ISUZU Truck 2016 User Manual

2016 Isuzu Truck

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0.1

Figure 0.1.1

Attention Body Builders! Isuzu N-Series Body Builder guides are now available for FREE!

- go to: www.isuzutruckservice.com

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.

Information contained in the guide includes:

•FMVSS safety standard

•EPA requirements

•OE recommendations

•Cautions for successful application up fitting and Frame modification procedures

•Last updated on “date”

2016 Isuzu Truck

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0.2

2016 Body Builder Guide Revisions

	REVISION	REVISION	SECTION	PAGE	REVISION DESCRIPTION	REVISION DESCRIPTION
	NUMBER	DATE	NUMBER	NUMBER
	1	5/1/15	0	0.2	Revision 1 Add 2016 Gas Chassis Sections	Revise chart for revision 1
	1	5/1/15	7	7.1-7.27	Revision 1 Sec07_NPR NPR HD Gas	Add section
	1	5/1/15	8	8.1-8.30	Revision 1 Sec08_NPR NPR HD Gas Crew Cab	Add section
	1	5/1/15	16	16.1-16.39	Revision 1 Sec 16_Gas Cab Chassis Electrical	Add section
	2	6/4/15	0	0.2	Revision 2 Revise Section 0,10, 11, 12, 13, 14, 15, 18, 19, 20,and 21	Revise chart for revision 2
	2	6/4/15	10	10.15	Revision 2 Revise Section 10	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	11	11.15	Revision 2 Revise Section 11	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	12	12.15	Revision 2 Revise Section 12	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	13	13.11	Revision 2 Revise Section 13	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	14	14.12	Revision 2 Revise Section 14	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	15	15.15	Revision 2 Revise Section 15	Revise note on page to include maximum body dimensions and correct west coast phone number.
	2	6/4/15	18	18.42	Revision 2 Revise Section 18	revise to add new page
	2	6/4/15	19	19.1-19.18	Revision 2 Revise Section 19	revise for new IVD
	2	6/4/15	20	20.1	Revision 2 Revise Section 20	add note to see section 19
	2	6/4/15	20	20.2-20.18	Revision 2 Revise Section 20	delete pages
	2	6/4/15	21	21.1	Revision 2 Section 21_Vertical exhaust	revise copy
	2	6/4/15	21	21.2	Revision 2 Section 21_Vertical exhaust	Add compairson views
	3	9/30/15	0	0.2	Revision 3 revise sections 2, 16,17,18	Revise chart for revision 3
	3	9/30/15	2	2.33	Revision 3 revise section 2	revise part number for the abs wire harness and clips
	3	9/30/15	16	16.1-16.39	Revision 3 revise section 16	revise wiring art work for 2016 Model year
	3	9/30/15	17	17.1-17.34	Revision 3 revise section 17	revise wiring art work for 2016 Model year
	3	9/30/15	18	18.1-18.42	Revision 3 revise section 18	revise wiring art work for 2016 Model year
	4	10/15/15	0	0.2	Revision 4 revise sections 18	Revise chart for revision 4
	4	10/15/15	18	18.1-18.42	Revision 4 revise section 18	add Manual Regeneration for GSE vehicles to BBG
	5	4/27/16	0	0.2	Revision 5 Revise Section 0, 3, 7, and 8	revise to add note for High Idle Mode
	5	4/27/16	3	3.1-3.2	revision 5 revise section 3	revise body application chart
	5	4/27/16	3	3.3-3.8	revision 5 revise section 3	delete weight distribution chart
	5	4/27/16	7	7.3	Revision 5 revise section 7	revise to add note for High Idle Mode
	5	4/27/16	9	8.3	Revision 5 revise section 8	revise to add note for High Idle Mode
	6	8/23/16	0	0.2	Revision 6 section 0	Revise chart for revision 6
	6	8/23/16	1	1.8	Revision 6 section 1	Delete fuel tank caution
	6	8/23/16	1	1.9	Revision 6 section 1	Add fuel tank caution

2016 Isuzu Truck

2016 Body Builder Guide Revisions

	REVISION	REVISION	SECTION	PAGE	REVISION DESCRIPTION
	NUMBER	DATE	NUMBER	NUMBER

PAGE	0.3

REVISION DESCRIPTION

2016 Isuzu Truck

2016 Body Builder Guide Revisions

	REVISION	REVISION	SECTION	PAGE	REVISION DESCRIPTION
	NUMBER	DATE	NUMBER	NUMBER

PAGE	0.4

REVISION DESCRIPTION

2016 Isuzu Truck

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1.1

INTRODUCTION

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.

