Loss of Engine Power from Electrical Corrosion – 2023-2024 Chevrolet 3500HG, 4500HG, 2024 5500HG, 5500XG LFC

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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 Vehicle has a Recall

 


Frequently Asked Questions (FAQs) for Safety Recall N232419340
Ignition Coil Pack Fuse

These questions and answers are being provided to help GM dealers respond to inquiries from involved vehicle owners about the Safety Recall identified above.

 

Q1) Which vehicles are involved?

A1) Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2023 and 2024 model year Chevrolet Low Cab Forward vehicles equipped with 6.6L (RPO L8T) gasoline engines.

 

Q2) What is the issue or condition?

A2) 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.

 

Q3) What symptoms may be experienced? What warning signs may be associated with the issue or condition described?

A3) None.

 

Q4) What is the remedy/repair?

A4) Dealers will apply a silicone sealant to the rear of the existing fuse holder plug.

 

Q5) What is the safety risk? Is the vehicle safe to drive?

A5) 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.

 

Q6) Does the customer have to pay for this remedy/repair?

A6) No, this inspection/repair will be done at no cost to the customer.

 

Q7) Is the remedy/repair available now?

A7) No, when a sufficient quantity of parts are available, the recall bulletin will be released, and dealers can begin repairing vehicles.

 

Q8) What should customers do until recall repairs can be completed? Are there any special instructions?

A8) If special instructions are provided, they will be included in the notification letters to customers.

 

Q9) How can customers check to see if their vehicle is involved in this field action?

A9) Customers who own a vehicle involved in the field action will be notified by mail by General Motors, but they may also check their Vehicle Identification Number (VIN) for field actions in GM Owner Center at https://my.gm.com/recalls or via NHTSA’s website at https://vinrcl.safercar.gov/vin/.

 

Q10) If customers are concerned, can they get a rental car or courtesy transportation?

A10) Courtesy transportation is not applicable to Medium Duty vehicles. Towing is covered to the nearest Chevrolet Medium Duty dealer if your vehicle cannot be driven because of a warrantied defect. Please refer to Warranty Administration Bulletin #07-00-89-037: Warranty Administration – GM Courtesy Transportation and Roadside Assistance Programs for further information.

 


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

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Defect Notice 573 Report

RCLRPT-23V564-1404.PDF 220.511KB

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Recall Acknowledgement

RCAK-23V564-6217.pdf 645.472KB

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Manufacturer Notices(to Dealers,etc) – GM Date: August 10, 2023 Subject: Stop Delivery Order for Safety Recall N232419340

RCMN-23V564-2748.pdf 128.307KB

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Manufacturer Notices(to Dealers,etc) – GM Frequently Asked Questions (FAQs) for Safety Recall N232419340 Ignition Coil Pack Fuse

RCMN-23V564-4846.pdf 104.947KB

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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

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Manufacturer Notices(to Dealers,etc) – GM August 25, 2023 Subject: N232419340 – Safety Recall

RCMN-23V564-6812.pdf 185.003KB

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Remedy Instructions and TSB

RCRIT-23V564-5740.pdf 1551.492KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V564&docType=RCL

 


 

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  • ✨【3 YEARS WARRANTY & FREE LIFETIME UPDATES】The diesel truck scanner is exclusively designed for US truck. it's come With a full service functions and full systems and provides 24/7 technical support, 3 years warranty, 90-days free return for refund or replacement. This diesel scan tool is suitable for auto repair shops and technicians.No subscription fee and free lifetime updates.
Bestseller No. 9
OBDResource Full Systems Heavy Duty Truck Scanner Tool HDOBD/EOBD/OBD2 Automotive Scanner Diagnostic Tool for Truck & Car 2 in 1 Code Reader for Most 12V 24V Diesel Vehicles
  • 【Full Systems Heavy Duty Scanner Tool】:this heavy duty scanner tool supports Read DTC and Clear DTC, Live Data,Engine Check, Transmission, Drivetrain, Suspension, Cluster, Suspension, Braking System, Cab Climate, Body Control, Instrument Panel, Fuel System and more, which are in compliance with J1939, J1708 and J1587 protocols,
  • 【OBD2/HDOBD/EOBD All Diagnosis】: supports both all 12V and all 24V truck, with 6 pin and 9 pin adapters for different interfaces.It support reading code, earsing trouble codes, Live Data, determine the MIL (check your Truck engine) and I/M Readiness, Freeze Frame, O2 Sensor Test, On-board Monitor, Vehicle Identification Info.It can lookup DTC, translates the related code's meaning to help you know what's wrong with the car.
  • 【Suitable for Most Trucks】:diesel diagnostic scanner support all truck standard protocols SAEJ1939/ J1587/ J1708,it work on heavy duty trucks/ light truck/ mini vans/ buses/ pickups from1996 to now.
  • 【CANBUS System】:Detect the CANBUS node, and easily find out the wrong modoles and lines.
  • 【Professional Automotive Scanner Diagnostic Tools】:Designed specifically for HDOBD/OBD2/EOBD.This HD10 covers all the functions of HDOBD,OBD2,and EOBD. What is more important is that it provide the results correctly and quickly, and you can read the results with graghs, which make you easier to read.
SaleBestseller No. 10
iCarsoft HD V3.0 Heavy Duty Diesel Truck Diagnostic Scanner Tool Code Reader Freightliner Cummins
  • COMPATIBLE WITH all heavy duty trucks in compliance with standard protocols (J1587, J1939 and J1708).
  • BEST IN CLASS INNOVATION- iCarsoft HD V3.0 can do it all-reads and clears trouble codes on most systems such as engine, transmission, ABS and airbag etc. Supports OBDII/EOBD, with Ten Modes of Operation, read live data, full ECU diagnosis etc.It automatically detects your car model and scans all modules for error codes. This special technology allows for specific diagnostic functions and testing!
  • DYNAMIC TEST CAPABILITIES- The Multi-lingual function allows you to view & graph live data in color while graphing at a blazing fast refresh rates for quicker results. Our OBD2 scanner allows you to read pending DTCs and permanent DTCs with a DTC Library to lookup while operating the tool. Providing you with accurate data results for all your error codes
  • DIAGNOSTIC FUNCTIONS & ADVANCED FEATURES- Along with the standard OBD functionscalibrate,Headlamp adjustment,Freeze Frame, O2 Sensor Test, and Evap System Test are just a few of the special functions this professional quality car scanner provides
  • TRY IT RISK FREE- Whether you’re your own personal auto mechanic or you’re a business owner, you’ll fall in love with our compact design of this diagnostic scanner. Its pocket-size and perfect for allowing diagnostic tests inside or outside of the car. No batteries required just plug it into the OBD II port and you’re all set. If for any reason you are not 100% satisfied, please contact us for a full hassle-free refund or replacement!

Last update on 2024-04-27 / Affiliate links / Images from Amazon Product Advertising API

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