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2003 Chevrolet Silverado 2500 HD CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & 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 Silverado 2500 HD 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 Silverado 2500 HD automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Component Replacement & Adjustment -> Sierra & Silverado -> Heating, Ventilation & Air Condition (HVAC) Module, Replace -> Less Air Conditioning -> With Air Conditioning
Vehicle: 2003 Chevrolet Silverado 2500 HD 6.0 V8 GAS
With Air Conditioning
- Drain engine coolant into suitable container.
- On models equipped with auxiliary battery, proceed as follows:
- Disconnect cap and auxiliary battery positive cable.
- Remove battery hold down retainer bolt and retainer, then the auxiliary battery and insulator.
- On all models, disconnect heater core inlet and surge tank outlet hoses.
- Remove accumulator as outlined in "Accumulator, Replace."
- Set air flow control to vent position.
- Set air flow control to vent positio...
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BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Power Brake Units -> Delco Brake Booster -> Power Brake Unit Replacement -> Aztek & Rendezvous -> C & K Series -> Express & Savana -> Montana, Silhouette, Trans Sport & Venture -> S & T Series -> Vue
Vehicle: 2003 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
Aztek & Rendezvous
- Remove coolant reservoir, then relieve fuel system pressure as outlined under. "Precautions."
- Remove cruise control cable from module, then disconnect electrical connector from cruise control module.
- Remove cruise control module from bracket, then the front end sheet metal diagonal brace.
- Remove PCM cover from air cleaner housing, then the PCM and set aside.
- Remove air cleaner intake duct, then bolts from air cleaner assembly and housing.
- Remove fuel lines from pipes and vapor line, then disconnect fluid level sensor switch from brake master cylinder.
- Disc...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Gasoline Engines Except Equinox, Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Uplander & Vue (2004-06) & 2004-06 Envoy, Rainier & TrailBlazer -> Returnless Fuel System
Vehicle: 2003 Chevrolet Silverado 2500 HD 8.1 V8 GAS
Returnless Fuel System
On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Pri...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
DRIVESHAFT, Replace -> Front -> Rear
Vehicle: 2003 Chevrolet Silverado 2500 HD 8.1 V8 GAS
Front
Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the propeller shafts, wheel drive shafts, pinion flanges and output shafts
Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly.
- Raise and support vehicle.
- Remove transfer case shield, if equipped.
- If equipped with double clamp style boot, remove clamp at transfer case by prying up ex...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Starter, Replace
Vehicle: 2003 Chevrolet Silverado 2500 HD 6.0 V8 GAS
- Disconnect battery ground cable.
- Remove mounting bolts and engine shield, if required.
- Remove mounting bolts and oil pan skid plate, if required.
- Remove righthand transmission cover bolt.
- Remove front axle mounting bracket nut, then position front axle mounting bracket bolt until tip is flush with support bushing. Do not remove bolt.
- Remove mounting bolts and slide starter forward until it clears transmission.
- Disconnect oil level sensor electrical connector.
- Remove start...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 1999-2007 Silverado, Sierra, 2000-07 Denali, Suburban, Tahoe, Yukon, Yukon XL, 2001-07 Escalade & 2002-07 Avalanche
Vehicle: 2003 Chevrolet Silverado 2500 HD 6.0 V8 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Remove the righthand instrument panel hush panel.
- Remove the A/C and heater modul...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
General Motors Corp./Saturn Trucks -> Change Trans Fluid Indicator ->
Vehicle: 2003 Chevrolet Silverado 2500 HD 8.1 V8 GAS
This message will appear on the DIC (Driver Information Center) when it is time to change the transmission fluid....
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2003 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
Lower
- Drain cooling system into a suitable container.
- Reposition radiator outlet hose clamp at radiator.
- Remove surge tank hose from surge tank.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump and from veh...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Chevrolet Silverado 2500 HD 8.1 V8 GAS
- Rotate tensioner counterclockwise, using suitab...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
Component location diagrams for most 2003 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1990+.
 A/C High Pressure Recirculating Switch Diagram for 2003 Chevrolet Silverado 2500 HD 6.0 V8 GASComponents on diagram: |
 Automatic Transmission Internal Electronic Components Diagram for 2003 Chevrolet Silverado 2500 HD 6.6 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S.
 2003 Chevrolet Silverado 2500 HD 6.0 V8 GAS Wiring DiagramComponents on diagram: |
 2003 Chevrolet Silverado 2500 HD 6.0 V8 CNG Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
OEM TSB listings for most 2003 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1985+.
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Document: 6.6L LB7, LLY Duramax Diesel Engine Cylinder Head Gasket Missing Thickness Grade Markings-Inspect Block for Stampings Vehicle: 2003 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Auto Systems: |
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Document: Information on 6.6L LBZ, LB7, LLY Duramax Diesel Engine Cylinder Head Gasket Design Change-New Head Gasket Part Numbers and Head Bolt Torque Specifications Vehicle: 2003 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Chevrolet Silverado 2500 HD AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Chevrolet Silverado 2500 HD 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 Silverado 2500 HD 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 Silverado 2500 HD 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 Silverado 2500 HD 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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