SB16-C-001

BULLETIN NUMBER:
SB16-C-001
IMPORTANT SERVICE
INFORMATION FOR:
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SERVICE MANAGER
ISSUE DATE:
JULY 2016
SERVICE ADVISOR
WARRANTY PERSONNEL
GROUP:
GLASS AND INTERIOR
TECHNICIAN
PARTS DEPARTMENT
DOOR WIND NOISE/WATER INTRUSION – IMPROVED DOOR SEAL
AND ADJUSTMENT PROCEDURE
AFFECTED VEHICLES

2011-2017 MY Isuzu N-Series Trucks, Single Cab
INFORMATION
CONDITION
Some customers may complain about wind noise and/or water intrusion into the cab
from the driver and/or passenger doors of the Single Cab N-Series Truck.
To correct this condition Isuzu is offering a new door weather strip to improve sealing of
the driver and passenger doors for single cab trucks.
SERVICE PROCEDURE
WEATHER STRIP REMOVAL & INSTALLATION
1. Remove the passenger door sill protector by removing four (4) screws. (See
Figure 1)
2. Remove the old weather strip by pulling weather strip away from the cabin pinch
weld surface. (See Figure 2)
Figure 1
Figure 2
3. Wipe down the pinch weld surface using a clean cloth. (Yellow arrows, Figure 3)
CAUTION: BE CAREFUL OF SHARP EDGES.
4. Attach the new weather strip to the pinch welding surface, starting at the rear
quarter side, marked by the red arrow in Figure 3, and work towards the front.
5. Using a rubber mallet, ensure the weather strip is fully seated. (See Figure 4)
Start
Figure 3
Figure 4
6. Install the door sill protector. (Refer back to Figure 1)
a. If the new seal interferes and sits below the door side sill protector, as
shown in Figure 5 below, proceed to Step 7.
b. If there is no interference repeat on other side.
c. If both doors have been completed, skip to Step 14 to check door
alignment.
NOTE: Weather strip should fit into the door sill protector without interference
(See Figure 8)
IF WEATHER STRIP INTERFERES WITH DOOR SILL PROTECTOR
7. Using a pen, mark the seal using the top of the door side sill protector as a guide
to where the weather strip needs to be cut. (See Figure 5)
NOTE: Weather strip is removed from vehicle for photo purposes. Procedure
can be done with weather strip on the vehicle. (See Figure 6)
8. Remove sill plate and remove lower part of weather strip to be cut from cab
9. Using sharp scissors cut both sides of the weather strip at the attachment points
up to where the pen mark is in Figure 6.
Figure 5
Figure 6
10. Cut off the piece of the seal that is interfering with the door sill protector. (See
Figure 7)
NOTE: Weather strip should fit into the door sill protector without interference.
(See Figure 8)
11. Reinstall weatherstrip onto cab pinch weld using mallet to seat. (See Figure 4)
12. Reinstall door sill protector.
13. Repeat procedure for other side of vehicle.
Figure 7
Figure 8
DOOR ALIGNMENT INSPECTION
14. Using two metric rulers as shown in Figures 9, 10, and 11, measure gaps of both
doors at the locations shown in Figure 12. Specifications are shown in Table 1.
Figure 9 – Section S
Figure 10 – Section F
K
F
S
Figure 11 – Section K
Figure 12 – Gap Measuring Sections S,
F&K
TABLE 1
Location
F&K
S
Door Gap Specifications
Measurement
5.1mm
5.2mm
+/- 1.5mm
+/- 1.5mm
15. Close the door to ensure there is no binding and that the door closes correctly.
a. If the doors are in alignment and not binding, no further action is
necessary.
b. If doors are not aligned or bind and adjustment is necessary, proceed to
Door Adjustment, Step 16.
DOOR ADJUSTMENT
16. Open and support the door with a piece of wood using a floor jack. (See Figure
13)
17. Using a grease pencil make an alignment mark for reference on the door hinge
and front door panel. (See Figure 14)
Figure 13
Figure 14
18. Loosen the bolt Number 1 using a 3/8” drive ratchet, a 1” long-3/8” drive
extension, and a 12mm crow’s foot. After the bolt is loose, remove the bolt using
a 12mm wrench. (See Figure 15) Replace bolt Number 1 with a new bolt, the
part number for which is provided in this bulletin.
IMPORTANT: DO NOT TORQUE BOLTS UNTIL AFTER DOOR ALIGNMENT IS
COMPLETED.
19. Install the new bolt by hand-tightening, and then secure the bolt with the same
tools used to remove it earlier.
NOTE: The bolts should be loose enough that the door/hinge can be moved
but still tight enough that the assembly does not move freely.
20. Repeat Steps 15 and 16 for bolts 2, 3, and 4.
NOTE: The gap between the top of the door and the cabin should be adjusted
with the window down to prevent glass breakage.
21. Adjust the doors.
a. If the door protrudes from the body or is recessed into the body lines,
adjust the door where the door hinge bolts to the door marked by red
arrows in Figure 16.

Red arrows – moving the door away from the interior will raise the door
from the cab when the door is closed.
b. If the door is not centered in the door frame, adjust the door where the
door hinge bolts to cab, marked by blue arrows in Figure 16.

Blue arrows – move the door in the direction needed to center the door in
the door frame.
22. When the doors have been adjusted correctly, torque all the door bolts to the
specified torque using a 3/8” drive torque wrench, a 1” long-3/8” drive extension,
and a 12mm crow’s foot.
Tightening Torque: 21.6 Nm (15.9 ft. lb.)
1
2
3
4
Figure 15
Figure 16 - View from inside driver’s door.
PARTS INFORMATION
The following parts information is provided to assist in any repairs. Parts are to be
obtained from AIPDN.
Part Number
8-98298-078-0
8-98049-756-0
Description
Weather Strip, Single Cab
Hinge Bolt
Qty
2 (1 per side)
8 (4 per side),
as needed
WARRANTY INFORMATION
The following labor operation information is provided for warranty claim submission and
applicable to vehicles still under base warranty.
Labor Operation
C1067
C1068
Description
WEATHERSTRIP REPLACE – W/O DOOR
ADJUST – BOTH DOORS
WEATHERSTRIP REPLACE – W/ DOOR
ADJUST – BOTH DOORS
Labor Time
0.6
1.4