Unexpected Command to Start Engine – 2020 IC Bus CE School Buses

SEOCONTENT-START

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POSTED ON ISIS
SEP 05 2019
Compliance Dept.
MAILED
SEP 122019
Comp I iance Dept.
SERVICE PROCEDURE
19512
SEPTEMBER 2019
SUBJECT: SAFETY RECALL
Starter Circuit on certain 2020 CE school bus
models built 24 April 2019 thru 02 May 2019 with
PSI gasoline or propane engine and C7 Body
Control Module (BCM).
DEFECT DESCRIPTION
The starter solenoid may cause damage to the starter crank output circuit of the
BCM, resulting in an unintended command to crank the engine when the ignition
key is in the ON position and the transmission is in the PARK or NEUTRAL
position. If the ignition is in the ON position during servicing, the engine could
start unexpectedly while someone is working in the engine compartment, which
could result in personal injury.
MODELS INVOLVED
This safety recall involves certain CE school bus models built 24 April 2019 thru
02 May 2019 with PSI gasoline or propane engine and C7 Body Control Module
(BCM).
ELIGIBILITY
This procedure applies ONLY to vehicles marked in the International® Service
Portal1
.. with Safety Recall 19512. Also complete any other open campaigns
listed on the Service Portal at this time.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 1
PARTS INFORMATION
Part Number Part Description Quantity
8900286R91 Kit; Jumoer Harness 1
306132C1 or Source
Locally Cable Tie Strap; 14-ln As Needed
Source Locally Wire Loom Taoe As Needed
27384R1 or Source Screw, Self-Tapping Machine Pan Head 1 Locally #10-16 X ¾ in
8900286R91 contains the following parts:
Part DescrlDtlon Quantity
Jumper Harness with Relay 1
Single Wire Jumoer 1
SERVICE PROCEDURE
WARNING! To prevent personal mJury, and / 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 / or death, or damage to
property, if the vehicle must be raised, do not work under the vehicle
supported only by jacks. Jacks can slip or fall over.
WARNING! To prevent personal injury and/ or death, always wear safe eye
protection when performing vehicle maintenance.
WARNING! To prevent personal injury, and /or death, or damage to
property, allow engine / vehicle components to cool before servicing.
WARNING! To prevent personal injury, and / or death, or damage to
property, keep flames, sparks, or other heat sources away from vehicle and
do not smoke while servicing the vehicle’s batteries. Batteries expel
explosive gases, which may cause an explosion resulting in personal
injury, death, or damage to property. Avoid contact with any heat sources.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 2
WARNING! To prevent personal injury, and / or death, or damage to
property, remove the ground cable from the negative terminal of the battery
box before disconnecting any electrical components. Always connect the
ground cable last.
1. Park vehicle on flat surface.
2. Shift transmission to Park or Neutral and set parking brake.
3. Tum vehicle ignition to Key OFF position.
4. Install wheel chocks.
5. Disconnect and isolate ground cable from negative terminal located on
main vehicle battery.
6. Unlatch and open hood.
2
Figure 1. Fuse Relay Panel
1. Start relay
2. Connector 4003
7. Locate start relay ( Figure 1, Item 1) in fuse I relay panel on firewall.
8. Remove connector 4003 (Figure 1, Item 2) by pushing lock down.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 3
2
uu 87 87A 85
0000481574
Figure 2. Connector 4003 Face View
1. Cavity 87
2. Cavity 30
9. Unlock connector and depopulate circuit from cavity 87 (Figure 2, Item
1 ).
10. Remove relay from new jumper harness.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All mar1<s are trademarks of their respective owners. 4
30 u
DOD 87 87A 85
Figure 3. Jumper Harness Relay Connector Face View
1. Cavity86
11. Unlock new jumper harness relay connector and remove GREEN plug
from cavity 86 (Figure 3, Item 1 ).
12. Populate cavity 86 of jumper harness relay connector with wire removed
in Step 9.
13. Install GREEN terminal lock onto jumper harness relay connector.
14. Populate cavity 87 of connector 4003 (Figure 2, Item 1) with spare
GRAY wire from jumper harness relay connector.
15. Remove terminal from cavity 30 of connector 4003 (Figure 2, Item 2).
Fold back the wire and, using wire loom tape, cover terminal and secure
wire in place.
16. Insert terminal from one end of single wire jumper into cavity 30 of
connector 4003 (Figure 2, Item 2).
