Recall 21508 Unexpected Engine Shut Down – 2020-2021 IC Bus CE Transit Buses

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October 25, 2021 NHTSA CAMPAIGN NUMBER: 21V838000

Unexpected Engine Shut Down

Unexpected engine shut down can increase the risk of a crash. Additionally, a disabled school bus may require an evacuation procedure in an uncontrolled traffic situation, increasing the risk of injury to passengers.

 

NHTSA Campaign Number: 21V838

Manufacturer Navistar, Inc.

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 5

 

Summary

Navistar, Inc. (Navistar) is recalling certain 2020-2021 IC CE transit buses. The engine control module (ECM) may set a fault code that results in an unexpected engine shut down.

 

Remedy

Dealers will update the engine control unit software, free of charge. Owner notification letters notifying owners of the safety risk were mailed January 18, 2022. Owners may contact Navistar customer service at 1-800-448-7825. Navistar’s number for this recall is 21508.

 

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.

 


DEFECT DESCRIPTION

With the vehicle in motion, the Engine Control Module (ECM) may set a fault code resulting in engine shut down without warning. In a bus application, unintended engine shut down without warning may result in evacuation concerns when students must be transferred to another bus near the roadway.

 

MODELS INVOLVED

This safety recall involves certain 2020, 2021, 2022, and 2023 CE school bus models built 01/17/2019 thru 01/06/2022 with PSI 8.8L gasoline engines and 2020, 2021, 2022 and 2023 CE school bus models built 04/11/2019 thru 01/06/2022 with PSI 8.8L LPG engines.

 

ELIGIBILITY

This procedure applies ONLY to vehicles marked in the International® Service Portal5M with Safety Recall 21507. Also complete any other open campaigns listed on the Service Portal at this time.

 

PARTS INFORMATION

There are no parts for this safety recall.

 

TOOLS REQUIRED

NOTE: Prior to performing this Recall, you must ensure your EZ-Tech@ or equivalent Electronic Service Tool (EST) has PSI Powerlink Software installed.

Descri tion Tool Number Quanti
Powerlink Pro rammin Cable 12-716-01 1
EZ-Tech@ or E uivalent 1
PSI ECU Field Pro rammer Software 1
NEXIQ USB- Link Series N/A 1
Batte Char er 55 Am PSC550CC 1

 

SERVICE PROCEDURE

WARNING! To prevent personal injury and I or death, or damage to property, park vehicle on hard flat surface, turn the engine off, set the parking brake and install wheel chocks to prevent the vehicle from moving in either direction.

WARNING! To prevent personal injury and I or death, always wear safe eye protection when performing vehicle maintenance.

WARNING! To prevent personal injury and I or death, or damage to property, allow engine I vehicle components to cool before servicing.

WARNING! To prevent personal injury and I or death, or damage to property, keep flames or sparks away from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel explosive gases.

1. Park vehicle on flat surface.

2. Shift transmission to Park or Neutral and set parking brake.

3. Turn vehicle ignition to Key OFF position.

4. Install wheel chocks.

5. Open battery compartment and connect battery charger to vehicle battery.

6. Unlatch and open hood.

7. Obtain a health report from vehicle.

 

8. Locate proprietary network connector located on the engine hamess below Engine Control Module (ECM). Remove protective cap (Figure 1 , Item 1) and save for reuse.

 

9. Using Powerlink programming cable, connect appropriate connector (Figure 2, Item 1) to proprietary network harness.

10. Route remainder of programming cable into vehicle interior.

 

11. Locate DLC (Figure 3, Item 1) under vehicle dash.

 

12. Connect 6-pin connector of programming cable (Figure 4, Item 1) to DLC.

 

NOTE: Ensure laptop screen saver and sleep settings are turned OFF or set to a minimum of one hour.

13. Connect programming cable (Figure 5, Item 1) to laptop / USB interface connector (Figure 5, Item 2).

14. Turn vehicle ignition to Key ON, Engine OFF.

NOTE: Refer to PSI Product Bulletin PS1220001 at the end of this document for calibration and programming information.

15. Using EZ-Tech@ or equivalent Electronic Sentice Tool (EST) with PSI Powerlink Software installed, program ECM. Refer to attached PSI Bulletin PS1220001 for additional information.

16. Turn vehicle ignition to Key OFF position.

17. Disconnect EST from DLC and underhood proprietary network connector.

18. Install protective cap to proprietary network connector.

19. Close and latch hood.

20. Disconnect battery charger from vehicle battery and close compartment.

21. Remove wheel chocks.

END OF SERVICE PROCEDURE

 


General Information

The calibration updates shown below change the reporting and reactions to SOH faults and prevents a forced shutdown reaction when a SOH fault sets.

