SB18-C-001D

BULLETIN NUMBER:
SB18-C-001D
IMPORTANT SERVICE
INFORMATION FOR:
 SERVICE MANAGER
 SERVICE ADVISOR
 TECHNICIAN
 PARTS DEPARTMENT
 WARRANTY PERSONNEL
ISSUE DATE:
DECEMBER 2020
GROUP:
GLASS AND INTERIOR
DOOR WIND NOISE/WATER INTRUSION – IMPROVED DOOR SEAL
AND ADJUSTMENT PROCEDURE
AFFECTED VEHICLES

2011MY - Current Isuzu N-Diesel

2011MY - Current Isuzu N-Gas

2018MY - Current Isuzu FTR
This bulletin is being revised to provide VIN breakpoint information and updated
vehicle applications. This bulletin supersedes bulletin SB18-C-001C. Please
discard bulletin SB18-C-001C.
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 affected N-Series and FTR trucks.
To correct this condition Isuzu Commercial Truck of America, Inc. (ICTA) is offering a new
door weather strip to improve sealing of the driver and passenger doors.
IMPORTANT
Trucks built after the production dates shown in Table 1 may need the CAB-side seal
installed and door adjusted, but will not need the DOOR-side seal and door adjustment.
Trucks built before the production dates shown in Table 1 may need both the DOOR-side
and CAB-side seals installed with door adjustment.
Table 1
VEHICLES INVOLVED
NO cab seal replacement will be necessary on truck models built after the VIN
breakpoints described in Table 2.
Model
Cable
Style
Model Year
VIN Breakpoint
FTR
Tilt
2021
54DK6S163MSG50004
NPR - Gas
Tilt
2020
54DB4W1B5LS806209
NPR - Gas
Crew Cab
2020
54DC4J1B7LS806476
NPR-Diesel
Tilt
2021
JALC4W169M7005989
NPR-Diesel
Crew Cab
2021
JALCDJ163M7006008
NPR-XD
Tilt
2021
JALC4W160M7K00993
NPR-XD
Crew Cab
2021
JALCDJ162M7K00979
NQR
Tilt
2021
JALEEW16XM7900848
NQR
Crew Cab
2021
JALE5J162M7900829
NRR
Crew Cab
2021
JALE5J160M7301704
NRR
Tilt
2021
JALE5W16XM7301738
Table 2
NOTE: On crew cab vehicles, only the front doors are affected by this bulletin.
SERVICE PROCEDURE
DOOR ALIGNMENT INSPECTION
1. Measure the offset and gap of the doors at the locations shown in Figure 1.
Specifications are shown in Table 3. Measurements are made using two metric
rulers as shown in Figures 2, 3 & 4.
TABLE 3
Location
F
K
S
Door Surface Offset & Gap Specifications
Offset
Gap
− 3.3mm
+/- 1.5mm
5.1mm
0.0mm
+/- 1.5mm
5.1mm
0.0mm
+/- 1.5mm
5.2mm
K
F
S
Figure 1 – Front Measuring Sections S, F
&K
+/- 1.5mm
+/- 1.5mm
+/- 1.5mm
Figure 2 –Top front corner of door
Figure 3 – Top rear corner of door
Figure 4 – Lower rear of door
2. Close the door to ensure there is no binding and that the door closes correctly.
 If the door’s offset is in alignment and is not binding, skip to Cab
Weatherstrip Inspection, Step 10.
 If the door’s offset is not aligned or binds and adjustment is necessary,
proceed to Door Adjustment, Step 3.
DOOR ADJUSTMENT
3. Open and support the door with a piece of wood using a floor jack. (See Figure 5.)
4. Using a grease pencil make an alignment mark for reference on the door hinge
and front door panel. (See Figure 6.)
Figure 5
Figure 6
5. Loosen bolt Number 1 shown in Figure 7 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. Replace bolt Number 1 with a new bolt, the part number
for which is provided on the last page of this bulletin.
IMPORTANT: DO NOT TORQUE BOLTS UNTIL AFTER DOOR ALIGNMENT IS
COMPLETED.
6. 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 adjusted but
still tight enough that the assembly does not move freely.
7. Repeat Steps 5 and 6 for bolts 2, 3, and 4. (See Figure 7.)
NOTE: The gap between the top of the door and the cabin should be adjusted
with the window down to prevent glass breakage.
8. Adjust the doors.
a. If the door protrudes from the body or is recessed into the bodylines, adjust
the door where the door hinge bolts to the door, as marked and shown by
the red arrows in Figure 8.

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 doorframe, adjust the door where the door
hinge bolts to the cab, as marked and shown by the blue arrows in Figure 8.

