🏷️ Basic Information

Make:

Isuzu / Chevrolet / GMC

Model:

W5500 Chassis (Commercial Truck)

Product Type:

Service and Repair Manual

Model Years Covered:

1999, 2000, 2001

Engine Designation:

Diesel (Specific engine code not provided in product info, likely Isuzu 4HE1-TC variant)

👋 Introduction

Vehicle Segment:

Class 3 Commercial Truck (GVWR 14,001 – 16,000 lbs). Designed for commercial applications, including delivery, shuttle services, utility work, and custom upfits.

Competitors:

Competed with models like Ford E-Series, Chevrolet Express/GMC Savana cutaway chassis (though often built on different platforms), and similar chassis offerings from Freightliner and Mitsubishi Fuso during its production run.

Chassis Design:

Robust, ladder-frame chassis designed for durability and to accommodate a wide variety of body styles and payloads. Front engine, rear-wheel drive configuration typical.

Powertrain Options:

Primarily powered by Isuzu's reliable diesel engines, known for their fuel efficiency and torque, making them ideal for commercial use. Transmission options typically included manual and automatic.

Buyer Profile:

Businesses and operators requiring a sturdy, versatile, and cost-effective chassis for specialized vocational applications.

📋 Manual Details

Primary Coverage:

Comprehensive service, repair, maintenance, and troubleshooting for the Isuzu/Chevrolet/GMC W5500 Chassis (Diesel) models from 1999-2001.

Estimated Page Count:

Detailed page count not specified in product information; typically 1000+ pages for comprehensive service manuals of this nature.

Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, rebuilding, cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system.

Engine Fuel System:

Fuel injection system (common rail or unit injector depending on specific engine), fuel pump, injectors, fuel filters, fuel lines, emissions control systems.

Engine Ignition System:

Glow plug system (for diesel cold starting), related sensors and control modules.

Transmission:

Manual and automatic transmission overhaul, repair, diagnostics, clutch system, driveshafts, differentials, axles.

Brakes:

Hydraulic brake system, power assist, ABS (if equipped), parking brake, brake linings, rotors, calipers, bleeding procedures.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, steering linkage, wheel alignment specifications.

Steering:

Power steering system, steering gearbox/rack, steering column, tie rods, alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, instrumentation, wiring diagrams, fuses, relays, body control modules.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant handling, diagnostics, repair.

Body And Frame:

Body panel repair, doors, windows, interior trim, chassis components, structural integrity.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), diagnostic procedures for various systems.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections.

Component Replacement:

Detailed step-by-step instructions for replacing major and minor components across all systems.

Rebuilding Overhaul:

Comprehensive procedures for engine, transmission, and differential rebuilding.

Diagnostics Troubleshooting:

Systematic diagnostic approaches and solutions for common and uncommon problems.

Electrical Troubleshooting:

Use of wiring diagrams, multimeter usage, pinpoint testing for electrical faults.

Specifications Tightening Torques:

Torque specifications for all critical fasteners, engine bearing clearances, ring gaps, etc.

Depth:

Extensive detail suitable for professional technicians and advanced DIY mechanics. Covers disassembly, inspection, repair, reassembly, and adjustment of all major vehicle systems.

📊 Manual Specifications

Format Details:

Digital PDF format, typically searchable text, allowing for easy navigation and keyword searches. High resolution for clear diagrams and text.

Printability:

Designed to be printable, allowing users to create hard copies of specific sections or the entire manual for workshop use.

Binding Type For Printed:

N/A (Digital PDF)

Paper Type For Printed:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Turbocharged Diesel Inline-4

Displacement:

Approximately 4.3 Liters (4300 cc)

Engine Code Example:

Likely Isuzu 4HE1-TC (Common in Isuzu NPR/NQR of similar era)

Horsepower Range:

Estimated 175 - 190 HP (Varies by specific calibration and year)

Torque Range:

Estimated 300 - 350 lb-ft (Varies by specific calibration and year)

Injection Type:

Common Rail Direct Injection (CRDi) or Isuzu's proprietary injection systems.

Emissions Controls:

Includes components like EGR (Exhaust Gas Recirculation), potentially a Diesel Particulate Filter (DPF) on later models or specific configurations, and catalytic converters.

