Isuzu I-350 Pickup Truck Complete Workshop Service Repair Manual 2005
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🏷️ Basic Information Identification Make: Isuzu Model: I-350 Pickup Truck Year: 2005 Generation Generation Designation: First Generation (GMT355 platform, shared with Chevrolet Colorado and GMC Canyon) Codes Platform Code: GMT355 👋 Introduction Market Position Segment: Compact/Mid-size Pickup Truck Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops, enthusiasts. Competitive Analysis Competitors 2005: Ford Ranger, Toyota Tacoma, Nissan Frontier, Chevrolet Colorado, GMC Canyon, Mazda B-Series. Key Features Value Proposition: Enables significant cost savings on maintenance and repairs by empowering owners with factory-level repair information and procedures. Instruction Style: Easy-to-follow, step-by-step instructions with accompanying diagrams and illustrations. Accessibility Device Compatibility: Compatible with all PCs and Macs, tablets, and smartphones. 📋 Manual Details Coverage Areas Geographical Coverage: North America (primarily, as it's a rebadged GM truck) Model Variants Covered: All I-350 Pickup Truck models, engines, trim levels, and transmission types for 2005 Page Count Estimated Page Count: Difficult to determine exact count without the manual; however, typical comprehensive workshop manuals of this era exceed 1000 pages. Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, engine management, cooling system, lubrication system, transmission (automatic and manual), drivetrain (front/rear axles, driveshafts, differentials). Chassis: Suspension (front and rear), steering system, braking system (ABS, components), wheels and tires, frame and body structure. Electrical: Battery, charging system, starting system, lighting system, instrument cluster, HVAC controls, power windows/locks, audio system, wiring diagrams for all vehicle systems, onboard diagnostics (OBD-II). Body And Interior: Body panels, doors, hood, tailgate, bumpers, interior trim, seats, airbags, climate control system. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication, inspections. Diagnostics And Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation, troubleshooting flowcharts. Repair And Rebuild: Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Specifications And Tolerances: Torque specifications, clearances, fluid capacities, resistance values, diagnostic parameters, and critical component tolerances. Electrical Diagnostics: Includes detailed wiring diagrams, component testing procedures, and troubleshooting guides for all electrical systems. Wheel Alignment: Specifications and procedures for front and rear wheel alignment. Body Repair: Information on body panel removal/installation, frame straightening (if applicable), and collision repair guidelines. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks and filter changes to complex engine and transmission rebuilds, electrical system diagnostics, and structural repairs. Engine Rebuild: Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), machining specifications, and reassembly. Transmission Rebuild: Comprehensive steps for overhauling both automatic and manual transmissions, including torque converter, clutch pack, gearset, and valve body repair. 📊 Manual Specifications File Format Format: PDF Readability Software: Adobe Acrobat Reader (or compatible PDF viewer) Print Quality Printability: Printable (user can print entire manual, specific chapters, or individual pages) Binding Type Binding Type Digital: N/A (Digital download) Paper Type Paper Type Digital: N/A (Digital download) Searchability Text Search: Searchable text content (if generated from OCR or native PDF text) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, DOHC Engine Code: 2.8L Vortec 2800 (GM L61) Displacement: 2770 cc (169 cubic inches) Bore X Stroke: 3.62 in x 3.19 in (92 mm x 81 mm) Performance Horsepower Rated: 175 hp @ 5600 rpm Torque Rated: 185 lb-ft @ 4400 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Engine Management Ignition System: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or similar electronic ignition. Emissions Control: Catalytic converter, oxygen sensors, EGR system (if applicable). 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission Features Drivetrain Options: Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) configurations available. Fluid Specifications Automatic Transmission Fluid: Dexron III/VI (check manual for precise specification) Manual Transmission Fluid: API GL-4 SAE 75W-90 Gear Oil (check manual for precise specification) 📐 Dimensions Exterior Wheelbase: Varies by configuration (e.g., 111.9 inches for standard cab, 125.9 inches for crew cab). Overall Length: Varies by configuration (e.g., approx. 192 inches for standard bed). Exterior Width: Approx. 70.7 inches (excluding mirrors). Exterior Height: Approx. 68.5 inches (varies with trim/4WD). Cargo Bed Length Options: Short Bed (approx. 61 inches), Long Bed (approx. 73 inches) - specific to cab/configuration. Weights Curb Weight: Varies significantly by configuration, typically starting around 3,700 - 4,000 lbs for 2WD models. 🛡️ Safety Features Ratings NHTSA Frontal Crash Test: Typically achieved 4-star ratings for driver and passenger in frontal impact (based on GM platform data for this era). IIHS Ratings: Good in frontal offset tests (based on GM platform data for this era). Active Features ABS: Standard Anti-lock Braking System (ABS). Traction Control: May be available as an option on higher trims or 4WD models. Passive Features Airbags: Driver and front passenger airbags. Seatbelts:...