If the ECM detects the fault once, the ECM will power cycle itself and the MIL will turn on and the vehicle will continue to operate normally. If the fault happens a second time within the same key-cycle, the engine will go into “Forced Limited Power and the dash will be beeping with the stop sign illuminated on the dash. The vehicle will still be drivable in this situation.

 

Calibration Information

The calibration shown in yellow on the following tables are the newest release calibrations as of the date of this publication.

Below gasoline calibrations will receive MY22 gasoline calibration: 38300107-2.

TABLE 1

MY22 GASOLINE CALIBRATION: 38300107-2
Product Replaces Old Calibration
MY19 GAS 38300064-1
MY19 GAS 38300064-2
MY20 GAS 38300081-1
MY20 GAS 38300081-2
MY21 GAS 38300090-1

 

Below LPG Gen2 calibrations will receive the MY22 LPG Gen2 calibration: 38300108-2.

TABLE 2

MY22 LPG Gen2 calibration: 38300108-2
Product Replaces Old Calibration
MY19 LPG 38300037-1
MY19 LPG 38300037-2
MY19 LPG 38300037-3
MY19 LPG 38300037-4
MY19 LPG 38300037-5
MY20 LPG 38300080-1
MY20 LPG 38300080-2
MY21 LPG 38300089-1

 

Below LPGULN calibrations will receive the MY22 LPGULN calibration: 38300109-2.

TABLE 3

MY22 LPGULN calibration: 38300109-2
Product Replaces Old Calibration
MY20 LPGULN 38300088-1
MY20 LPGULN 38300088-2
MY21 LPGULN 38300102-1

 

How to update the ECM calibration?

The ECM calibration is updated using the PSI Powerlink electronic service tool. Follow the steps provided in the PSI Powerlink user manual shown on page 46 “Calibration Programming”

 


  • 03/02/2021 Navistar Field service receives communication from a customer describing a vehicle stall.
  • 03/09/2021 Navistar Field Service and Compliance review the customer engine shut down condition and decide to monitor the condition.
  • 03/15/2021 Field Service initiates investigation into possible ECM faults related to the engine stall condition.
  • 03/24/2021 Navistar ships ECM to supplier for root cause analysis to determine failure behind multiple fault codes resulting in engine shut down.
  • 04/01/2021 through 04/27/2021 No reports of engine shut down related to the multiple fault codes condition.
  • 04/28/2021 Navistar receives root cause analysis of the ECM from PSI and their supplier Borg Warner. Borg Warner concluded the ECM was acceptable with no internal hardware failure, no solder failure, and ECM functionality was intact. Failure could not be duplicated.
  • 05/13/2021 Navistar and PSI perform additional quality inspections of the vehicle interface connector (VIC) to verify the engine harness pin connections were not the cause of the power surge resulting in the fault codes and shut down.
  • 05/26/2021 Navistar and PSI review data collected to date and determine fault 629/12 may be related to the engine stall condition.
  • 06/10/2021 Navistar and PSI develop a diagnostic plan for a vehicle that is experiencing fault 629/12 to narrow down the scope or identify root cause.
  • 06/15/2021 through 09/10/2021 A Control Tec Data logger was installed on a vehicle that previously experienced fault code 629/12 with engine shut down with no repair after the incident. The failure could not be duplicated with over 5,000 miles logged.
  • 06/23/2021 Navistar and PSI meet to discuss potential failures such as intermittent loss of power supply to ECM and/or EMI/CAN bus overload or corrosion at the pin terminal resulting in communication error.
  • 06/28/2021 Navistar and PSI meet to discuss inventory inspection performed at PSI manufacturing. There were no bent pins found in the VIC. Additionally, Borg Warner confirmed shut down was appropriate when fault code 629/12 is set.
  • 07/16/2021 Navistar and PSI review fault code 629/12 occurrence and related Warranty data resulting in ECM replacement for 629/12. A test strategy was developed to test VIC power interruption to ECM and/or pin connections.
  • 07/17/2021 through 10/14/2021 No new reports of engine shut down resulting from fault code 629/12.
  • 08/12/2021 Navistar Compliance and Field Service meet to identify any additional failures since July 2021 and discuss progress to date of the Control Tec Data logger installed on suspect vehicle. There were no incidents of fault code 629/12 and engine shut down recorded. Data collection continues on this vehicle with the Control Tec Data logger installed.
  • 08/18/2021 Navistar Compliance and Engineering meet internally to discuss potential issue with ECM programming software that may cause fault 629/12.
  • 8/19/2021 Navistar Compliance Committee meet to review failure mode, potential root cause, and fault code 629/12 occurrence. The Committee recommended to continue review of the ECM programming software and investigation of fault code 629/12 and reaction with supplier.
  • 09/03/2021 Navistar, PSI, and Borg Warner meet to discuss the functionality of the ECM and Fault code 629/12 and ECM sequence of fault reaction.
  • 09/10/2021 PSI and Borg Warner confirmed the sequence of fault code reaction was correct and determined to measure loop count from main micro to safety micro operation and maximum loop time of micro MPM software exchange.
  • 09/14/2021 PSI and Borg Warner confirmed measured loop count from main micro to safety micro was working properly and within program timing. Borg Warner confirms vehicle can restart after fault code 629/12 with a five second key off event before restart.
  • 09/24/2021 Navistar, PSI, and Borg Warner meet to discuss potential on-vehicle testing and bench testing of the ECM.
  • 10/05/2021 Tests interrupting the PT ignition were performed by Borg Warner and PSI. Borg Warner tests involved the use of a bench set-up with increased RPMs to simulate increase in CPU load. PSI performed the same increase in CPU load in their on-vehicle testing. Borg Warner and PSI were unable to reproduce the 629/12 shut down failure.
  • 10/14/2021 Navistar Compliance Committee meet to review the progress of the investigation causing fault code 629/12. Review the potential of main micro software delay/unsent message, software reacting to harness power interruption, and restart capability after vehicle shutdown caused by 629/12. Additional information for occurrence, time period of fault code 629/12, and vehicle build population was requested.
  • 10/15/2021 PSI and Borg Warner inspect four vehicles that experienced Fault code 629/12. One vehicle, the pins in the VIC inspected good and the failure could not be reproduced. The remaining three vehicles had a bent pin in the VIC connection and the failure could still not be reproduced.
  • 10/19/2021 Navistar reviewed the failure time periods.  There was a total of 42 reports of fault code 629/12 occurring during the suspect date range. Not all of these reports could be confirmed as causing a vehicle shutdown. Based on these fault code reports Navistar declares a safety recall even though a cause could not be determined.
  • 10/22/2021 Navistar, PSI, and Borg Warner meet to discuss software programming change; should a vehicle experience fault code 629-12, can the program reaction be changed from shut down and reset to just reset.
  • 10/29/2021 through 01/04/2022 Borg Warner and PSI develop new software programming and validate there are no effects to ECM safety functionality.
  • 11/09/2021 Navistar mails interim notice to affected bus owners instructing the restart procedure until the final field remedy becomes available.
  • 01/07/2022 PSI and Navistar release new software programming to production and for the final field remedy.

