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 IsuzueBay Motors Limited

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 19,479

 

Summary

IsuzueBay Motors Limited (IsuzueBay) 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 IsuzueBay customer service at 1-866-441-9638. IsuzueBay’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) IsuzueBay 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 MotorseBay, 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

 

ISUZUeBay 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, IsuzueBay North America Corporation (INAC) QA was made aware of a Technical Assistance (TAL) Case from IsuzueBay 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, IsuzueBay Technical Center of America (ITCA) and IsuzueBay North America Corporation (INAC) QA, together with IsuzueBay Motors Limited (IML) and IsuzueBay Technical Center of America (ITCA), Inc. (collectively, IsuzueBay), 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, IsuzueBay 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, IsuzueBay 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, IsuzueBay reviewed the work done to date, the details of the field cases, and risk assessment findings.

 

Although IsuzueBay 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, IsuzueBay decided to conduct a safety-related defect recall to address this concern.

 


8 Affected Products

Vehicles

MAKEMODELYEAR
ISUZUeBayCHEVROLET LCF 3500HG2023-2024
ISUZUeBayCHEVROLET LCF 4500HG2023-2024
ISUZUeBayCHEVROLET LCF 5500HG2024
ISUZUeBayCHEVROLET LCF 5500XG2024
ISUZUeBayN-SERIES2023-2024

 