Includes detailed wiring diagrams, component testing procedures, and troubleshooting guides for all electrical systems.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
Body Repair:
Information on body panel removal/installation, frame straightening (if applicable), and collision repair guidelines.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks and filter changes to complex engine and transmission rebuilds, electrical system diagnostics, and structural repairs.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), machining specifications, and reassembly.
Transmission Rebuild:
Comprehensive steps for overhauling both automatic and manual transmissions, including torque converter, clutch pack, gearset, and valve body repair.
📊 Manual Specifications
File Format
Format:
PDF
Readability Software:
Adobe Acrobat Reader (or compatible PDF viewer)
Print Quality
Printability:
Printable (user can print entire manual, specific chapters, or individual pages)
Binding Type
Binding Type Digital:
N/A (Digital download)
Paper Type
Paper Type Digital:
N/A (Digital download)
Searchability
Text Search:
Searchable text content (if generated from OCR or native PDF text)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, DOHC
Engine Code:
2.8L Vortec 2800 (GM L61)
Displacement:
2770 cc (169 cubic inches)
Bore X Stroke:
3.62 in x 3.19 in (92 mm x 81 mm)
Performance
Horsepower Rated:
175 hp @ 5600 rpm
Torque Rated:
185 lb-ft @ 4400 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Engine Management
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or similar electronic ignition.
Emissions Control:
Catalytic converter, oxygen sensors, EGR system (if applicable).
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) configurations available.
Fluid Specifications
Automatic Transmission Fluid:
Dexron III/VI (check manual for precise specification)
Manual Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil (check manual for precise specification)
📐 Dimensions
Exterior
Wheelbase:
Varies by configuration (e.g., 111.9 inches for standard cab, 125.9 inches for crew cab).
Overall Length:
Varies by configuration (e.g., approx. 192 inches for standard bed).
Exterior Width:
Approx. 70.7 inches (excluding mirrors).
Exterior Height:
Approx. 68.5 inches (varies with trim/4WD).
Cargo
Bed Length Options:
Short Bed (approx. 61 inches), Long Bed (approx. 73 inches) - specific to cab/configuration.
Weights
Curb Weight:
Varies significantly by configuration, typically starting around 3,700 - 4,000 lbs for 2WD models.
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
Typically achieved 4-star ratings for driver and passenger in frontal impact (based on GM platform data for this era).
IIHS Ratings:
Good in frontal offset tests (based on GM platform data for this era).
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
May be available as an option on higher trims or 4WD models.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point seat belts for all occupants.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional MP3 capability, and available premium sound system with subwoofer.
Display:
Basic dashboard display for radio, clock, and vehicle status indicators.
Driver Assistance
Cruise Control:
Available on most trim levels.
Connectivity
OBD Ii Port:
Standard OBD-II diagnostic port for emissions and system diagnostics.
Comfort And Convenience
Power Features:
Power windows, power door locks, available power mirrors.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles or 6 months, whichever comes first (synthetic or synthetic blend recommended).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter:
Replace every 15,000 - 30,000 miles, depending on driving conditions.
Coolant Flush:
First change at 5 years/100,000 miles, then every 2-3 years/30,000-50,000 miles thereafter (Dex-Cool or equivalent).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (synthetic blend or full synthetic recommended for most conditions).
Coolant Type:
GM P/N 12346290 (Orange) or Dex-Cool compatible Long Life Antifreeze/Coolant.
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
Suspension components (ball joints, control arm bushings), exhaust system corrosion, brake wear, ignition coils (on some models).
Engine Reliability:
The 2.8L inline-4 is generally considered a robust engine for its class, but proper maintenance is key. Issues can include minor oil leaks or sensor failures.
Transmission Issues:
Automatic transmissions can occasionally exhibit issues related to valve bodies or solenoids if fluid maintenance is neglected.
📚 Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long history of producing reliable commercial and light-duty trucks globally.
Model Evolution
Relationship To Gm:
The Isuzu I-350 was a rebadged version of the Chevrolet Colorado/GMC Canyon, part of GM's global compact truck strategy. Isuzu was a minority partner in GM's truck manufacturing operations.
Introduction Year:
The I-350 was introduced for the 2006 model year in North America, with this manual specifically for the 2005 model as indicated (likely a pre-production or early release designation).
Production
Manufacturing Location:
North America (Shreveport, Louisiana, USA - same plant as Colorado/Canyon).
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
While the I-350 itself may not have specific awards, its GM platform counterparts (Colorado/Canyon) generally received good to excellent safety ratings from IIHS and NHTSA for their class during this period.