Following is a list of Federal Motor Vehicle Safety Standards applicable to those vehicles with a GVWR greater than 10,000 lbs. Please refer to the chart on the next page

2016 Isuzu Truck

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1.2

PART I – CHART A

LIST OF CANADA MOTOR VEHICLE SAFETY STANDARDS (CMVSS),

FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS), CANADIAN ON-ROAD VEHICLE AND ENGINE

EMISSION REGULATIONS, AND CANADA INTERFERENCE CAUSING EQUIPMENT STANDARD, APPLICABLE TO

GASOLINE OR DIESEL – FUELED TRUCKS WITH A GVWR OF GREATER THAN 4536 kg (10,000 lb)

SEE STATEMENTS REGARDING CMVSS AND FMVSS ON PAGES THAT FOLLOW

CMVSS	FMVSS	TITLE		MODEL
No.	No.		NPR		NQR
			NPR-HD NPR-XD		NRR
1106	–	Exterior noise	1		1
101	101	Controls and displays with a GVWR of more than 4536 kg (10,000 lb)	1		1
102	102	Transmission shift lever sequence, starter interlock and transmission braking effect	1		1
103	103	Windshield defrosting and defogging systems	1		1
104	104	Windshield wiping and washing systems	1		1
105	105	Hydraulic brake systems	2		2
106	106	Brake hoses	1		1
108	108	Lamps, reflective devices and associated equipment	2		2
111	111	Rearview mirrors	1		1
113	113	Hood latch system	1		1
115	–	Vehicle Identification Number	1		1
116	116	Motor-vehicle brake fluids	1		1
120	120	Tire selection and rims	2		2
121	121	Air brake systems	3		3
124	124	Accelerator control systems	1		1
205	205	Glazing materials	1		1
206	206	Door locks and door retention components	1		1
207	207	Seating systems	1		1
208	208	Occupant Crash Protection	1		1
209	209	Seat belt assemblies	1		1
210	210	Seat belt assembly anchorages	1		1
213.4	213	Child restraint systems	3		3
302	302	Flammability of interior materials	1		1

CANDA	US	TITLE		MODEL
			NPR		NQR
			NPR-HD NPR-XD		NRR
o	–	On-Road Vehicle and Engine Emission Regulations	1, 3		1
o	–	ICES-002 Canada interference causing equipment standard	1		1

• TYPE 1, 2 or 3 numbers to the right hand side of the table above designate the appropriate paragraph in the CMVSS or FMVSS standards that follow.

2016 Isuzu Truck

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1.3

Statements Regarding Canada Motor Vehicle Safety Standards (CMVSS),

Federal Motor Vehicle Safety Standards (FMVSS),

Canadian On-Road Vehicle and Engine Emission Regulations,

and Canada Interference Causing Equipment Standard.

CMVSS 1106 – EXTERIOR NOISE

Applies to all models of incomplete vehicles contained in this book

TYPE 1 The following statement is applicable to all models of incomplete vehicles (unless otherwise noted on the cover of this document).

A.This incomplete vehicle, when completed, will conform to the above standards providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:

Exhaust System

Tires (including correct tire pressure) Engine assembly

Transmission assembly

Diesel Particulate Filter (DPF), Diesel Exhaust Fluid (DEF) Tank, Selective Catalitic Reduction (SCR) System and its locations

Powertrain cooling fan Intake system

Axle

Catalytic converter and its location (if equipped)

B. Final compliance with CMVSS 1106 is the responsibility of the final stage manufacturer for any modifications, or added material, components, or systems.

2016 Isuzu Truck

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1.4

CMVSS 101 and FMVSS 101 – CONTROLS AND DISPLAYS

Applies to all models of incomplete vehicles contained in this book with a 4536 kg (10,000 lb) GVWR or more

TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book with a GVWR of more than 4536 kg (10,000 lb) (unless otherwise noted on the cover).

