Description
Factory Isuzu I-Series Workshop Manual (2002–2008)
This official factory-sourced workshop manual covers every service and repair procedure for the first-generation Isuzu I-Series pickup truck sold in the US market from 2002 through 2008, including the i-280 and i-350 cab configurations in both 2WD and 4WD.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 2.8L Vortec 2800 I4 (C24SE), 3.5L Vortec 3500 I5 (HFV6) |
| Diesel | 2.5L 4JA1-T, 2.5L 4JJ1-TC, 2.5L 4JK1-TC, 3.0L 4JH1-TC |
| Transmissions | 4-speed automatic, 5-speed manual |
| Drive | 2WD and 4WD |
| Model Years | 2002–2008 |
| Badge Twins | Chevrolet Colorado (first gen), GMC Canyon (first gen) |
Common I-Series Repairs Covered
| System | Procedures |
|---|---|
| Engine — Vortec I5 Timing Chain | Timing chain tensioner inspection, replacement, and stretch diagnosis for 3.5L HFV6 engines known to rattle on cold start |
| Fuel System | Fuel injector cleaning and replacement, fuel pressure regulator testing, throttle body service |
| Suspension — Front End Wear | Upper and lower control arm bushing replacement, ball joint inspection and R&R, alignment specification reset |
| Electrical — ABS/Brake System | ABS wheel speed sensor diagnosis and replacement, brake master cylinder overhaul, rear drum brake adjustment |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why does my 3.5L I-Series rattle on cold startup?
The 3.5L Vortec 3500 I5 (HFV6) is known for timing chain tensioner wear that produces a cold-start rattle. This manual includes full timing chain and tensioner inspection, torque specifications, and step-by-step replacement procedures to resolve this issue correctly.
Is the I-Series the same truck as the Chevy Colorado and GMC Canyon?
Yes. The first-generation Isuzu I-Series shares its GMT355 platform with the Chevrolet Colorado and GMC Canyon. The i-280 uses the 2.8L inline-four and the i-350 uses the 3.5L inline-five. Much of the mechanical content in this manual applies across all three badge variants from this generation.
Does the manual cover 4WD transfer case service?
Yes. Four-wheel drive system coverage includes the front axle, transfer case, front differential, propeller shafts, and all associated actuators and wiring. Both 2WD and 4WD drivetrains are fully documented with torque values and rebuild procedures.
What format is the manual?
This manual is a PDF file delivered via instant download after purchase. It is fully searchable, can be viewed on Windows, Mac, Linux, iOS, and Android devices, and individual pages or sections can be printed as needed for shop use.
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