 


22E084 – Unexpected Engine Shut Down – Power Solutions International

 

22E084 – Unexpected Engine Shut Down – Power Solutions International

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
IC BUS CE 2020-2021

 


14 Associated Documents

Miscellaneous Document

RMISC-21V838-8217.pdf 22.848KB

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Recall 573 Report – Amendment 2 12/20/2021

RCLRPT-21V838-6312.PDF 213.78KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V838-7807.pdf 35.762KB

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Remedy Instructions and TSB

RCRIT-21V838-5057.pdf 349.889KB

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Recall 573 Report – Amendment 11/03/2021

RCLRPT-21V838-4231.PDF 213.69KB

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Recall Acknowledgement

RCAK-21V838-9000.pdf 646.277KB

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Miscellaneous Document- Chronology

RMISC-21V838-0139.pdf 22.031KB

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Defect Notice 573 Report

RCLRPT-21V838-2708.PDF 212.87KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V838-7342.pdf 42.275KB

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Recall 573 Report – February 8, 2022

RCLRPT-21V838-3306.PDF 213.703KB

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Recall 573 Report – January 14, 2022

RCLRPT-21V838-3901.PDF 213.661KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-21V838-2392.PDF 211.117KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V838-4653.PDF 211.213KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-21V838-6670.PDF 211.294KB

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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=21V838&docType=RCL

 


 

Heavy Duty Truck Reprogramming

Description:

Designed for flexibility, the USB-Link 3 Wired Edition connects to your PC, tablet, or smartphone with a USB cable, allowing techs to directly connect to a device when working in the field or during signal interruptions.

Built to support the latest protocols (CAN FD, DoIP) and compatible with a wide range of OEM diagnostics software, the USB-Link 3 is our most advanced VCI to date, with the performance and technology you can rely on well into the future.