This incomplete vehicle, when completed, will conform to CMVSS 101 and FMVSS 101 providing no alterations are made which affect this location, identification, or illumination of the controls and displays identified below or the location, travel and type of seat. If the seat is installed by the final stage manufacturer, the visibility and operation of the controls and displays listed below must meet the requirements of the standard:

Vehicle and system controls and displays including:
Accelerator	Horn control
Brake failure warning	Ignition switch (engine start & stop control)
* Brake failure displays	Illumination intensity control
Clutch	Low fuel indicator
Driver’s sunvisor	Manual/automatic transmission shift lever
Electrical charge indicator	* Odometer
Engine coolant temperature display	Engine oil pressure display
Engine idle speed control	Service brake
Fuel level display	* Speedometer
Hazard warning control & indicator	Steering wheel
Master lighting switch (includes clearance lamp, identification lamp, and tail lamp control)	Turn signal, control & indicator
Heating & air conditioning system control	Windshield defrosting & defogging controls
Heating system & air conditioning system fan	Windshield washer control
Gear position display	Windshield wiper control
High beam indicator & control	Anti-lock brake failure warning display

If the intermediate or final stage manufacturer installs any of the above controls and displays, those controls and displays will also have to meet the requirements of this standard. * For CMVSS only, when Canadian option is specified.

2016 Isuzu Truck

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1.5

ON-ROAD VEHICLE AND ENGINE EMISSION REGULATIONS

Applies to all models of incomplete vehicles contained in this book

TYPE 1 The following statement is applicable to all models of incomplete vehicles equipped with diesel engines and contained in this book (unless otherwise noted on the cover).

This incomplete vehicle, when completed, will conform to the above standard providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:

Air Inlet System	Exhaust Gas Temperature Sensor
Boost Pressure Sensor	Exhaust Oxygen Sensors (if equipped)
Catalytic Converter, its Location and Related Sensors	Exhaust System
Charge Air Cooler and Related System	Fuel Injection Components / Controls
Crank Case Emission Control System	Fuel System
Diesel Exhaust Fluid (DEF) Injector	Injection Pump
Diesel Exhaust Fluid (DEF) Plumbing and Wiring	Injector and High Pressure Lines
Diesel Exhaust Fluid (DEF) Pump, Diesel Exhaust Fluid (DEF) Tank	Intake Manifold
Diesel Particulate Filter (DPF), its Location and Related Sensors	Intake Manifold Temperature Sensor
Engine Assembly	MAF Sensor
Engine Coolant Temperature Sensor	NOX Sensors
Engine Electronics (ECM, PCM, VCM)	Selective Catalytic Reduction (SCR) System, its Locations and Related Sensors
Engine Speed Sensor	Transmission Control Module (TCM)
Exhaust Emission Control System	Turbo Charger and Associated Equipment/ Controls
Exhaust Gas Recirculation System and Related	VNT Compressor Out Air Temperature Sensor
Sensors

TYPE 2 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).

This incomplete vehicle, when completed with the vertical exhaust system, will conform to the above standard providing it is completed by the final stage manufacturer in accordance with the following specific conditions:

a.the incomplete vehicle manufacturer‘s vertical exhaust system kit is used, and

b.the vertical exhaust system kit is installed to the vehicle in accordance with the incomplete vehicle manufacturer‘s instructions For more information on the kit and instructions, please call the telephone number shown on page 1.

TYPE 3 The following statement is applicable to all models of incomplete vehicles equipped with gasoline engines and contained in this book (unless otherwise noted on the cover).

Conformity with On-Road Vehicle and Engine Emission Regulations cannot be determined based upon the components supplied on the incomplete vehicle, and ISUZU Motors makes no representation to conformity with the standard.

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1.6

INTERFERENCE CAUSING EQUIPMENT STANDARD – ICES-002

Applies to all models of incomplete vehicles except vehicles equipped with diesel engines contained in this book

TYPE 1 The following statement is applicable to all models of incomplete vehicles except vehicles equipped with diesel engines (unless otherwise noted on the cover of this document).

