BULLETIN NUMBER:
SB19-L-002

IMPORTANT SERVICE
INFORMATION FOR:

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SERVICE MANAGER

ISSUE DATE:
JULY 2019

SERVICE ADVISOR
TECHNICIAN

GROUP:
FUEL AND EXHAUST

PARTS DEPARTMENT
WARRANTY PERSONNEL

HEATED FUEL SEDIMENTER ASSEMBLY INSTALLATION
AFFECTED VEHICLES


2011 MY – 2017 MY Isuzu N-Series
Equipped with 5.2L 4HK1 Engines
INFORMATION

Isuzu Commercial Truck of America is pleased to announce the availability of a front
frame mounted heated fuel sedimenter kit for 2011 MY – 2017 MY N-Series trucks
equipped with a 5.2L 4HK1 diesel engine. Installing these kits can help minimize the
chances of fuel filters becoming clogged due to gelling in cold weather conditions. The
kit part number, ordering information, and installation instructions are in this bulletin.
These kits are not designed for use on 2018 model year and newer Isuzu trucks.
NOTE: Be sure to perform regular fuel filter maintenance per the Owner’s Manual.
MAINTENANCE INTERVAL
Description

Fuel Filter Maintenance Interval

Description

Miles (Km)

Time

Main Fuel Filter

15,000 (24,000)

Or every 12 months

Secondary Fuel Filter

15,000 (24,000)

Or every 12 months

PARTS INFORMATION
The following fuel sedimenter kits are available from AIPDN.
Model Year

Part Number

Description

Quantity

16MY – 17MY

2-90KIT-001-0

16/17MY HEATED FUEL SEDIMENTER KIT

1

11MY – 15MY

2-90KIT-002-0

14/15MY HEATED FUEL SEDIMENTER KIT

1

11MY – 13MY

2-90KIT-003-0

CLEAR BOWL TO SEDIMENTER TO
METAL KIT

*

*For 11 MY – 13 MY, This kit will be required to complete installation only if bulletin
SB14-L-001 has not been completed. If the fuel sedimenter has a clear bowl then,
bulletin SB14-L-001 has not been performed.
SERVICE PROCEDURE
Installation
1. Place the vehicle in park, apply the parking brake, and remove the key from the
Engine Control Switch.
2. Disconnect the negative battery cable.
3. Lay extension harness on the floor, under the driver’s side frame as shown in
Figure 1.
4. Route the white/blue wire and relay wires from the extension harness along the
front chassis harness. Direct the white/blue wire up to the H-52 connector and the
relay wires over to the relay box. (See Figure 2.)

Figure 1 – Extension harness under driver’s
side frame.

Figure 2 – Routing for White/Blue
wire to H-52 connector and relay
box.

5. Remove the three (3) 12mm fuse box mounting bolts shown in Figure 3 and set
these aside for later use.
6. Disassemble the fuse box by using a flat blade screwdriver to release the locking
tabs holding the lower cover to the bottom of the fuse block. Set lower cover to the
side for later use.

2

7. Continue removing the inner cover by removing PVC tape, pulling the grommet off
the end of the fuse box halves (see Figure 4) and using the same process to
release the locking tabs as in Step 6. Move cover to the side as shown in Figure
5.

Figure 3 - Mounting bolts

Figure 4

Figure 5 - Back of disassembled fuse box
8. Feed the female spade terminals from the extension harness through rubber
grommet and into fuse box. (See Figure 6.) On Model Years 2011 to 2015 route
the extension harness’s eight wires to the Engine Run Relay and Fuel Heater
Relay locations as shown in Figures 6 and 7. Model years 2016 and 2017 have
only four extension harness wires that route to the Fuel Heater Relay location as
shown in Figure 8 and 9. Ensure that the proper size terminals are installed into
the proper locations to ensure the correct fit and to avoid terminal and connector
damage.
CAUTION: Insertion of female spade terminals into the wrong locations may cause
damage to connector, terminals, and electrical system.

3

Grommet

RELAY; FUEL HEATER

RELAY; ENG RUN

Figure 6 2011 – 2015 MY harness shown.

B

RELAY; FUEL HEATER

L/W

B/R

R
NC

R/B

L/W

W/L

NC
R/B

This terminal has two Red/Black wires.

