V2305 – Loss of Engine Power from Electrical Corrosion – 2023-2024 Isuzu NPR, NPR HD, 2024 NQR, NRR

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
2-90008-008-0Super X Silicone1 tube for up to 30 vehicles*
N/A8” Black Zip Tie2

*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

  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.)

 

  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.
  2. 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.
  3. 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.)

 

  1. Gently pull back the corrugated tube and PVC tape away from the fuse holder. (See Figure 4.)

 

  1. Clean the harness side of the fuse holder with electrical contact cleaner. (See Figure 5.)
    1. Use plastic bristle brush. Spray cleaner onto the brush and remove debris.
    2. Wipe dry with clean paper towel or cloth.

 

  1. 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.)

 

  1. 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.

 

  1. Apply the Super X silicone onto the fuse holder where the wires pass through the connector insulation. (See Figure 8.)

 

  1. 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.)

 

  1. Secure each fuse holder back into position onto the chassis harness with a zip tie.
    1. (NPR NPRHD ONLY) See Figure 10. Then proceed to Step 13.
    2. (NQR NRR ONLY) See Figure 11. Then proceed to Step 16.

 

  1. (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.)
  2. (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)
  3. (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.)

 

  1. 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.
  2. Connect the negative battery cable.
  3. 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

MAKEMODELYEAR
ISUZUCHEVROLET LCF 3500HG2023-2024
ISUZUCHEVROLET LCF 4500HG2023-2024
ISUZUCHEVROLET LCF 5500HG2024
ISUZUCHEVROLET LCF 5500XG2024
ISUZUN-SERIES2023-2024

 


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

RCMN-23V564-7474.pdf 68.18KB

 


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

 


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