This incomplete vehicle, when completed, will conform to the above regulations providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:

Ignition wires & plugs	Spark plug wires
Ignition coil(s)

PART 2

U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION REQUIREMENTS AND ON-BOARD DIAGNOSTIC SYSTEM (OBDII/HD-OBD/EMD) REQUIREMENTS

To assure that EPA and California emission certificate requirements and OBDII/HD-OBD/EMD requirements are met, this incomplete vehicle (except where noted) must be completed in strict accordance with all instructions contained in this document, especially the following instructions which relate to:

A.Exhaust emission related components

B.Specification for fill pipes and openings of motor vehicle fuel tanks (applicable only to California gasoline powered vehicles)

C.Labels

(A) EXHAUST EMISSION RELATED COMPONENTS

1. Compliance of this vehicle with EPA/California emission certification requirements and OBDII/HD-OBD/EMD requirements will be maintained providing no alterations (except where noted) are made to the components identified below:

Air Inlet System	Exhaust Gas Temperature Sensor
Boost Pressure Sensor	Exhaust Oxygen Sensors (if equipped)
Catalytic Converter, its Location and Related Sensors	Exhaust System
Charge Air Cooler and Related System	Fuel Injection Components/Controls
Crank Case Emission Control System	Fuel System
Diesel Exhaust Fluid (DEF) Injector	Ignition System (Gasoline Engine)
Diesel Exhaust Fluid (DEF) Plumbing and Wiring	Injection Pump
Diesel Exhaust Fluid (DEF) Pump, Diesel Exhaust Fluid (DEF) Tank	Injector and High Pressure Lines
Diesel Particulate Filter (DPF), its Location and Related Sensors	Intake Manifold
Engine Assembly	Intake Manifold Temperature Sensor
Engine Coolant Temperature Sensor	MAF Sensor
Engine Electronics (ECM, PCM, VCM)	NOX Sensors
Engine Speed Sensor	Selective Catalytic Reduction (SCR) System, its Locations and Related Sensors
Exhaust Emission Control System	Transmission Control Module (TCM
Exhaust Gas Recirculation System and Related Sensors	Turbo Charger and Associated Equipment/Controls
VNT Compressor Out Air Temperature Sensor	* Evaporative Emission Control System (if equipped)

* All Federal/California gasoline powered heavy duty vehicles will have an evaporative emission control system that is certified for a fuel tank capacity not to exceed the amount shown on Vehicle Evaporative Emission Control Information Label. Persons wishing to add fuel tank capacity above the amount shown must contact California Air Resources Board and/or submit a written statement to the EPA Administrator that the Hydrocarbon Storage System has been upgraded according to the requirements of 40 CFR 86-095-35 (g) (2).

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1.7

2.Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to the fuel filler neck(s).

Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to change material or increase the size or length of the following nonmetallic fuel and evaporative emission hoses.

Fuel feed hoses front and rear

Fuel return hoses front and rear

Fuel tank filler hoses to filler neck

Fuel tank vent hoses to filler neck

Fuel vapor lines at canister

Fuel vapor lines from engine to chassis pipes

Fuel vapor lines from fuel tank sender to chassis pipes

(B) SPECIFICATION FOR FILL PIPES AND OPENINGS OF MOTOR VEHICLE FUEL TANKS (APPLICABLE ONLY TO CALIFORNIA GASOLINE POWERED VEHICLES)

This incomplete vehicle, when completed, will conform to Title 13, California Administrative Code Chapter 3 Air Resources Board Subchapter 7, “Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks”, if no alterations are made to the fuel filler neck(s).

(C) LABELS

The emission control related information labels and ultra low sulfur diesel fuel label that are permanently affixed are required by government regulation and must not be obstructed from view or defaced so as to impair its visibility or legibility.

2016 Isuzu Truck

CAUTIONARY NOTES:

Electrical Sensitivity and Battery Relocation Warning

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1.8

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.

All Fluids and Lubricants Caution

Any fluids or lubricants added to the chassis during the final manufacturing process must meet Isuzu’s fluids and lubricants specifications. These fluids and lubricant specifications vary based on model year and chassis model code. A recommended fluids list based on model and model year can be found in the Vehicle Owner’s Manual or on line at www.isuzutruckservice.com

Low Speed Applications for N-Series Chassis

Any low speed vehicle applications using the Aisin Transmission such as sweeper, highway striping and road side mowing airport service must adhere to the following guidelines in order to prevent the over heating of the automatic transmission fluid.

