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

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


Potential Number of Units Affected 19,479



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.



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.



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



ISUZU Campaign: V2305

Chronology of Defect Determination



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


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

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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  • 🔹【Revolutionary Bluetooth Code Reader for Cars and Trucks】 Tired of cumbersome diagnostic cables? The ANCEL HD100 Heavy Duty Truck Scanner is the first wireless diagnostic tool to feature a dual OBDII 16-pin and Green 9-pin interface for both gasoline and diesel vehicles. ✅This diesel code reader provides comprehensive diagnostics without the need for bulky cables and adapters, thanks to its industrial-grade Bluetooth module.✅Compact and lightweight, it delivers comprehensive diagnostics for cars, trucks, and loaders, enabling quick troubleshooting of diesel issues.
  • 🔹【Easy To Use And Set Up】 Simply download the ANCEL TRUCKER app to your smartphone, register, and connect. The app features a user-friendly interface that is ideal for beginners and professionals alike. Note that for optimal Bluetooth pairing accuracy, the phone's location feature should be enabled. 👉Compatible with Apple and Android smartphones only, not tablets.
  • 🚍【Powerful Forced Regen Tool for Cummins&Caterpillar】 Supports exclusive OEM-level regeneration and reset functions for Cummins and Caterpillar diesel engines, helps you get better MPG, throttle response, longer unit life, less downtime and frequent regeneration (passive). Save hundreds or even thousands of dollars in repair costs.
  • 🚍【Enhanced Full System HDOBD Scanner with Auto Scan】The HD100 commercial truck system diagnostics enable you to seamlessly read and clear all electronic modules, encompassing the truck's engine, ABS, transmission, and chassis. It also provides support for transmissions and ABS from leading manufacturers such as Allison, Bendix, Eaton, Wabco, and ZF. Ideal for both garage and on-the-road use, this compact diesel scan tool ensures efficient and rapid completion of tasks.
  • 🚍【Compatible with Top US Trucks】This compact diagnostic tool streamlines truck repairs and supports the latest standard diedel code reader protocols SAE J1939, SAE J1708, and ISO 27145. It caters to 99% of truckers and truck fleets, offering comprehensive support for engines such as Cummins, Caterpillar, Detroit, and Paccar. Additionally, it is widely compatible with popular truck brands including Freightliner, International, Kenworth, Mack, Peterbilt, Sterling, Western Star, and Volvo.
Bestseller No. 10
KZYEE KC601 Heavy Duty Scan Tool, Diesel Truck Diagnostic Scanner Transmission DPF Code Reader and Eraser with Live Data/ECU Info for J1587/J1708 J1939 Trucks
  • ❶【What is the KC601】 It is the latest portable vehicle heavy duty code reader. You can use it to quickly and efficiently read DTCs in the vehicle's electrical control system, diagnose the fault location and find out the cause of the fault. Good for all auto repair shops to read and clear fault codes and read live data.
  • ❷【Powerful Functions】KC601 scanner is able to read and clear fault codes of all major systems, including engine, transmission, ABS, and supports checking body, chassis, cruise, instrument cluster, gateway and other control modules. Equipped with a standard OBDII diagnostic jack, allowing you to diagnose DTCs in your vehicle's electrical control system anytime, anywhere.
  • ❸【Unmatched Compatibility】KZYEE's KC601 diagnostic scanner supports heavy-duty vehicles in compliance with standard protocols (J1939 or J1587/J1708). Covers most ECU such as Cummins, Freightliner, International, Kenworth, Mack, VOLVO, etc. Power is supplied directly from the vehicle. Included are both a 6-pin and 9-pin cable for maximum vehicle compatibility and a micro USB cable for internet update.
  • ❹【User-friendly design】The 2.8-inch, 320*240 LED display meets the operating habits of each user. The well-designed appearance, menu and functions of the products support the all-in-one function of OBD/EOBD vehicles, multi-language and LED -guided operation. Easy operation and high practicability
  • ❺【100% Satisfactory Service】What you get ➤KZYEE KC601 high performance code reader, user manual, USB cable, storage bag, OBDII cable and diesel-6 and diesel-9 cable. KZYEE offers 30 days return policy & 1 years warranty & lifetime technical support & friendly customer service.

Last update on 2023-11-27 / Affiliate links / Images from Amazon Product Advertising API

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