2003 GMC Sierra 3500 Service and Repair Manual

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Factory-Grade Data

2003 GMC Sierra 3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Standard Cab Pickup 2-Door
  • SLT Crew Cab Pickup 4-Door
  • Base Extended Cab Pickup 4-Door
  • SLE Cab & Chassis 4-Door
  • SLE Cab & Chassis 2-Door
  • SLE Crew Cab Pickup 4-Door
  • Base Crew Cab Pickup 4-Door
  • Base Cab & Chassis 4-Door
  • Base Cab & Chassis 2-Door
  • SLT Extended Cab Pickup 4-Door
  • SLE Extended Cab Pickup 4-Door
  • SLE Standard Cab Pickup 2-Door

Engines covered

  • 6.6L 6599CC 403Cu. In. V8 DIESEL OHV Turbocharged
  • 6.0L 5967CC 364Cu. In. V8 GAS OHV Naturally Aspirated
  • 8.1L 496Cu. In. V8 GAS OHV Naturally Aspirated
  • 6.0L 5967CC 364Cu. In. V8 CNG OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2003 GMC Sierra 3500 Recalls & Complaints

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURE

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. I

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOB

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

TSB #11012907

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11010544

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

TSB #11004761

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should

Showing the 8 most recent of 107 technical service bulletins on file with NHTSA.

20060215Component: SEAT BELTS:FRONT:RETRACTORCrash reported1 injured

DT*: THE CONTACT STATED WHILE DRIVING AT 35 MPH, THE VEHICLE WAS INVOLVED IN A CRASH. THE VEHICLE WAS HIT ON THE DRIVER'S SIDE REAR QUARTER PANEL BY ANOTHER VEHICLE. AFTER THE VEHICLE WAS STRUCK, I

20060215Component: AIR BAGS:FRONTALCrash reported1 injured

DT*: THE CONTACT STATED WHILE DRIVING AT 35 MPH, THE VEHICLE WAS INVOLVED IN A CRASH. THE VEHICLE WAS HIT ON THE DRIVER'S SIDE REAR QUARTER PANEL BY ANOTHER VEHICLE. AFTER THE VEHICLE WAS STRUCK, I

20141112Component: SERVICE BRAKES

BRAKE LINES ARE HEAVILY RUSTED, TRUCK IS BEYOND WARRANTY, DEALER WILL NOT REPLACE UNLESS RECALLED. *TR

20130108Component: SERVICE BRAKES

I ONLY HAD 27050 MILES WHEN BRAKE LINES, BURST LUCKILY TRAVELING ONLY 5 MPH. I HAD TO REPLACE ALL BRAKE LINES, REAR BRAKE CALIPERS. THEN AT 28,640 MILES I HAD TO REPLACE THE MASTER CYLINDER. WHAT IN T

20120125Component: POWER TRAIN

I RECENTLY HAD A BRAKE FAILURE ON MY 2003 GMC SIERRA 3500 SERIES TRUCK. I WAS DRIVING WHEN MY BRAKES GAVE OUT. THE PEDAL WENT TO THE FLOOR AND I WAS BARELY ABLE TO STOP BEFORE STRIKING A PARKED CAR.

Showing the 5 most serious of 9 complaints filed with NHTSA.

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