Factory Recommendation:

Select Range 1 for low speed operations under 11 mph, (18km/h). Select Range 2 for low speed operation under 22 mph, (36km/h).

Auxiliary Transmission Cooler Warning

Installation of Auxiliary automatic transmission fluid cooler will void warranty on transmission/engine.

Transmission Temperature Warning Lamp

Automatic transmission fluid temperature warning lamp illuminates over 140 Centigrade/284°Fahrenheit.

Tapping into Engine Cooling System

Do not connect any auxiliary heating devices to the chassis cooling system. The chassis cooling system is part of the vehicle emission system and is used to thaw DEF fluid and meet mandatory emission thaw times.

Brake Override Logic

The ECM logic in the2013 NPR and 2014 NPR-HD, NQR, NRR model year chassis has been revised to adopted Brake Override Logic that will reduce engine RPM to idle RPM when the brake and accelerator pedals are applied simultaneously. This ECM logic has been adopted to enhance the safe operation of the vehicle. The brake override logic disables the accelerator pedal input and protects against vehicle malfunction in cases where the accelerator pedal and brake pedal are operated simultaneously, or if unintended driver acceleration pedal operations are detected.

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1.9

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.

NOTE: Do not diagnose starters, alternators, ECMs or other no-start conditions prior to ensuring the battery is fully charged and none of the above common causes exist

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.

2016 Isuzu Truck

20154--20162015 - ISUZU

MEDIUM DUTY

V.I.N IDENTIFICATION

JALE5B120F7900750

CODE	DESCRIPTION
JAL	ISUZU INCOMPLETE, JAPAN BUILT
54D	SPARTAN MOTORS INC. USA

	GVWR	BRAKE
CODE	RANGE	SYSTEM
B	10001-14000	HYDRAULIC
C	14001-16000	HYDRAULIC
E	16001-19500	HYDRAULIC

CODE	MAKE DESCTIPTION
4	ISUZU NPR / NPR-HD / NPR-XD
5	ISUZUNQR/NRR

CODE

CAB TYPE

W71 BBC STEEL TILT CAB

J110 BBC STEEL NON-TILT CAB

TFORWARD CONTROL CHASSIS ONLY

Sample VINs:
Sample VINs:
2014 Reach: JALB4T170F7W09999
2014 Reach:	JALB4T170D7W09999

2015 NQR Crew Cab JALE5J1699G7909999

2015 NQR Crew Cab: JALE5J160E7909999

2015NPR-HD- Gas Standard Cab: 54DC4W1BGS80999954DC4W1B0ES80 999

Plant Sequential Number

CODE

DESCRIPTION

W Stripped Chassis (DSL)

(12,000 GVW)

PLANT SEQUENTIAL NUMBER

M Stripped Chassis (DSL) (13,000 GVW)

K NPR-XD (DSL)

CODE

DESCRIPTION

WStrippedChassis (DSL) (12,000 GVW)

0 NPR-HD (DSL)

MStrippedChassis (DSL) (13,000 GVW)

3KNRRNPR-XD(DSL)

(DSL)

(12,000 GVW)

4 NPR (DSL)

0 -HD

(DSL)

(13,000 GVW)

F NPR (DSL)

3 NRR

(DSL)

8 NPR NPR-HD (GAS)

4

(D L)

8 NPR NPR-HD

(GAS)

99NQRNQR (DSL)

(DSL)

PLANT CODE

7 - FUJISAWA

S - CHARLOTTE, MICHIGAN

Model

MODEL YEAR

C FOR 2012

D For 2013

EDForFOR20142013

F

2015

EForOR 2014

G For 2016

F FOR 2015

CHECK DIGIT

CODE

ENGINE DESCRIPTION

6

5.2L Diesel

7

3.0L Diesel

B

6.0L GAS L96

C

6.0L GAS LC8 (convertable to CNG/LPG)

CODE

AXLE DESCRIPTION

1

4X2, 2AXLE, 1 DRIVING

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1.10

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2.1

INSTALLATION OF BODY AND SPECIAL EQUIPMENT

Clearances

Engine

At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler.

