2003 Chevrolet Express 2500 Service and Repair Manual

This factory service and repair manual for the 2003 Chevrolet Express 2500 has four overhead-valve engines to specify: a 6.0L V8 of 364 cubic inches able to run on gasoline or compressed natural gas, a 5.3L V8 of 325, a 4.8L V8 of 294 and a 4.3L V6 of 262. Standard and extended cargo and passenger bodies appear in Base and LS trim. The natural gas build changes fuel storage, delivery and sensing enough that it is treated on its own terms throughout the fuel chapters.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 5.3L V8 (325 cu in) — OHV, naturally aspirated, gasoline
• 4.8L V8 (294 cu in) — OHV, naturally aspirated, gasoline
• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

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

Trims covered

• Base
• LS

Known issues on the 2003 Express 2500. Eight recalls attach to the 2003 Express 2500, and three of them shape how one of these vans comes into a shop. One begins with water entering the rear license plate lamp socket: the corroded socket can overheat until the plastic softens, smokes and eventually ignites at the rear doors. Another covers front and rear belt buckles that will not latch or will not release, leaving an occupant unrestrained in a crash. A third involves an out-of-specification bore in the brake hydro-boost housing that can fracture the valve seal and raise the pedal effort needed to stop. The 127 owner complaints break down with 21 against the electrical system, 17 against the fuel system and 14 against the service brakes.