 

The USB-Link™ 3 comes with the following:

  • Latching USB Cable (PN 404032)
  • 9-Pin Deutsch Adapter, 1 Meter (PN 493128)
  • J1962 Adapter (16-Pin OBD II, 1 Meter (PN 491113)

The USB-Link™ 3: Wireless is also available (PN 121052).

 

Specifications

Vehicle Network Protocol Support

CAN FD / J1939 FD / ISO15765 FD - 250K, 500K, 1M b/s with auto baud detection

Single wire CAN (SWCAN)

ISO 11898-3 Fault Tolerant CAN (FTCAN)

Diagnostics Over Internet Protocol (DoIP)

J1708

J1850 VPW (Class 2)

ISO PWM (SCP)

ISO 9141 / KWP2000 (ISO 14230) K/L line

ALDL 9600 and 8192 baud

ATEC 160 baud

 

Windows® Vehicle Communication API

Windows® Vehicle Communication API

RP1210 a/b/c

J2534 (2004 draft)

J2534-1 partial implementation (commercial vehicle focused)

 

Operating System Compatibility

iOS

Android™

Windows® 10, 11

 

Interfaces to Computing Platforms

USB 2.0 (vehicle-to-PC connectivity)

Bluetooth® 2.1 + EDR

Wi-Fi (dual band)

 

Compatible Software

Detroit Diesel Diagnostic Link

CAT Electronic Technician (On-Highway only)

Cummins Insite

International - ServiceMAXX Fleet Pro

Hino eXplorer

Volvo PTT

VCAD Elite Mack/Volvo

V-MAC Service Tools

Allison DOC® For PC-Service Tool - Protocols Supported: J1939, J1708/J1587, and J1850

Allison DOC® For Fleets (1000/2000) - Protocols Supported: J1939, J1850

Allison DOC® For Fleets (3000/4000) - Protocols Supported: J1939, J1708/J1587

Eaton ServiceRanger

Bendix ACom

WABCO Toolbox

Freightliner ServiceLink

International ABS

International DLB

International Intune

International IPC v2.02

PACCAR DAVIE4

 

121052

121054

 

Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Diesel Laptops Nexiq USB Link 3 Wireless Edition with Repair Information & Diagnostic Software
Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Diesel Laptops Nexiq USB Link 3 Wired Edition with Repair Information & Diagnostic Software

 

Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light iCarsoft HD V3.0 Heavy Duty Diesel Truck Diagnostic Scanner Tool Code Reader Freightliner Cummins
Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light XTOOL HD900 CAN Bus Engine Code Reader Heavy Duty Truck Diesel Scanner OBDII Diagnostic Tool Work for J1587 J1708 and J1939 Protocols
Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Heavy Duty Truck Scan Tool NL102 Plus Auto Scanner with DPF/ Sensor Calibration / Oil Reset + Check Engine for Cars; Truck & Car 2 In 1 Code Reader (NL102 Plus)
Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Autel MaxisysCV MS908CV Diagnostic Tool with No-Delay Delivery for J2534 ECU Programming, Heavy Trucks Diagnostics, Coding, Service Functions

 

Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Nexiq Blue-Link Mini
Product Number NQ126015
Nexiq Blue Link Mini™ Vehicle Communication Interface

 

Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light NEXIQ Technologies 124032 USB-Link 2 Connector
Recall 21508 Unexpected Engine Shut Down - 2020-2021 IC Bus CE Transit Buses | small light Dearborn DPA5 Pro Universal RP1210 Protocol Adapter

 


Daimler Truck

DiagnosticLink Order Site:

DiagnosticLink Direct Link:

https://diagnosticlink.nexiq.com/DTNA/Default.aspx

 


 