Front and Back Clearance

1 inch

Figure 2.1.1

Transmission

The transmission is removed from the rear. Enough clearance must be provided to allow rearward movement of the transmission assembly. Clearance should be sufficient to allow 5 to 6 inches of unrestricted movement of the transmission assembly. In addition, provide at least 2 inches of clearance around the control lever on the side of the transmission to allow free movement without any binding.

Front and Back Clearance

1 inch

Figure 2.1.2

2016 Isuzu Truck

At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal.

Figure 2.2.1

Front and Center Propeller Shafts

At least 1.25 inches of clearance should be maintained around front and center propeller shafts.

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2.2

Figure 2.2.2

2016 Isuzu Truck

Rear Propeller Shaft

With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft.

RearPropeller Shaft

Figure 2.3.1

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2.3

2016 Isuzu Truck

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2.4

Exhaust System

The exhaust system has a crucial role in meeting 2010 EPA regulations. In order to maintain compliance with the 2010 EPA emissions levels the Diesel Particulate Filter (DPF) and SCR package must not be moved. The distance between the engine exhaust manifold down pipe and Diesel Particulate Filter (DPF) / Selective Catalytic Reduction Package (SCR) must be maintained and the pressure in the system must be sustained at a constant level. Due to increased temperatures

in the exhaust system during the regeneration cycle and the heat stress caused by these temperatures, body builders should closely evaluate the placement of equipment and provide protection to these added components as needed.

Diesel Particulate Filter and Selective Catalytic Reduction (SCR) Restrictions

The DPF/SCR has exhaust pressure pipes and temperature sensors. Care must be taken when a body is installed so as to not damage pipe sensors.

The DPF/SCR should be free from impact or vibration during body installation. The DPF/SCR must have enough room for disassembly of the unit for service and cleaning.

The DPF/SCR switch in the cab should not be removed or disabled. No modification or relocation of the DPF/SCR unit, pressure pipes, and sensor is permitted.

No Modification Zones

The DPF/SCR unit CAN NOT be modified or moved .

The DEF tank and pump CANNOT be modified or removed. DEF lines and coolant lines CANNOT be modified or rerouted.

Figure 2.4.1

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2.5

EXHAUST CLEARANCES

If flammable materials such as wood are used in the body, provide at least 3.9 inches of clearance between the body and any parts of the exhaust pipe, DPF/SCR Package. If it is impossible to maintain the minimum clearance, use a heat shield. Also use a heat shield if an oil pump or line is located above the exhaust pipe, muffler or catalytic converter.

Figure 2.5.1

1)Clearances around SCR system components must be greater than 1.0 inch at all times to avoid potential contact between the body and the exhaust components. The 1.0 inch allows for thermal expansion and assembly tolerance of the exhaust system. It does not account for dynamic movement in the body due to road conditions and other loads. Body companies are instructed to adjust this 1.0 inch clearance as required to account for body displacement while driving. This guidance does not supercede guidance or exhaust clearances for temperature sensitive or flameable components.

2)Exhaust temperatures have not changed since the introduction of DPF in 2007.

2016 Isuzu Truck

Exhaust system surface temperatures During Manual Regeneration

N-Series Modification Guideline (heat issue)

(EXHAUST PIPE HEAT)

4 inches from vehicle end or side

More than		More than		Less than
8 inches		18 inches		45 deg

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2.6

Figure 2.6.1

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2.7

Rear Wheel Axle

The design and installation of the body should allow sufficient clearance for full vertical movement of the rear wheels and axle when the vehicle travels over rough or unlevel surfaces.

See Note

Figure 2.7.1

Note: For recommended clearances, please refer to the Rear Axle Chart in each model’s respective section.

Other Clearances

The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum clearance should be provided. When cable is detached from body mounting, be sure not to bend the cable.

Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not hampered.

Parts	Minimum Clearance	Location
Brake Hose	6.7 in.	Axle Side
	1.6 in.	Frame Side
Parking Brake Cable	1.2 in.	—
Fuel Hose	1.6 in.	—
Shock Absorber	2.4 in.	Axle Side
	1.2 in.	Frame Side

Figure 2.7.2

2016 Isuzu Truck

Body Installation

PAGE

2.8

Figure 2.8.1

2016 Isuzu Truck

Body Installation

PAGE

2.9

Figure 2.9.1

2016 Isuzu Truck

PAGE

2.10

Mirrors

The Isuzu NPR series chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets.