RELAY; ENG RUN

Figure 7 - Top view: Model Years 2011 to 2015
Wire Colors: W - White R - Red B – Black L - Blue

4

RELAY; FUEL HEATER

B

NC

W/L

B/R
R

Figure 8 - Top view: Model Years 2016 and 2017
Wire Colors: W - White R - Red B – Black L - Blue

RELAY; FUEL HEATER

R
B/R
B

NC

W/L

Figure 9 - Bottom view: Model Years 2016 and 2017
9. Use the mastic tape (provided with the Kit) to secure the added wiring as shown in
Figure 10.

5

Figure 10 – Red arrow shows tape holding
extension harness wires.
10. Install inner cover onto fuse box, secure the rubber grommet over the lower cover
and fuse box. Use electrical tape to insulate the added extension harness wiring.
(See Figure 11.)

Figure 11 – Tape on extension harness behind
grommet
11. Install lower cover.
12. Re-install the fuse box using the three (3) fuse box mounting bolts set aside earlier
and torque to 15 N•m (11lb•ft). Apply tie strap to secure to the fuse box to the front
frame harness. (See Figure 12.)
13. On Model Years 2011 to 2015 install the Engine Run Relay and the Fuel Heater
Relay in the locations specified as shown in Figure 13. On Model Years 2016 and
2017, install the Fuel Heater Relay as shown in Figure 14.
14. Install the fuse box cover by snapping the locking tabs into place.

6

RELAY; FUEL HEATER

RELAY; ENG RUN

Figure 13 – Model Years 2011 to 2015

Figure 12 - Tie strap location

RELAY; FUEL HEATER

Figure 14 – Model Years 2016 and 2017
15. Locate black H-52 connector as shown in Figure 15.

7

Front of Vehicle

Figure 15 – Red circle shows H-52 connector
16. Disconnect the H-52 connector. On the front frame side of the harness, remove 60
mm of electrical tape from the back of the connector. Pull back the protective cover
exposing the white/blue wire going to pin 16.
17. Using wire strippers, remove 15mm of insulation from the white/blue wire in the
front frame harness starting 30mm from the back of the H-52 connector, as shown
in Figure 16.

Figure 16
IMPORTANT: Be careful not cut the white/blue wire in half while removing the
insulation.
8

18. Use wire strippers to remove 15mm of insulation from the end of the white/blue
wire on the extension harness and attach to white/blue wire from the front frame
harness in Step 17, as shown in Figure 17.
19. Use a soldering iron and solder the two wires together as shown in Figure 18.

Figure 17

Figure 18

20. Use the supplied mastic tape to wrap and insulate the exposed wiring as shown in
Figure 19 and then cover with vinyl electrical tape.
21. Re-secure the wiring into the wire loom protective cover. (See Figure 20.)
 Use electrical tape to wrap harness at the ends of the wiring loom protective
cover rests on the electrical harness.
 Secure the wires into the loom ensuring that all exposed wiring is covered.
 Wrap the wiring loom protective cover with vinyl electrical tape.
 Apply tie straps to secure to front frame harness as shown in Figure 21.

9

Figure 19

Figure 20

Figure 21 - Tie strap
locations

22. Route extension harness behind sedimenter bracket and apply a clip to secure
harness to the bottom of frame. (Route the harness so that it starts underneath the
frame then faces to the inner side of the frame as shown in Figure 22.)

Figure 22
23. Attach the extension harness to the front frame harness using tie straps as shown
in Figure 23.
TIE STRAPS

CLIP ALREADY
ON WIRE HARNESS

Figure 23 - Tie strap locations
24. Route the heated fuel sedimenter 2 pin black connector from extension harness
towards fuel sedimenter and attach to sedimenter bracket using the connector

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supplied on the harness. Apply tie straps to hold extension harness to fuel
sedimenter bracket. (See Figure 24.)

TIE STRAPs

CLIP ALREADY
ON WIRE HARNESS

Figure 24
25. Route extension harness along front frame harness. A blue line in Figure 25
represents the extension harness. Install tie straps loosely every 9 ½” (250 mm) to
hold the extension harness in place.

Figure 25 – 2016 & 2017 MY vehicles do not have the Red/Black wire to the H-101
connector.