2016 ISUZU Truck Body Builder Guide

This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and Federal Motor Vehicle Safety Standards and be aware of their specific responsibility in regards to each standard.

Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the complete vehicle should be constantly alert to all effects, direct or indirect, on other components, assemblies or systems caused by such alterations. No alterations should be made to the incomplete vehicle that directly or indirectly results in any either component, assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards.

Isuzu Commercial Trucks of America, Inc. (ICTA) will honor its warranty commitment (for the cab-chassis only), to the ultimate consumer, provided: (1) the final stage manufacturer has not made any alterations or modifications which do not conform to any applicable laws, regulations or standards, or adversely affect the operation of the cab-chassis; and (2) the final stage manufacturer complied with the instructions contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty becomes the responsibility of the final stage manufacturer.

The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle Safety Standards. The information contained in this guide has been provided for the final stage manufacturer’s information and guidance. This guide contains information pertaining to the: NPR; NPR-HD Gas, NPR; NPR-HD Gas Crew Cab; NPR; NPR-HD NPR-XD, NQR, NRR Diesel Chassis Cab. NPR-HD, NQR Diesel Crew Cab.

Download Isuzu’s Body Builder Guide or sections for important information about up fitting your N-Series Medium Duty Commercial truck. Please check Section 0 to review information that has changed since your last visit as the guide is updated from time to time to include the latest information available. All printed material, specifications, and drawings contained in the Isuzu’s Body Builder Guide are based on the latest information available at the time of publication / posting. The manufacturer reserves the right to discontinue or change, at any time, without notice specifications, options, materials, equipment, design and models.

Electrical Sensitivity and Battery Relocation Warning
Starting with the 2011 Model year Diesel and 2012 Model year Gas N series, these products are more sensitive to poor electrical integrity of the starting circuit when compared to previous year models. This is due to the ever increasing electrical demands from the base vehicle that includes the new emissions componentry as well as more sophisticated engines and transmissions. The control modules for these devices require healthy electrical circuits without significant voltage drops through the supply and return circuits.

A relocation or modification of batteries coupled with insufficient wire gauge, poor terminal crimps, weak conductivity to frame rails , terminal corrosion, or loose bolts, could contributed to a possible no start condition.

NO-START CONDITION – CLICKING OR BANGING FROM STARTER 2012-2015MY Isuzu N-Series Equipped with 5.2L (4HK1) Diesel Engines
It is possible to experience a no-start condition accompanied by a clicking or banging-type noise from the starter. This condition presents itself when vehicle battery voltage is low. The insufficient voltage/current will cause an improper ground for the X-17 starter relay. As a result, the starter will not remain engaged to start the engine. This is not an indication of a defective starter, alternator or ECM.

The following is a list of common causes for low battery voltage. Inspect these items as possible causes for the described condition before further diagnosis.

  1. Extreme low ambient temperatures (below 10°C / 50°F). The chemical reactions inside of batteries take place more slowly when the battery is cold. The vehicle systems therefore have less energy to work with when it tries to start the engine.
  2. Vehicles stored for long periods without proper battery charging and maintenance.
  3. Batteries that have been relocated further away from the starter than the original designed location.
  4. Batteries or battery cables that have been replaced with improper gauge.
  5. Corroded battery terminals and cables.
  6. Vehicles that are started and stopped multiple times without allowing the charging system to replenish the batteries’ charge.
  7. Excessive use of electrical equipment such as electric lift gates.
  8. Interior and exterior lighting left “On” without the engine running.

Fuel Tank Caution
Fuel fill kit must be installed on cab chassis if it will be driven for an extended distance (Note: fuel tank kit provides venting for the fuel tank. DO NOT RESTRICT OR KINK THE FUEL TANK VENT HOSE Operating this vehicle with a restricted or kinked fuel tank vent hose may cause serious damage to the fuel tank and/or fuel injection pump. Continued operation may cause engine failure.

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