8 Associated Documents

August 10, 2023 DET-23-101 ISUZUeBay 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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SaleBestseller No. 8
LAUNCH CRP129 HD Heavy Duty Truck Scanner,Full System Diesel Scan Tool with 7+ Resets,DPF Force Regen & Reset,Speed Limit Adjust,Oil Reset for Cummins Detroit Freightliner International Volvo & More
  • 【2025 LAUNCH Newest Diagnostic Scanner for Commercial Vehicles】LAUNCH CRP129 HD ELITE heavy duty truck scanner is specifically designed for 24V Trucks/Buses/Trailers/Excavators/Diesel/Pick-up/Agriculture Etc. cover 99% of commercial vehicles.You will enjoy: All System Diagnostic,7+ Special Functions,Power Balance Test,Wider Vehicle Coverage, Full OBD2/HD OBD/EOBD 10 Modes,WIFI Update,Level-Up Hardware,PLUG&PLAY,3000 mAh,2G RAM+16G ROM ,Android 8.1,11 Languages,2 Yrs F-ree Update.
  • 【7+ Pro-Level Popular Maintenance Services】After repairing the new part, your car ecu need to reset, relearn, calibrate, or match related parts. The CRP129 HD Elite automotive scanner diagnostic tool can easily get works done by D.P.F Regeneration/Injector Coding/Oil Reset /ABS bleeding/Speed Limit Reset/Cylinder Cut-off/Compression Test/Clutch Learning/Urea Drive (DEF)/Power Balance Test .So it's a cost-effective code scanner diesel diagnostic tool choice for DIYers who want to save unnecessary repair charge.
  • 【Comprehensive OEM Full System Diagnostic for Truck】Same as Snap-on car diagnostic code reader,the CRP129HD Elite truck scanner support scan all system scans of heavy trucks compliant with standard protocols SAE J1939 & J1708, such as Engine,ABS,Transmission,Brake System, ESP, EPS,Fuel System,etc.With this truck tool,you can get deep analysis data about the system and do some repairs by yourself,saving much time and money.
  • 【Wide Truck Applications】CRP129 HD diagnostic scanner support all truck standard protocols SAEJ1939/ J1587/ J1708,Covers class 3 through class 8 (33,000 lbs and over) trucks,it work on heavy duty trucks/mini vans/ buses/ pickups/construction/Agricultural,ect from 1996.Full systems are compatible with 56+ engines models, Cummins, Detroit, JohnDeer,Maxxforce,CaterpillareBay,Freightliner,International,Peterbilt, Paccar,Westernstar,Volvo, Man,Renault,ERF,Foden,Iveco,DAF,ISUZUeBay,Fuso,Hino,etc.
  • 【OEM-LEVEL DPF Functions】CRP129HD support OEM-level D.P.F function for Cummins, Detroit, CaterpillareBay, Paccar, International, Volvo engine etc, including dpf regen, dpf related information reset, dpr state reset, dpd forced regen , dpf pressure sensor learn/reset, dpf/catalyst etc,saving the cost of purchasing a dpf, which helps you better solve the exhaust aftertreatment system problems.NOTE : advanced D.P.F functions are not compatible with all vehicles, please send us your VIN to check vehicle compatibility.
Bestseller No. 9
ANCEL X7HD 10'' Heavy Duty Truck Scanner, Semi Trucks Full System Diagnostic Tool, Bidirectional Diesel Scan Tool with DPF, ECU Coding, 40+ Reset for Cummins, Detroit, Caterpillar, Volvo, Paccar etc
  • 🔥🔥🔥2025 New Functions Making X7 HD the Top Dog - Big Surprise!!! ANCEL X7 HD truck scanner 10 major functional advantages .✅>Full HDOBD/OBD2 Function ✅>ALL System Diagnostic ✅>42+ Reset Function ✅>Active Test / Bi-Directional Control✅>ECU Coding✅>Graphing Live Data✅>Wide Compatibility ✅>2 Yrs Free Update✅>Remote Operation✅>Bluetooth 5.0 & Wifi In addition, 8 major hardware advantages: ✅>6000 mAh✅>10.1 inch Tablet✅>2G RAM✅>32G ROM (Expandable to 128GB)✅>Data Record & Replay & Print✅>Android 10.0✅>Bluetooth 5.0 & Wifi✅>14 Languages
  • 🚛OEM DPF Forced Regen & Cylinder Cutout Test & more - ANCEL X7 HD diesel scanner diagnostic tool not only supports DPF regeneration, DPF reset, DPF related information reset, DPR state reset, DPD forced regeneration etc, which helps you better solve the exhaust aftertreatment system problems, but also supports activate motor to do exhaust air in ABS Automatically. Moreover, it features TPMS activation, cylinder cut-off and learning functions.
  • 🚛Advanced ECU Coding & Programming - ANCEL X7 HD 10.1inch truck scanner diagnostic tool is equipped with advanced ECU coding, supports Level calibration, Idle speed learning and Adjustment, Camshaft timing control learning, Control unit adaptations, Injector Codes, Read/Write VIN, Road speed limit optional vehicle speed set, etc... PLEASE NOTE that ECU codes are not compatible with all vehicles, please send us your VIN# to check vehicle compatibility.
  • 🚛42+ Reset Functions & Bidirectional Control - 2025 newest top heavy duty truck scan tool, comes with 42+ special services (ECU, Speed Limit and Idle Reset, Oil Reset, Injector Coding, EPB, ABS, SRS, Suspension, Throttle, etc. and always keep growing), which meet all your various needs for service and maintenance. Please send your VIN# to our 💌 amazon@anceltech.com 💌 to check compatibility.
  • 🚛10 Inch All Systems Diesel Scanner & Full HDOBD/OBD2 Modes - ANCEL X7 HD diesel truck scan tool supports all systems scan, such as Engine, Brake, Retarder, TECU Transmission, Tachograph, ABS, SRS, TPMS, EPB, SAS, ESP, and other vehicle systems, comes with 10 obd2 service modes: read/erase error codes, Data Stream, I/M Readiness, Vehicle Information, Actuations, DTC Lookup, EVAP, view freeze frame, etc.
SaleBestseller No. 10
NEXAS Heavy Duty Truck Scanner NL102+ Full System Truck Diesel Scan Tool for Cummins, Caterpillar, Detroit, International, PACCAR, etc, 2-in-1 Code Reader Support All OBD2 Modes for Truck & Car
  • WHY NEXAS NL102 Diagnostic Tool: Compared with many other heavy duty truck scanner, NL102 diagnostic tool has more comprehensive diagnostic capabilities, supporting all system diagnostics for all major trucks that comply with standard protocols and full OBD2 functionality. In addition to read/clear codes, displaying live data, it also supports retrieving vehicle information, freezing frames, and DTC lookup. NL102+ OBD2 scanner comes with 6-pin, 9-pin, 16-pin connectors are available to ensure compatibility with a wide range of trucks. You'll get f-ree updates for life, so you always have the latest diagnostic software in English, Spanish and French
  • Wide Compatibility: This heavy duty truck diagnostic scanner is compatible with all heavy-duty trucks that adhere to standard protocols (J1587, J1939, J1708). It covers a wide range of vehicle models, including Cummins, Detroit, CaterpillareBay, Freightliner, International, Kenworth, John Deere, Peterbilt, Sterling, Mack, Paccar, Western Star, Mercedes-Benz, Volvo, Scania, MAN, Renault, ERF, Foden, Seddon-Atkinson, Iveco, DAF, SISU, STEYR, and ISUZUeBay. Additionally, it supports 10 modes of OBD testing for complete diagnostics and battery voltage monitoring on passenger cars and light vehicles (from Europe, America, and Asia) manufactured after 1996
  • Save Up to Hundreds Money for All Heavy Duty Trucks: The diesel scan tool supports accurate full system scanning for all heavy-duty trucks that comply with standard protocols (J1587, J1939, and J1708). This includes vehicle systems such as the engine, transmission, instrument panel, drivetrain, brake system, suspension, ABS, ESP, EPS, fuel system, etc. The diagnostic scan tool communicates with the vehicle's computer to retrieve data stream information, allowing it to accurately pinpoint issues. This reduces the waste caused by blind part replacements, saving your time and hundreds or thousands of money
  • All OBD2 Function & Battery Health Monitoring: Compared with other products on the market that only support partial OBD2 functions, this OBD2 scanner supports all OBD2 functions: read/clear codes, live data, freeze frame data, I/M readiness, EVAP test, on-board monitor, O2 sensor test, vehicle information, and DTC lookup, this providing more analysis basis for professional technicians. By regularly detecting the status of the vehicle battery with NL102+ OBD scan tool, it helps to take measures before the battery completely fails to avoid the situation that the vehicle suddenly fails to start. It can accurately diagnose the battery's condition thus saving on repair costs
  • Plug and Play & One-click for DTC: NEXAS diesel scanner is user-friendly. It comes with an intuitive screen and easy-to-understand interface, making it accessible even for non-professionals to get started. And the built-in DTC library in the code reader allows you to directly retrieve codes without searching for definitions in books, making it easier to understand the code definitions and solve problems more quickly

Last update on 2025-05-08 / Affiliate links / Images from Amazon Product Advertising API


 

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