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Paccar All System Diesel Diagnostic Scan Tool Truck & Car 2in1 Code Reader with Oil Reset"> Bestseller No. 5
FCAR F802 Plus Heavy Duty Truck Scanner DPF Regen Tool Fit for Cummins Detroit Caterpillar International Volvo Paccar All System Diesel Diagnostic Scan Tool Truck & Car 2in1 Code Reader with Oil Reset
  • 🚛【2024 Most Professional DPF Regen & Reset Tool】F802 heavy duty truck code reader support fully exclusive OEM-level DPF functions fit for Cummins, Detroit, Caterpillar, International, Volvo, Isuzu, Fuso, Hino. F802 diesel scanner diagnostic tool can perform DPF regen, DPF reset, DPF related information reset, DPR state reset, DPD forced regen, Forced DPR Regen, Ash Service Regen, Reset the soot level, etc, to make your truck breathe smoothly and recover power performance quickly.
  • 🚛【Available for Cummins】F802 heavy duty truck scanner support full systems diagnosis, alll basic functions and dpf regen & reset for Cummins engine: ISB/ISD/ISL/ISG/ISX/ISC/ISF/ISM/ISBe/QSM11/ISM/QSX15/ISC/ISN/ISK/X12/X15/L9/B6.7/L9N/QSB,etc. F802 heavy duty scanner support vehicle models like Freightliner/Kenworth/International/Peterbilt/Volvo Truck/Western Star/Kenworth/Autocar/Western Star Mack/Ford/Autocar/RAM/Terex/Bluebird and more.
  • 🚛【Available for Caterpillar & International】F802 heavy duty truck scan tool fit for Caterpillar engine: C7/C9/ C11/C13/C15/C32; Support Caterpillar 320D/320E/312E/312F, Ford Pick-up F-650/750, Freightliner M2/Argosy, Peterbilt 379/387/385/378/357, Kenworth C500, etc. F802 heavy duty code reader can work on International engine: MaxxForce 5/7/11/13/15/DT9/DT10, International A26; Support international HV/HX /LT/RH Series, DuraStar/WorkStar/CXT and more.
  • 🚛【Available for Detroit & Paccar】F802 heavy truck scanner can work on Detroit engine: Series 50/55/60, MBE 900/4000, OM501/502, DDDL 6/7, DD5/8/13/15/16; Support Freightliner: Cascadia/M2/M2 106 Plus/M2 112 Plus/108SD/108SD Plus/114SD/114SD Plus/122SD, Western Star: 4700/4800/4900/6900, 47X/49X/57X/X-Series. F802 diesel code reader fit for Paccar engine: PX-7/PX-9, MX-11/MX-13; Support Kenworth K270E/K370E/W990/T180 - T880, Peterbilt 579/389/567/367/365/548/535/536/537/220, ect.
  • 🚛【Available for Volvo & Hino】F802 dpf regen tool is compatible with Volvo engine: Volvo(J1708), Volvo(500K) ( D11, D13, D13TC); Support Volvo HD truck FM7/9/10/12, FH12/16/565, FH16, FL10/FL12/FL6/FL7, NH12/535/565, F10/12/16. F802 diesel obd2 scanner can work on Hino engine: A09C/J05E/J05C/J05D/J07E/J08E/S05C/N04C/N05C/A09C/E13C/P11C,etc; Support Hino 300/500/600/700, Retro, Hino bus, Hino Coach, Hyundai, KATO, Kobelco, Takeuchi, etc.
Bestseller No. 6
LAUNCH CR-HD Plus Heavy Duty Truck Scanner Diagnostic Full System Scan Tool Fit for Cummins, Caterpillar, International, Volvo, Detroit, Isuzu, Fuso, Diesel Truck & Car 2-in-1 OBD2 Code Reader
  • 🔎【Comprehensive Full Systems Diagnostic Tool For Truck】Launch Heavy Duty Truck Diagnostic Tool offers OE-Level diagnosis for all systems of heavy truck/Pickups/Bus/Van in compliance with OBD-II Communication Modes 1-10 and J1587, J1708 and J1939 protocols,Including Engine, Transmission, Drivetrain, Suspension, ABS, ESP, Cluster, E-xhaust, P-articular, Suspension, Braking System, Cab Climate, Body Control, Instrument Panel, Fuel System and more.
  • 🔥【All OBD/EOBD Diagnosis】This truck scanner diagnostic tool supports both most 12V and 24V truck, and it comes with 6 pin, 9 pin and 16 pin adapters for different interfaces. Our truck scan tool can read codes, erase codes, I/M Readiness, Live data, EVAP Test. . . etc for obd2/eobd cars. Built in a DTC lookup library you can find the related code definition to help you determine if your car needs repair.
  • 🚚【Wide Truck Applications】Heavy duty truck scan tool covers almost J1587, J1708 and J1939 protocols heavy duty trucks and OBD II vehicles. Such as Cummins, Paccar, Detroit, Perkins, International, Peterbilt, Allison, Eaton, Ford duty trucks and so on, Covers class 4 (14,001 lbs) through class 8 (33,000 lbs and over) heavy duty trucks. One that meets all the requirements! NOTE:Compatibility will vary on vehicles model and year, please send V-IN to check the compatibility before purchase.
  • 💡【Friendly Design, Easy of Use】This heavy duty diagnostic scan tool is plug and play, simple and convenient, The excellent 2.8 inch LCD color screen makes it easy to view the displayed results and gives you a better overview of your car's problem areas and the identified codes. In addition, the processor is super-fast and responds without lagging, providing maximum comfort and efficiency in diagnostic and service work.
  • ✨【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.

Last update on 2024-03-18 / Affiliate links / Images from Amazon Product Advertising API

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