Production Dates : JUN 02, 2023 – JUN 07, 2023 VIN Range 1 : Begin : 54DEEJ1D3RS500147 End : 54DEEJ1D5RS500151 ✔ Not sequential Vehicle 8 : 2024-2024 CHEVROLET LCF 5500XG Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : Recall population determined by production and sales records. It includes all production vehicles of these model years, makes, and models between the manufacturing dates provided. [44] Production Dates : JUN 02, 2023 – JUL 08, 2023 VIN Range 1 : Begin : 54DEEW1D0RSR00549 End : 54DEEJ1D9RSR01159 ✔ Not sequential Description of Defect : Description of the Defect : When the chassis harnesses of the subject vehicles were designed, an incorrectly sized wire seal was selected for the 2 externally mounted engine ignition coil pack fuse holders. This results in the potential for water intrusion into the fuse holders and eventual corrosion or failure of the fuses. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the ignition coil pack fuses corrode or fail, one or more of the following events could occur – in each case, increasing the risk of a crash: • Engine will begin to misfire and power output may be reduced, resulting in slower than normal vehicle acceleration (roughly 30% increased acceleration times); • Engine will derate and maximum vehicle speed will be limited to 5 MPH (power brake assist and power steering assist will still function normally); • While trying to start the engine, it may stall and not restart. Description of the Cause : There was a subcomponent specification error in the engineering drawing for the chassis harness which improperly called out for the use of a silicone wire seal with two large 2.45mm openings for the wires instead of one 2.45mm and one 1.55mm opening. Part 573 Safety Recall Report 23V-564 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : • A steady Check Engine MIL with an audible engine misfire and vehicle shake or vibration may occur. • The vehicle will also have reduced power and may emit a fuel smell from the exhaust. • Continued use in this condition will result in a continuous flashing Check Engine MIL and a vehicle speed derate to 5MPH. If this occurs, power steering assist and power brake assist functions are still retained. Involved Components : Component Name 1 : Main Chassis Harness Component Description : Harness, Chassis Component Part Number : 8977986391, 8978736183, 8977986401, 8978736193, 8977986411, 8978736203, 8977986421, 8978736213, 8978 Supplier Identification : Component Manufacturer Name : American Furukawa INC Address : 2181 International St. Columbus Ohio 43228 Country : United States Chronology : Chronology uploaded separately. Part 573 Safety Recall Report 23V-564 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : For vehicles that have not yet been delivered to the first retail purchaser, dealers will apply a silicone sealant to the rear of the existing fuse holders or install revised coil pack fuse holders (“pigtails”) depending on vehicle class and body upfit status. For vehicles delivered into customer hands, dealers will replace both engine ignition coil pack fuse holder assemblies with the revised coil pack fuse holders (“pigtails”). REIMBURSEMENT: All vehicles that previously had this condition repaired would have been covered under the New Truck Warranty or Engine Emission Warranty standard on all new purchases. How Remedy Component Differs from Recalled Component : The Ignition coil pack circuits in future chassis harnesses will be assembled with two 2.9mm diameter wires instead of one 2.1mm and one 2.9mm diameter wire, this will result in a correct wire to seal interference and prevent water intrusion into the fuse holder. Identify How/When Recall Condition was Corrected in Production : Vehicles produced on or after July 12, 2023 have silicone applied to the rear of the fuse holders to prevent water intrusion. A revised harness is planned for future production which will utilize two 2.9mm diameter wires for each fuse holder. Recall Schedule : Description of Recall Schedule : Isuzu and Chevrolet will notify their respective vehicle owners and dealers of this recall. They will be informed that the recall repairs will be done free of charge. However, remedy parts for customer vehicles are not currently available and Isuzu does not yet know when the parts will become available. Therefore, it will be necessary to send an Interim Owner Letter advising vehicle owners of the recall, that remedy parts are not currently available and that they will receive a second letter when remedy parts become available. The interim recall owner notification is expected to begin 9/29/2023. In addition, it is anticipated that remedy parts for affected