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2003 Chevrolet Express 3500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 Chevrolet Express 3500 car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Chevrolet Express 3500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
General Service Domestic Vehicles -> 2003-04 -> Oil Charge -> Alero & Malibu -> Bonneville, LeSabre & Park Avenue -> Caravan, Town & Country & Voyager -> Catera -> Cavalier & Sunfire -> Century -> Cherokee, Dakota, Full Size Pickups, Grand Cherokee & Wrangler -> Corvette -> DaimlerChrysler Corp. -> DeVille & Seville -> Eldorado -> Except Lincoln LS -> Except Tracker -> Ford Motor Company -> Full Size & Ram Vans -> General Motors Corp. -> Geo Tracker -> Grand Prix, Impala, Intrigue, Lumina, Monte Carlo & Regal -> L-Series -> Liberty -> Light Trucks & Vans -> Lincoln LS -> Metro -> Passenger Cars -> Prizm -> PT Cruiser -> S-Series -> Saturn -> VUE
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
DaimlerChrysler Corp.
Passenger Cars
Before installing replacement compressor, drain oil from replacement and failed compressors (drain oil from suction port). Add same amount of oil to replacement compressor as drained from failed compressor.
Remove defective components. Add the proper amount of oil to each replacement component. Most recovery/recycling equipment will measure the amount of oil being removed. This is the amount of oil to be added back to the system, follow manufactures instructions provided with the recovery/recycling station.
When other ai...
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BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Drum Brakes -> Brake Service -> Astro, Bravada, S & T Series & Safari -> Aztek, Rendezvous & Vue -> C & K Series -> Duo-Servo -> Express & Savana -> Installation -> Montana, Silhouette, Trans Sport & Venture -> P Series -> Removal -> Single-Servo -> Tracker
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
C & K Series
Duo-Servo
Removal
- Raise and support vehicle.
- Mark relationship of wheel to hub, then remove tire and wheel assembly.
- On models equipped with full-floating axles, remove hub and drum assembly as outlined in. "Drive Axles."
- On models equipped with semi-floating axles, proceed as follows:
- Install pin into park brake lever.
- Mark relationship of drum to axle.
- Remove rear brake drum retainers, as required.
- Remove rear brake drum.
- On all models, remove return springs and shoe guide,. Fig. .
- Remove brake hold down springs and pins.
- Disconnect actuator lever and pivot.
- Remove lever return sp...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1996-03 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
Light Duty Emissions
Normal Service
Replace every 30,000 miles
Severe Service
Rep...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.
Disassemble
- Support propeller shaft in a line horizontal with table of a press.
- Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
- On models equipped with external snap ring retainers, proceed as follows:
- Disassemble snap rings by ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Starter, Replace
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
- Raise and support vehicle.
- Remove starter to engine brace and heat shields.
- Disconnect wires from solenoids.
- Remove starter motor mounting bolts, washers and lower starter. Record position of shims, if required.
- Remove starter motor from vehicle.
- Reverse procedure to install, noting the fol...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Service Throttle Soon Indicator Lamp ->
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
A "Service Throttle Soon" indicator lamp is mounted in the lower righthand instrument cluster corner on these models. It lights when the ignition is turned On, but should go out approximately 1-5 seconds after the engine starts.
Traditional throttle cables are no longer used on these models. The PCM receives signals from an electron...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from engine.
- Remove radiator outlet hose from engine.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator and from vehicle.
- Reverse procedure to install.
...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
- Rotate tensioner clockwise to release belt tension using suitable wrench, then remove belt.
- Route belt over pulleys excep...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Component location diagrams for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
 Upper Right Side Of The Engine Diagram for 2003 Chevrolet Express 3500 6.0 V8 GASComponents on diagram: |
 Vehicle Speed Sensor Diagram for 2003 Chevrolet Express 3500 6.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Chevrolet Express 3500 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S.
 2003 Chevrolet Express 3500 6.0 V8 GAS Wiring DiagramComponents on diagram: |
 2003 Chevrolet Express 3500 6.0 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Chevrolet Express 3500 AUTOMOBILES
OEM TSB listings for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS Auto Systems: |
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Document: Front or Rear Axle Vent Hose Fluid Leak Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Chevrolet Express 3500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 Chevrolet Express 3500 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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