17. Install GREEN terminal lock onto connector 4003.
18. Insert connector 4003 into start relay on fuse I relay panel.
19. Connect jumper harness connector to relay removed in Step 11 .
20. Open fuse/ relay panel.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 5
21. Using self-tapping screw, mount jumper harness relay to an open
location near start relay.
22. Close fuse / relay panel.
1 2
0000,1815 75
Figure 4. Location for Maxi Fuse
1. Main engine harness
2. Maxi fuse
23. Locate maxi fuse (Figure 4, Item 2) of jumper harness and secure to
main engine harness (Figure 4, Item 1) using two cable tie straps.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reseived. All marks are trademarks of their respective owners, 6
1
Figure 5. Mega Fuse Terminal and Nut
1. Mega fuse nut
24. Remove upper mega fuse nut (Figure 5, Item 1 ).
OCCIO,IO ,!.?t
25. Connect eyelet of RED wire in jumper harness to upper mega fuse
terminal (Figure 5, Item 1 ).
26. Install mega fuse nut. Using a torque wrench, tighten to 100 lb-in ( 11.3
N•m).
NOTE: Cable tie straps should be placed every 14 in (35 cm).
27. Using cable tie straps, route and secure wire installed in Step 25.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 7
Figure 6. Ground Terminal and Nut
1. Ground nut
1
28. Remove ground nut (Figure 6, Item 1 ).
29. Connect eyelet of WHITE ground wire of jumper harness to ground stud
(Figure 6, Item 1 ).
30. Install ground nut. Using a torque wrench, tighten to 25 – 30 lb-in (2.8 –
3.3 N•m).
NOTE: Cable tie straps should be placed every 14 in (35 cm).
31. Using cable tie straps, route and secure wire installed in Step 29.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective ownefS. 8
3
4
Figure 7. Vehicle Interface Connector
1. Vehicle interface connector
2. Cable tie strap
3. Engine connector lock
4. Mounting bracket
32. Remove vehicle interface connector cable tie strap (Figure 7, Item 2).
33. Open vehicle interface connector (Figure 7, Item 1 ).
34. Push vehicle interface connector lock (Figure 7, Item 3) and release
vehicle interface connector from mounting block (Figure 7, Item 4).
VEHICLE RECALL 19512
@ 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 9
□□□□ □□□□
□□□□□□ □□□□□
□□□□□□ □□□□□
□□□□ □□□□
0000461572
Figure 8. Vehicle Interface Connector Face View
1. Cavity C6
35. Remove terminal lock from the vehicle interface connector half with
BLUE latch.
36. Locate and remove terminal from cavity C6 (Figure 8, Item 1 ).
37. Fold back wire and, using wire loom tape, cover terminal and secure
wire in place.
38. Insert terminal of single wire jumper into cavity C6 (Figure 8, Item 1) of
vehicle interface connector.
39. Install terminal lock onto vehicle interface connector.
40. Reconnect vehicle interface connector halves.
41 . Install connector onto its bracket and secure in place using a cable tie
strap.
NOTE: Cable tie straps should be placed every 14 In (35 cm).
42. Route and secure single wire jumper harness to main engine harness
with cable tie straps.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 10
2
0000,IO I S80
Figure 9. Terminals
1. Mega fuse terminal
2. Ground terminal
43. Add dielectric grease and completely cover mega fuse terminal (Figure
7, Item 1) and ground terminal (Figure 7, Item 2} connections to avoid
corrosion.
44. Connect ground cable to negative terminal located on main vehicle
battery.
45. Start the bus to verify correct installation.
46. Close and latch hood.
47. Remove wheel chocks.
END OF SERVICE PROCEDURE
LABOR INFORMATION
Operation Number Description Time
A40-19512-1 Install Overlay Harness and Relay 1.0 hr
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 11
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with this
campaign must be marked with a CTS-1075
Campaign Identification Label.
Complete the label and attach on a clean surface
next to the vehicle identification number (VIN) plate.
COMPLETED
Service LacaUon Code*
ADMINISTRATIVE/ DEALER RESPONSIBILITIES
WARRANTY CLAIMS
Warranty claim expense is to be charged to Warranty. Claims are to be
submitted in the normal manner, making reference to Safety Recall 19512.
Section 7 of the Warranty Policy and Procedures Manual contains further
information related to the submission and processing of AFC/ Recall claims.
As with all claim submissions, items acquired locally must be submitted in the
Mother Charges” tab. The cost of any bulk items (such as a bag of cable tie
straps, roll of wire, barrel of oil, or tube of silicone) should be prorated for the
cost of the individual pieces / amount used during each repair.