vehicles in dealer inventory will not be available for approximately six weeks. As a result, the Stop Sale Notice that will be provided to dealers upon submission of this Defect Information Report will instruct dealers to hold affected vehicles in their inventory until receiving further notification and a Campaign Bulletin when remedy parts become available. For additional information, Isuzu owners may contact Isuzu Customer Relations at 1-866-441-9638 and Chevrolet owners may contact the GM Medium Duty Truck assistance line at 1-800-862-4389. Planned Dealer Notification Date : AUG 11, 2023 – AUG 11, 2023 Planned Owner Notification Date : SEP 29, 2023 – SEP 29, 2023 Part 573 Safety Recall Report 23V-564 Page 6 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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Isuzu Commercial Truck of America, Inc. Customer Relations Department 1400 S. Douglass Road, Suite 100, Anaheim, CA 92806 *1-866-441-9638 DOC ID: SS_V2305_20230811 STOP SALE AND DELIVERY – SAFETY RECALL Date: August 11, 2023 Subject: Stop Sale and Delivery for Upcoming Safety Recall Affected Models: • Certain 2023-2024MY N-Series Vehicles Equipped with 6.6L (L8T) Gasoline Engines 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 2023-2024MY N-Series vehicles equipped with 6.6L (L8T) gasoline engines. In the affected vehicles, an incorrectly sized wire seal was selected for the 2 externally mounted engine ignition coil pack fuse holders. This results in the potential for water intrusion into the fuse holders and eventual corrosion or failure of the fuses. If the ignition coil pack fuses corrode or fail, one or more of the following events may occur, in each case increasing the risk of a crash: (1) the Check Engine Malfunction Indicator Light (MIL) may illuminate and the engine may misfire and result in reduced power output and slower than normal acceleration; (2) the vehicle may derate and limit maximum vehicle speed to 5 MPH (power steering and power brake assist will still function normally); and (3) if you shut off the engine, it may stall when you try to start it and not restart. WHAT WE WILL DO We are preparing a new service procedure and procuring parts to repair these vehicles. You will receive another notice regarding owner notification and campaign bulletin release as soon as the schedule is available. WHAT YOU SHOULD DO Confirm the affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and hold the vehicles until further notification is received. We regret any inconvenience this action may cause you. Sincerely, Isuzu Commercial Truck of America, Inc.
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Isu IMPORTANT SAFETY RECALL IGNITION COIL PACK FUSE (New Dealer Inventory Only) – 23V-564 (Transport Canada 2023-444) • 2023 – 2024MY Isuzu N-Series Vehicles Equipped with 6.6L (L8T) Gasoline Engines CONDITION Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2023-2024MY N-Series vehicles equipped with 6.6L (L8T) gasoline engines. In the affected vehicles, an incorrectly sized wire seal was selected for the 2 externally mounted engine ignition coil pack fuse holders. This results in the potential for water intrusion into the fuse holders and eventual corrosion or failure of the fuses. If the ignition coil pack fuses corrode or fail, one or more of the following events may occur, in each case increasing the risk of a crash: (1) the Check Engine Malfunction Indicator Light (MIL) may illuminate and the engine may misfire and result in reduced power output and slower than normal acceleration; (2) the vehicle may derate and limit maximum vehicle speed to 5 MPH (power steering and power brake assist will still function normally); and (3) if you shut off the engine, it may stall when you try to start it and not restart. CORRECTION For New Vehicle Dealer Inventory Only: Isuzu dealers will apply a silicone sealant to the rear of the existing fuse holder plug. Note: A separate campaign bulletin will be published which will include sample owner letters and a different service procedure applicable to affected customer-owned and used vehicles. VEHICLES INVOLVED Involved are certain 2023 – 2024MY Isuzu N-Series vehicles equipped with 6.6L (L8T) gasoline engines. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using IVIS (Isuzu Vehicle Information System). AFFECTED VEHICLES INFORMATION IMPORTANT SERVICE INFORMATION FOR: SERVICE MANAGER SERVICE ADVISOR TECHNICIAN PARTS DEPARTMENT WARRANTY PERSONNEL BULLETIN NUMBER: CB23-N-001 ISSUE DATE: SEPTEMBER 2023 GROUP: ELECTRICAL CV 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 Dealers will each be shipped one tube of Super X silicone in order to complete immediate repairs to affected new vehicle inventory. Most dealers will NOT REQUIRE additional orders. However, if needed, additional orders may be placed with American Isuzu Parts Distribution Network (AIPDN). Please refer to your “involved vehicles listing” before ordering additional parts. Part Number Description Quantity 2-90008-008-0 Super X Silicone 1 tube for up to 30 vehicles* N/A 8” Black Zip Tie 2 *Super X silicone should be utilized within one (1) year of the manufacture date. Make sure to keep the cap on the adhesive any time it is not actually being applied. Store the adhesive in a cool, dry location out of direct sunlight. FOR NEW VEHICLE INVENTORY ONLY 1. Disconnect the negative battery cable. 2. (For NPR/NPRHD ONLY) – Remove three (3) nuts and bolts (14mm) securing the transmission cooler lines and release one (1) chassis harness clip. (See Figure 1.) Figure 1 (NPR/NPRHD) 1. Transmission Cooler Line Bracket Nut & Bolt 2. Harness Clip 3. (For NPR/NPRHD ONLY) – Gently pull the transmission cooler lines away from the frame rail to create access to the inline ignition fuse holders. SERVICE PROCEDURE 1 1 1 2 4. If a body mounting bolt or other upfitter modification interferes with access to these fuse holders, loosen and move those parts out of the way to access this location. 5. Locate the inline ignition fuse holders J-432 and J-433. Cut and remove two (2) zip ties and tape securing the fuse holders. (See Figures 2 & 3.) Figure 2 (NPR/NPRHD) Figure 3 (NQR/NRR) 6. Gently pull back the corrugated tube and PVC tape away from the fuse holder. (See Figure 4.) Figure 4 7. Clean the harness side of the fuse holder with electrical contact cleaner. (See Figure 5.) a. Use plastic bristle brush. Spray cleaner onto the brush and remove debris. b. Wipe dry with clean paper towel or cloth. Figure 5 Locations to prepare for sealant 8. Wrap the base of the fuse holder with PVC electrical tape (any PVC tape is acceptable). This will create a small cavity or cup to retain the Super X silicone. (See Figure 6.) Figure 6 9. Prepare the Super X silicone by cutting the very tip of the applicator nozzle off. (See Figure 7.) Figure 7 NOTE: Wear latex/disposable gloves while using Super X silicone to reduce clean up. 10. Apply the Super X silicone onto the fuse holder where the wires pass through the connector insulation. (See Figure 8.) Figure 8 11. After ensuring each wire is covered where it exits the connector, fill the remaining area of the cup with the Super X silicone. Allow the Super X silicone to “set” (about 5 minutes @ 73°F / 23°C) so it will not run out of the cup. (See Figure 9.) Figure 9 12. Secure each fuse holder back into position onto the chassis harness with a zip tie. a. (NPR NPRHD ONLY) See Figure 10. Then proceed to Step 13. b. (NQR NRR ONLY) See Figure 11. Then proceed to Step 16. Figure 10 (NPR/NPRHD) Figure 11 (NQR/NRR) 13. (NPR NPRHD ONLY) – Secure the chassis harness to the frame by pushing the one (1) clip removed in Step 2 back into the frame. (See Figure 1.) 14. (NPR NPRHD ONLY) – Install the transmission cooler line mounting bracket bolts and nuts and torque to specification. (See Figure 1.) Torque specification 40 Nm (30 ft lb) 15. (NPR NPRHD ONLY) – Check the transmission cooler line position. Be sure the white tape mark on the cooler line lines up with the clip on the mounting bracket. (See Figure 12.) Figure 12 (NPR/NPRHD) 16. Reinstall any upfitter components that were removed to access the fuse holders. Refer to the upfitter for any necessary torque specifications and guidance in resecuring these parts. 17. Connect the negative battery cable. 18. Proceed to Applying the Campaign Label. APPLYING THE CAMPAIGN LABEL 19. Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number 23V-564 (US) or 2023-444 (Canada), Isuzu dealer code, and repair date. 20. Affix the campaign label onto the driver’s side B-pillar. Refer to the Isuzu ICS Claims Processing Manual for details on Campaign Claim Submission. Submit only one claim as indicated below. Labor Operation Code Description Labor Time Sublet Allowance V2305D Apply Super X Silicone 23V-564 Safety Recall • NQR/NRR • NPR/NPRHD Body Interference — Submit for OLH 0.4* 0.5* OLH $5.00 (Reimbursement for 2 zip ties and 1/30 of the cost of Super X Silicone) *Includes 0.1 hours for administrative allowance. 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 IVIS (Isuzu Vehicle Information System). 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 Sample recall letters that will be sent to owners of affected vehicles already retailed in the United States and Canada will be added in a future bulletin revision. CLAIM INFORMATION
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