The Isuzu NPR-HD, NPR-XD, NQR ,and NRR chassis will accommodate up to 96 inch wide bodies without modification to the mirror brackets. Bodies from 97 to 102 inches wide will require that the mirror brackets be modified. This Modification can be made at the port and the vehicle order/label will indicate a Regular Product Option of IU2 indicating “Mirror Bracket for 102 wide body”. The brackets can also be modified by the N-Series Dealer or the Body Company by installing mirror brackets ordered from Isuzu Parts.

Side Step Door Installation recommendations

Floor of body should be at least 10” above frame rail (2.5” wood + 4” long sill + 3” cross sill + 1.125” floor)

Forward end plate of step well area can interfere with SCR system

All body components should maintain a minimum 1.0” of clearance to exhaust components UNDER ALL (DYNAMIC) CONDITIONS. (Body company will need to add to this 1.0” clearance to account for flex or movement in the body)

Outer heat shield on SCR system can be removed prior to mounting body if required for clearance

Care should be taken to adequately shield exhaust

Driver’s side steps can also be accommodated, if door is located behind DEF tank

Battery may have to be relocated, depending on door location

Access hatch for DEF tank fill may have to be added, depending on door location

DPF/SCR Heat shield Removal

The exhaust external heat shield does not impact vehicle emissions or emissions system durability. This shield can be removed or modified in order to facilitate body or equipment mounting, but the completed vehicle manufacturer should ensure that, when completed, the exhaust will be adequately shielded to prevent unintentional contact with hot exhaust components, and that heat transfer to body components is not so high as to present safety or durability risks. Detailed information on removal of the heat shield can be found in the Isuzu service manual available on line at www. isuzutruckservice,com.

2016 Isuzu Truck

Heat Shield

19.6”

PAGE

2.11

DPF/SCR Heat Shield Removal

this bracket can be Cut Off

2016 Isuzu Truck

PAGE

2.12

NPR ECOMAX

Special Equipment on the Chassis

When installing special equipment on the chassis, extra consideration must be given to the weight and construction of the equipment to assure proper distribution of the load. Localization of the load should be prevented. All special equipment should be properly secured into position. We recommend the use of sub frame members when installing special equipment.

Sub frame Design and Mounting

The sub frame assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions of the chassis frame as closely as possible

Figure 2.12.1

2016 Isuzu Truck

NPR-HD, NPR-XD, NQR, NRR

Figure 2.13.1

PAGE

2.13

2016 Isuzu Truck

PAGE

2.14

Subframe Contour

Contouring of the front end of the subframe members as shown in the three illustrations below will prevent stresses from being concentrated on certain areas of the chassis frame.

Figure 2.14.1

2016 Isuzu Truck

When using a steel subframe, do not close the end of the subframe.

Figure 2.15.1

Prohibited Attachment Areas

Do not attach the sub frame with a bolt or bracket to the chassis frame at the points indicated in the following illustrations.

1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe.

PAGE

2.15

Figure 2.15.2

2016 Isuzu Truck

PAGE

2.16

2. Front U-bolt and Mounting Bracket, Mounting Locations Ahead of Transmission

Mandatory location due to after treatment device location and interior frame components. The chassis will be supplied with one steel crush block in cab for left hand forward body attaching location as illustrated in the drawings below and one body mounting bracket (painted yellow) attached to the right hand frame rail in the location shown in the drawings below. Body Builder will be required to design a mating bracket for attaching the body to the yellow painted chassis body mounting bracket (Ref page 2.16 for illustration of bolt clamping 2 brackets ). No U bolt type attaching allowed.

	NPR ECO MAX	NPR-HD, NPR-XD, NQR ,and NRR
Forward		Forward

	Ref 4J Body mount kit 2901400230						Ref. 4H Body mount Kit PN 2901400270
Crush Block and U-Bolt			Body Mounting Bracket			Crush Block and U-Bolt			Body Mounting Bracket
(Left Hand -Rail)				(Right Hand -Rail)		(Left Hand -Rail)				(Right Hand -Rail)
			Figure 2.16.1						Figure 2.16.2