GROUP
GROUP – Enter n umber
NOUN – Leave b lank –:
4- I
–
C (CAUSE)- Enter either 1, 2. 3. (See below)
1 . Inspected (No repair required).
2. Inspected and repaired.
3. Defective part from parts stock. –
arranty Code) Enter 40. _
I
WARRANTY – (W
TYPE PART – En
PAO – Enter 00
ter P for type part causing failure
–
VEHICLE RECALL 19512
I
—
NOUN C WARR. TP
I I I
I
PAO
@ 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 12
UNITED STATES AND POSSESSIONS
The National Traffic and Motor Vehicle Safety Act, as amended, provides that
each vehicle that is subject to a vehicle recall campaign must be adequately
repaired within a reasonable time after the owner has tendered it for repair. A
failure to adequately repair within 60 days after a tender of a vehicle is prima
facie evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within 60 days, the owner may be entitled to replacement
with an identical or reasonable equivalent vehicle at no charge, or to a refund of
the purchase price less a reasonable allowance for depreciation.
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
CANADA
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 13
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
EXPORT
Export Distributors should proceed immediately to make necessary correction to
units in inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your distributor location.
Export Distributors are to submit warranty claims in the usual manner making
reference to this recall number.
Export Distributors are expected to provide full cooperation and follow-up with
respect to this important subject matter. If you have any questions or need
further assistance, please contact the Regional Service Manager at your regional
office.
NAVISTAR, INC.
VEHICLE RECALL 19512
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 14

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P\lbl c
•
A &IV1S1ilR COMPANY
IC Bua, LLC
2701 Navistar Drive
Usie, IL 60532 USA
navlstar.com
IMPORTANT SAFETY RECALL 19512
NHTSA RECALL NO. 19V-534
This notice applies to your vehicle Identified on the
enclosed card.
Dear IC Bus Customer,
This notice is sent to you in accordance with the
requirements of the National Traffic and Motor Vehicle
Safety Act.
IC Bus has decided that a defect which relates to motor
vehicle safety exists in certain 2020 CE school bus models
built 04/24/2019 thru 05/02/2019 with PSI gasoline or
propane engine and C7 Body Control Module (BCM).
REASON FOR THIS RECALL
An unintended engine start could occur when the ignition
key is in the run position and the transmission is in the par1<
or neutral position.
RISK TO MOTOR VEHICLE SAFETY
If the ignition is in the run position during servicing, the
englne could start unexpectanUy while someone is working
in the engine compartment which could result in personal
injury.
DEFECT REMEDY
The remedy will involve the installation of an overlay
harness and relay to provide electrical power to the starter
solenoid. Dealers have parts and Instructions to repair your
vehicle. The repair will be performed free of charge and
take approximately 1 hour and 15 minutes to complete.
ACTIONS YOU SHOULD TAKE
If you own this vehicle, please schedule an appointment
with any IC Bus dealer to have your vehicle repaired. You
can find your nearest dealer by calling 1-800-448-7825 or
by using the dealer locator at https://www.icbus.com.
MAILED
SC:? 12 2019
Compliance Dept.
SEPTEMBER 2019
If you have already paid for repairs prior to this notice
that corrected the defect, you may be eligible for
reimbursement of certain repair expenses if they occurred
07/17/2018 thru 09/23/2019. Present your original repair
papeiwork and proof of payment to any IC Bus dealer and
your eligibility will be reviewed. You may also subrntt a
claim using the enclosed Request for Reimbursement can:I.
If you are the lessor of this vehicle, please fo,ward a
copy of this notice to the lessee within ten days to comply
with federal regulations.
If you do not own this vehicle, please fill out and return
mail the enclosed card so that you will not be contacted
again about this recall.
IF YOU NEED ASSISTANCE
If you believe that IC Bus has failed to remedy the defect
without charge or within a reasonable time, please follow
the procedure described in the Owner Assistance Guide
section in your Owner’s Manual or call toll free 1-800448-
7825.
You may also submit a complaint to the Administrator,
National Highway Traffic Safety Administration, 1200 New
Jersey Ave, SE, Washington, DC 20590; or call the toll
free Vehicle Safety Hotfine at 1-888-327-4236 (TTY: 1-800-
424-9153); or go to https://www.safercar.gov.
IC Bus requests your prompt attention and patience
regarding the correction of this defect and apologizes for
any inconvenience this may cause you.
IC Bus, LLC

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