2003 Chevrolet Express 1500 Service and Repair Manual

This factory service and repair manual for the 2003 Chevrolet Express 1500 pairs a 5.3L V8 of 325 cubic inches with a 4.3L V6 of 262, both pushrod, naturally aspirated and gasoline-burning, in three-door cargo and passenger bodies sold as Base or LS. The engine control and emissions material is written to those two units specifically, with their own sensor values and diagnostic charts, while the transmission, axle, brake and steering chapters give clearances and torque values that hold across the range.

Engines covered

• 5.3L V8 (325 cu in) — OHV, naturally aspirated, gasoline
• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door standard cargo van
• 3-door standard passenger van

Trims covered

• Base
• LS

Known issues on the 2003 Express 1500. Eight recalls sit on the federal record for this year, and the most consequential are chassis fasteners. A pitman arm nut left under-tightened can let the steering linkage separate, and a loose right-hand tie rod end nut can part the tie rod from the steering knuckle, either one taking the driver's control of the van with it. A corroded fuel filler pipe can also leak during refueling, with fire the risk near an ignition source. Complaints reach 127, led by the electrical system at 21, fuel at 17 and service brakes at 14.