Cooling Type:

Liquid-cooled, pressurized system with engine-driven fan or electric fan.

Oil Capacity:

Typically around 8-10 quarts (7.5-9.5 liters) of diesel-specific engine oil (e.g., API CJ-4 or CK-4).

Oil Filter Part Number Example:

Likely an Isuzu OEM filter or equivalent from brands like Wix or Baldwin (e.g., Wix 57400XP, Isuzu 8-94390-163-0).

🔧 Transmission

Type:

Manual transmission (e.g., Isuzu MYY6S 6-speed) or Allison automatic transmission (e.g., Allison 1000 or 2000 series).

Type:

Depending on specific configuration, may have offered different manual or automatic variants.

Automatic Features:

Torque converter lock-up, electronic control (on later models), PTO (Power Take-Off) provisions on some units.

Manual Fluid Type:

API GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.

Automatic Fluid Type:

Allison TES 295 approved synthetic fluid or equivalent (e.g., Dexron III/VI for some older models, but TES 295 is standard for Allison).

📐 Dimensions

Wheelbase Options:

Variable depending on body upfit; typical chassis wheelbases range from 109 inches to 175 inches or more.

Gvwr:

14,500 lbs to 16,000 lbs (Class 3).

Gcwr:

Significantly higher, depending on drivetrain and trailer rating.

Curb Weight:

Highly variable based on body and equipment; typically 5,000 - 7,000 lbs for the chassis alone.

🛡️ Safety Features

Crash Test Data:

Specific crash test ratings for chassis cabs are not typically published in the same way as light-duty passenger vehicles. Focus is on structural integrity for upfitting and payload.

ABS:

Anti-lock Braking System (ABS) typically standard on the front axle, optional or standard on rear depending on configuration and year.

Seat Belts:

Three-point seat belts for driver and passenger seats.

Airbags:

Driver and passenger airbags typically standard.

💡 Technology Features

Standard Features:

Basic AM/FM radio with CD player or cassette player. Limited in-dash technology compared to modern vehicles. Focus is on functionality.

Features Available:

ABS (Anti-lock Braking System) is the primary electronically controlled driver assistance feature. Other features are minimal by modern standards.

Connectivity Options:

Very limited. May have options for auxiliary inputs for aftermarket audio devices.

🔧 Maintenance

Engine Oil Filter Change:

Typically every 5,000 - 10,000 miles or 6-12 months, depending on operating conditions and oil type used. Consult manual for specific intervals.

Fuel Filter Replacement:

Generally recommended every 15,000 - 30,000 miles, or as per manual recommendations, crucial for diesel longevity.

Transmission Fluid Change:

Automatic transmissions: every 30,000 - 60,000 miles, manual transmissions: every 50,000 - 100,000 miles (check manual).

Coolant Flush:

Every 30,000 - 60,000 miles or 2-4 years using appropriate long-life coolant.

Engine Oil Specification:

API CJ-4 or CK-4 rated diesel engine oil, viscosity typically 15W-40 or 10W-30 (refer to manual for climate-specific recommendations).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Power Steering Fluid:

Typically ATF Dexron III/VI compatible fluid or specific power steering fluid. Refer to manual.

Common Wear Items:

Brake components (pads, rotors), suspension bushings and ball joints, exhaust components, glow plug reliability can be a concern on older diesels.

Diesel Specific Concerns:

Fuel injector reliability, EGR system clogging, turbocharger wear, potential for coolant leaks if not maintained.

Manual Utility:

The manual provides structured troubleshooting trees and diagnostic flowcharts to help identify the root cause of problems efficiently.

📚 Vehicle History

Isuzu Trucks:

Isuzu has a long-standing reputation for building durable and reliable commercial vehicles, particularly in the light and medium-duty segments.

W Series Lineage:

The W-series chassis (like the W4, W5, W6) are part of Isuzu's global commercial vehicle platforms, often rebadged and sold through GM's Chevrolet and GMC divisions in North America.

Manufacturing Location:

Isuzu trucks are primarily manufactured in Japan, with some assembly or final production possibly occurring in other global locations, including North America for the GM rebadged models.

🏆 Awards & Recognition

Industry Awards:

Specific awards for the W5500 chassis are not widely publicized. However, Isuzu as a brand has received numerous accolades for its commercial truck reliability and efficiency over decades.