Blue arrows – move the door in the direction needed to center the door in
the doorframe.
9. When the doors have been adjusted correctly, torque all the new 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 N•m (15.9 lb•ft)
1
2
3
4
Figure 8 - View from inside driver’s door.
Figure 7
CAB WEATHERSTRIP INSPECTION
10. On single cab, N-Series vehicles check the seal on the cab-side of the door
opening (See Figure 9) to determine if it is an original seal design or a previously
offered revision. (See Figures 10 & 11.)
a. If the original seals are present as shown in Figure 10, replace them with
the redesigned cab seal and continue to Step 11.
b. If the seals on the vehicle’s cab are as those shown in Figure 11, skip to
Step 24.
c. If vehicle is an FTR, continue to Step 11.
Additional sealing surface
Figure 9
Figure 10 - Original Seal
Figure 11 – Updated
Seal
CAB WEATHERSTRIP REMOVAL & INSTALLATION
11. Remove the passenger door sill protector by removing four (4) screws. (See
Figure 12.)
12. Remove the old weather strip by pulling weather strip away from the cabin pinch
weld surface. (See Figure 13.)
Figure 12
Figure 13
13. Wipe down the pinch weld surface using a clean cloth. (See yellow arrows in
Figure 14.)
CAUTION: BE CAREFUL OF SHARP EDGES.
14. Attach the new weather strip to the pinch welding surface, starting at the rear
quarter side, marked by the red arrow in Figure 14, and work towards the front.
15. Using a rubber mallet, ensure the weather strip is fully seated. (See Figure 15.)
Figure 14 – Start at red arrow
Figure 15
16. Install the door sill protector. (Refer back to Figure 12.)
a. If the new seal interferes with and sits below the door side sill protector, as
shown in Figure 16 below, proceed to Step 17.
b. If there is no interference, repeat on other side.
c. If both doors have been completed, skip to Step 24.
NOTE: Weather strip should fit into the door sill protector without interference.
(See Figure 19.)
IF WEATHER STRIP INTERFERES WITH DOOR SILL PROTECTOR
17. 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 16.)
NOTE: Weather strip is removed from vehicle in the photo below for
illustrative purposes only. Procedure can be done with weather strip
remaining on the vehicle. (See Figure 17.)
18. Remove both sill plate and lower part of weather strip to be cut from cab
19. Using sharp scissors, cut both sides of the weather strip at the attachment points
up to where the pen mark is shown in Figure 17.
Figure 16
Figure 17
20. Cut off the piece of the seal that is interfering with the door sill protector. (See
Figure 18.)
NOTE: Weather strip should fit into the door sill protector without interference.
(See Figure 19.)
21. Reinstall weatherstrip onto cab pinch weld using mallet to seat. (See Figure 15.)
22. Reinstall door sill protector.
23. Repeat procedure for other side of vehicle, as necessary.
Figure 18
Figure 19
DOOR WEATHERSTRIP INSPECTION
24. On single cab, N-Series vehicles check the seal on the door side of the door
opening (See Figure 20) to determine if it is an original seal design or a previously
offered revision.
Figure 20
a. If the original seals are present as shown in Figure 20, continue to Step 25.
b. If the seals on the vehicle’s door are as those shown in Figures 21 & 22,
skip to Step 29.
c. If vehicle is an FTR, skip to Step 26.
Figure 20 - Original Seal
Figure 21 - Updated Seal
– location of plastic pin
stopper
Figure 22 –plastic pin
stopper
DOOR WEATHERSTRIP REMOVAL & INSTALLATION
25. Remove the side door seal shown in Figure 23 by pulling door seal from the door.

Using a trim panel tool or wire cutters remove mounting fasteners from
door. (See Figure 24.)
Figure 23
Figure 24
26. Wipe down seal mounting surface using a clean cloth.
27. Attach the new door seal:
 Start at the top, outside corner, as shown by red arrow in Figure 25.
 Fasten the seal, working across the top of the door and then down to the
bottom of the door – see yellow arrows in Figure 25.
 Go back to the top corner and connect the seal down the opposing side of
the door, working towards the bottom.
 Now fasten the seal across the bottom, as shown by yellow arrows in
Figure 26.
Figure 25
Figure 26
28. Repeat the procedure on the remaining door/s.
PARTS INFORMATION
The following part numbers are for revised seals and non-shouldered bolts. The nonshouldered bolts will allow slight movement so the door can be adjusted. Parts are to be
obtained from AIPDN.
Model
N-Single
N-Single
N-Crew
N-Crew
N-Series
N-Series
FTR
FTR
FTR
FTR
Front Door
Part Number
Description
CAB-SIDE WEATHERSTRIP
8-97664-929-0 WEATHERSTRIP; FRONT, RH
8-97664-930-0 WEATHERSTRIP; FRONT, LH
8-97664-931-0 WEATHERSTRIP; FRONT, RH
8-97664-932-0 WEATHERSTRIP; FRONT, LH
DOOR-SIDE WEATHERSTRIP
8-98484-919-0 WEATHERSTRIP; FRONT, RH
8-98484-920-0 WEATHERSTRIP; FRONT, LH
FTR CAB-SIDE WEATHERSTRIP
8-97664-929-0 WEATHERSTRIP;FRT SIDE, RH
8-97664-930-0 WEATHERSTRIP;FRT SIDE, LH
FTR DOOR SIDE WEATHERSTRIP
8-98484-921-0 WEATHERSTRIP;FRT SIDE, RH
8-98484-920-0 WEATHERSTRIP;FRT SIDE, LH
N-SERIES AND FTR
Qty
1
1
1
1
1
1
1
1
1
1
ALL
8-98049-756-0 HINGE BOLT
16 (4 per hinge,
8 per door, as
needed)
WARRANTY INFORMATION
The following labor operation information is provided for warranty claim submission and
applicable to vehicles still covered by the New Vehicle Warranty.
Labor Operation
C1067
C1068
Description
WEATHERSTRIP (DOOR SEAL), FRONT
DOORS BOTH – REPLACE
ADD: REPLACE FRONT DOOR CAB BOTH
WEATHERSTRIP
WEATHERSTRIP (DOOR SEAL) – FRONT
DOORS BOTH – REPLACE AND ADJUST
ADD: REPLACE FRONT DOOR CAB
WEATHERSTRIP
Labor Time
0.3
0.6
1.4
0.6