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2003 Chevrolet Silverado 3500 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 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 Silverado 3500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> Technical Service Bulletins -> Poor Air Conditioning Performance -- Will Not Blow Cold Enough -> 2003 Sierra & Silverado
Vehicle: 2003 Chevrolet Silverado 3500 6.0 V8 GAS
2003 Sierra & Silverado
On some of these models equipped with 6.6L diesel engine the air conditioning performance is less than desirable, especially when ambient temperature is more than 90°F.
To correct this condition perform system inspects as follow:
- Calibrate actuators
- Inspect lower condenser deflector for proper installation. Deflector should be positioned at lower part of condenser and extend forward into top of front bumper and below two fresh air intake holes.
- Inspect engine coo...
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BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
Disc Brakes -> Bendix Single Piston Sliding Caliper -> Precautions -> Brake Disc Service -> Brake Lines & Linings -> Brake Roughness -> General
Vehicle: 2003 Chevrolet Silverado 3500 8.1 V8 GAS
Brake Lines & Linings
Remove one of the front wheels and inspect the brake disc, caliper and linings.
Do not allow any oil or grease on the linings. It is recommended that linings be replaced in sets when worn or damaged.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness v...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2003 Chevrolet Silverado 3500 6.0 V8 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
Engines Less Fuel Pressure ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
DRIVESHAFT, Replace -> Front -> Rear
Vehicle: 2003 Chevrolet Silverado 3500 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 3500 AUTOMOBILES
Starter, Replace
Vehicle: 2003 Chevrolet Silverado 3500 6.6 V8 DIESEL
- Disconnect battery ground cable.
- Raise and support vehicle, then remove righthand front tire and wheel assembly.
- Remove righthand front fender wheelhouse inner panel.
- Remove starter motor battery positive cable, then solenoid wires.
- Remove star...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 3500 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 3500 6.6 V8 DIESEL
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 3500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2003 Chevrolet Silverado 3500 6.6 V8 DIESEL
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned On as a bulb check. If the warning lamp turns On during vehicle operation, a vehicl...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 Chevrolet Silverado 3500 6.6 V8 DIESEL
Inlet
- Drain cooling system into a suitable container.
- Remove air intake tube.
- Remove heater and surge tank hose from mounting clip.
- Reposition heater core inlet hose clamp at engine coolant outlet fitting.
- Remove hose from engine coolant outlet fitting.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Chevrolet Silverado 3500 6.6 V8 DIESEL
- Rotate tensioner to release belt tension using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley, then remove belt.
- Route be...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
Component location diagrams for most 2003 Chevrolet Silverado 3500 cars and light trucks sold in the U.S. from 1990+.
 Auxiliary Battery Relay Diagram for 2003 Chevrolet Silverado 3500 8.1 V8 GASComponents on diagram: |
 Steering Column Diagram for 2003 Chevrolet Silverado 3500 6.6 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Chevrolet Silverado 3500 cars and light trucks sold in the U.S.
 2003 Chevrolet Silverado 3500 6.0 V8 GAS Wiring DiagramComponents on diagram: |
 2003 Chevrolet Silverado 3500 8.1 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
OEM TSB listings for most 2003 Chevrolet Silverado 3500 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 3500 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 3500 6.6 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Chevrolet Silverado 3500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Chevrolet Silverado 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 Silverado 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 Silverado 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 Silverado 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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