2003 Chevrolet W4500 Tiltmaster Service and Repair Manual
This factory service and repair manual for the 2003 Chevrolet W4500 Tiltmaster has three engines to document: a 6.0L overhead-valve V8 of 364 cubic inches and a 5.7L OHV V8 of 350 cubic inches, both naturally aspirated on gasoline, plus a turbocharged 4.8L inline-four of 290 cubic inches on diesel. All three go into the straight truck, in low crew cab or low tilt form, under the W4S042 code. Three engines means three sets of fuel, ignition or injection specifications and one common driveline.
Engines covered
- 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
- 4.8L inline-four (290 cu in) — turbocharged, diesel
Body styles covered
- Straight truck, low crew cab
- Straight truck, low tilt
Trims covered
- W4S042
Known issues on the 2003 W4500 Tiltmaster. One recall stands on the federal record. On trucks with the fuel switching manifold, the solenoids could not keep water and salt out; a failed solenoid sends fuel to the wrong place and it backs up out of the filler neck, and spilled diesel near an ignition source can catch fire. The single owner complaint concerns tires. Fuel storage, transfer and delivery are exactly the systems this manual specifies, tests and wires, alongside the wheel, tire and axle torque figures.
