SB20-N-001

BULLETIN NUMBER:
SB20-N-001
IMPORTANT SERVICE
INFORMATION FOR:





SERVICE MANAGER
ISSUE DATE:
DECEMBER 2020
SERVICE ADVISOR
TECHNICIAN
GROUP:
ELECTRICAL
PARTS DEPARTMENT
WARRANTY PERSONNEL
Starter Clicks When Cranking - E-98 Ground Relocation
AFFECTED VEHICLES

2018-2020MY Isuzu NPR/NPRHD equipped with 6.0L Gasoline
Engine.
INFORMATION
While attempting to start their vehicle, some customers may experience a condition in
which the starter audibly “clicks” one or even a few times before fully engaging. If
normal diagnosis cannot find fault with the battery, charging system or any other related
system, relocate the E-98 ground as described in the service procedure below to correct
the condition.
SERVICE PROCEDURE
1. Set the parking brake and block the wheels.
2. Disconnect the negative battery cable.
3. Per the instructions in the applicable Work Shop Manual (WSM), safely tilt the
cab and install the safety lock pin. (On crew cab models, remove the rear engine
cover.)
4. Unpackage the new Ground Pigtail and install ¼” convoluted tubing on it. Use
convoluted tubing with a minimum temperature range of -40 to 85°C (-49 to
185°F.)
5. Using 3M Temflex™ Tape 1755 (or equivalent) wrap the convoluted tubing at the
eyelet to secure it in place and seal the end of the tubing to the extension
harness. Wrap tape around the convoluted tubing approximately every 6 inches
(150mm). Do not wrap the last 12 inches of the harness/tubing. This area
should remain open to complete the splice connection described in Step 17
below.
6. Remove battery negative cable mounting bolt from the frame. (See Figure 1.)
Figure 1
7. Remove the bolt from the negative battery cable. If corrosion is present use a
wire brush to clean bolt, cable terminal, and frame contact areas. Insert the bolt
into the extension harness eyelet, then into the negative battery cable. Then
install the bolt with both harness connections back into the frame tightening to
26Nm (19 lb ft). (See Figure 2.)
Figure 2
8. Use 3M Temflex™ Tape 1755 (or equivalent) to double-wrap the portion of the
convoluted tubing where it will cross over air cleaner mounting bracket. (See
Figure 3.)
Figure 3
9. Starting near the air cleaner, route the extension harness upward toward the
front of the engine. Secure the harness in the frame clip (1) as shown in Figure 4.
Ensure there is at least 10mm of space between the air cleaner mounting bracket
and the extension harness. Continue routing underneath the air intake duct and
finally on top of the air intake duct next to the existing harness as shown in
Figure 4.
1
Figure 4
10. Loosely position the extension harness onto the engine harness along the
routing location. (See Figure 4.) Loosen the three 10mm bolts (1) securing the
engine identification plate for access when securing harness. (See Figure 5.)
1
E-98
Front of Engine
Figure 5
11. Loosely install 3 tie straps securing the extension harness to the chassis harness
beneath the air intake duct. Place the tie straps approximately 6 inches (150mm)
apart from each other in the locations shown in Figure 6.
Figure 6
12. Install 6 tie straps to secure the extended harness onto the engine harness
approximately every 6 inches (150mm) up to the identification plate as shown in
Figure 7. Do not secure the harness under the identification plate until the end of
this procedure.
Identification Plate
Figure 7
13. Remove the ground-mounting bolt for E-97 and E-98. (See Figure 8.)
Figure 8
14. Pull the E-97/E-98 grounds up past the bracket. (See Figure 9.)
Figure 9
15. Remove tape from the end of the engine harness and pull back on the
convoluted tubing as necessary to expose the ground wires. Find the E-98
ground, the largest gauge wire in the tubing, and separate it from other wires.
(See Figure 10.)
NOTE: E-98 has a single wire going to the ring terminal.
Figure 10
16. Measure 20mm from the back of the E-98 ground ring terminal and cut the wire.
Discard the terminal. (See Figure 11.)
Back of ring terminal
Figure 11
17. Splice the E-98 extension wire to the E-98 ground wire. Divide each of the
stripped wire portions in two, join and then twist them together. (See Figure 12.)
Figure 12
18. Solder the twisted wire joint together. Make sure that the soldered joint goes
completely around the wires and is at least 10mm in length. (See Figure 13.)
Figure 13
19. Weatherproof the splice connection using heat shrink tubing or Scotch®
Professional Grade Rubber Mastic Sealing Tape 2228 (or equivalent). (See
Figure 14.)
Figure 14
20. Tape and secure the engine harness into three directions with black vinyl
electrical tape. Cover the connections with 3M Temflex™ Tape 1755 (or
equivalent). (See Figure 15.)
E-97
E-98
E-98
Extension
Figure 15
21. Using the ground-mounting bolt removed in Step 13, install the E-97 ground
terminal into its original location and tighten to 33Nm (24.5 lb ft). (Refer back to
Figure 8.)
22. Loosely install three additional tie straps starting approximately 6 inches
(150mm) beneath the engine identification plate as shown in Figure 16.
Figure 16
23. Tighten all tie straps starting from E-98 ground, securing the extension harness
to the chassis harness and engine harness. Be careful not to stretch, crush, or
damage the extension harness.
24. Tighten the three 10mm bolts that secure the engine identification plate (that
were loosened in Step 10) to 5 Nm (44 lb in).
25. Per the instructions in the applicable WSM, remove and properly stow the safety
lock pin and tilt the cab back down. Ensure the cab is locked into place. (On crew
cab models install the rear engine cover 13 Nm (9.5 lb ft).
26. Connect the negative battery cable.
27. Start the vehicle and verify the repair.
PARTS INFORMATION
The following parts are available from AIPDN (American Isuzu Parts Distribution
Network)
Part Number
Description
Quantity
2-90120-320-0
Ground Pigtail
1
Source the following from a local parts retailer.
Description
Quantity
¼” Convolute Tubing 8’ (2500mm)
1
Tie Straps 5mm X 205mm
12
3M Temflex™ Tape 1755 8’ (2500mm)
1
Heat Shrink Tubing (60mm) or
1
Scotch® Professional Grade Rubber Mastic Sealing Tape 2228 8’ (60mm)
WARRANTY INFORMATION
For vehicles repaired under warranty, use:
Labor
Operation
N6980
Description
Labor Time
Net Item
E-98 Extension Harness Install
0.9
$25.00
Add: For Crew Cab
0.5