2003 Chevrolet Express 3500 Service and Repair Manual

This factory service and repair manual for the 2003 Chevrolet Express 3500 is built around three naturally aspirated overhead-valve V8s: a 6.0L of 364 cubic inches able to run gasoline or compressed natural gas, a 4.8L of 294 and a 5.3L of 325. The van itself comes in five configurations, three-door cargo and passenger vans in standard and extended lengths plus the two-door cutaway, and in Base or LS trim, so a single chassis section serves shells that look nothing alike once finished.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 4.8L V8 (294 cu in) — OHV, naturally aspirated, gasoline
• 5.3L V8 (325 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
• 2-door cutaway van

Trims covered

• Base
• LS

Known issues on the 2003 Express 3500. Eight recalls stand on the federal record. One covers corrosion at the fuel filler that can let fuel spill during refueling. Another covers steering linkage fasteners left under-tightened, so a tie rod or pitman arm can separate and take the steering with it. A third covers a rear license plate lamp socket that corrodes when water gets in, overheats, and can melt or ignite. Owners have logged 127 complaints, 21 on the electrical system, 17 on the fuel system and 14 on the service brakes.