2003 Chevrolet C5500 Kodiak Service and Repair Manual
This factory service and repair manual for the 2003 Chevrolet C5500 Kodiak is shaped by four bodies and two engines. The engines are the 6.6-liter turbocharged diesel of 403 cubic inches and the 8.1-liter naturally aspirated gasoline V8 of 496; the bodies run from a two-door conventional cab and chassis to a crew cab and chassis, a cutaway chassis and a motorhome cutaway, ordered as C5C042, C5E042, C5U042 or C5V042. Each leaves the plant incomplete, so the chassis and electrical documentation carries the load.
Engines covered
- 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
- 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- Cab & chassis, crew cab
- Motorhome, cutaway
- Cab & chassis, cutaway
- 2-door cab & chassis, conventional
Trims covered
- C5C042
- C5E042
- C5U042
- C5V042
Known issues on the 2003 C5500 Kodiak. Three owner complaints are recorded for the 2003 Kodiak, one each on engine and engine cooling, structure, and the service brakes. On a medium-duty chassis those three tend to be related in service, since a mounted body loads the frame and the brakes have to stop whatever was added. The manual specifies cooling system testing and engine diagnosis, frame and crossmember repair with the fastener torques involved, and full brake coverage — components, adjustment, bleeding and fault diagnosis — for both the diesel and gasoline versions.
