Service CHEVROLET SUBURBAN 2003 9.G Repair Manual

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
Doing Your Own Service Work
If you want to do some of your own service work, you'll
want to use the proper service manual. It tells you
much more about how to service your vehicle than this
manual can. To order the proper service manual,
see
Service Publications Ordering Information on
page 7-11.
Your vehicle has an air bag system. Before attempting
to do your own service work, see
Servicing Your Air
Bag-Equipped Vehicle on page 1-87.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. See
Part E: Maintenance Record on page 6-20.
{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
·Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.
CAUTION: (Continued)
5-3

Gasoline Octane
Use regular unleaded gasoline with a posted octane of 87
or higher. If the octane is less than 87, you may get a
heavy knocking noise when you drive. If this occurs, use
a gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine.
A little pinging noise when you accelerate or drive uphill is
considered normal. This does not indicate a problem
exists or that a higher-octane fuel is necessary. If you are
using 87 octane or higher-octane fuel and hear heavy
knocking, your engine needs service.
Gasoline Speci®cations
It is recommended that gasoline meet speci®cations
which were developed by the American Automobile
Manufacturers Association and endorsed by the
Canadian Vehicle Manufacturers Association for better
vehicle performance and engine protection. Gasoline
meeting these speci®cations could provide improved
driveability and emission control system performance
compared to other gasoline.
In Canada, look for the
ªAuto Makers' Choiceº
label on the pump.
Canada Only
5-5

Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors does
not recommend the use of such gasolines. Fuels
containing MMT can reduce the life of spark plugs and
the performance of the emission control system may
be affected. The malfunction indicator lamp may turn on.
If this occurs, return to your authorized GM dealer for
service.
Fuel E-85 (85% Ethanol)
The 8th digit of your vehicle identi®cation number (VIN)
shows the code letter or number that identi®es your
engine. You will ®nd the VIN at the top left of the
instrument panel. See
Vehicle Identi®cation Number
(VIN) on page 5-107.
If your vehicle has the 5.3L V8 engine (VIN Code Z
only), you may use either regular unleaded gasoline or
ethanol fuel containing up to 85% ethanol (E-85);
also see
Fuel on page 5-4. In all other engines, including
the 5.3L V8 (VIN Code T), use only regular unleaded
gasoline.Only vehicles that have the 5.3L V8 engine (VIN Code Z)
may use 85% ethanol fuel (E-85).
Many service stations will not have an 85% ethanol fuel
(E-85) pump available. The U. S. Department of
Energy has an alternative fuels website
(http://afdcmap.nrel.gov/nrel/) that can help you ®nd
E-85 fuel. Those stations that do have E-85 should have
a label indicating ethanol content. Do not use the fuel
if the ethanol content is
greaterthan 85%. Your vehicle
may not operate properly if the ethanol content is
greater than 85%.
At a minimum, E-85 should meet ASTM Speci®cation
D 5798.
To insure quick starts in the wintertime, the E-85 fuel
must be formulated properly for your climate according
to ASTM speci®cation D 5798. If you have trouble
starting on E-85, it may be because your E-85 fuel is
not properly formulated for your climate. If this happens,
switching to gasoline or adding gasoline to your fuel
tank may improve starting. Your vehicle is designed to
accommodate a mixture of gasoline and E-85 fuel.
For good starting and heater efficiency below 32ÉF
(0ÉC), the fuel mix in the fuel tank should contain no
more than 70% ethanol.
5-7

The engine oil ®ll cap for
the VORTECŸ 4800,
5300, 6000 and 8100 V8
engine is located on
the engine valve cover, on
the passenger's side of
the vehicle.
Your vehicle may have a cap with text and a graphic, or
just a graphic as shown. See
Engine Compartment
Overview on page 5-14for more information on location.
Be sure to ®ll it enough to put the level somewhere in
the proper operating range. Push the dipstick all the way
back in when you're through.
What Kind of Engine Oil to Use
Oils recommended for your vehicle can be identi®ed by
looking for the starburst symbol.
This symbol indicates that the oil has been certi®ed by
the American Petroleum Institute (API). Do not use
any oil which does not carry this starburst symbol.If you choose to perform
the engine oil change
service yourself, be sure
the oil you use has
the starburst symbol on
the front of the oil
container. If you have your
oil changed for you, be
sure the oil put into
your engine is American
Petroleum Institute certi®ed
for gasoline engines.
You should also use the proper viscosity oil for your
vehicle, as shown in the viscosity chart.
5-20

When to Change Engine Oil
(GM Oil Life System)
Your vehicle has a computer system that lets you know
when to change the engine oil and ®lter. This is
based on engine revolutions and engine temperature,
and not on mileage. Based on driving conditions,
the mileage at which an oil change will be indicated can
vary considerably. For the oil life system to work
properly, you must reset the system every time the oil is
changed.
When the system has calculated that oil life has been
diminished, it will indicate that an oil change is necessary.
A CHANGE ENGINE OIL message will come on. Change
your oil as soon as possible within the next two times you
stop for fuel. It is possible that, if you are driving under the
best conditions, the oil life system may not indicate that
an oil change is necessary for over a year. However, your
engine oil and ®lter must be changed at least once a year
and at this time the system must be reset. Your dealer
has GM-trained service people who will perform this work
using genuine GM parts and reset the system. It is also
important to check your oil regularly and keep it at the
proper level.
If the system is ever reset accidentally, you must
change your oil at 3,000 miles (5 000 km) since your
last oil change. Remember to reset the oil life system
whenever the oil is changed.
How to Reset the CHANGE ENGINE OIL
Message
The GM Oil Life System calculates when to change
your engine oil and ®lter based on vehicle use. Anytime
your oil is changed, reset the system so it can
calculate when the next oil change is required. If a
situation occurs where you change your oil prior to a
CHANGE ENGINE OIL message being turned on, reset
the system.
To reset the CHANGE ENGINE OIL message, see ªGM
Oil Life Systemº under
DIC Operation and Displays
on page 3-54for vehicles equipped with the DIC, or do
the following:
1. Turn the ignition key to RUN with the engine off.
2. Fully press and release the accelerator pedal three
times within ®ve seconds.
If the OIL LIFE RESET message ¯ashes for 10 seconds,
the system is reset.
If the system does not reset, try the procedure once
again. If it still does not reset, see your dealer for service.
5-22

What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Don't let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly dispose of clothing or
rags containing used engine oil. See the manufacturer's
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
®lter before disposal. Never dispose of oil by putting it in
the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Instead, recycle it by taking it
to a place that collects used oil. If you have a problem
properly disposing of your used oil, ask your dealer, a
service station or a local recycling center for help.
Engine Air Cleaner/Filter
SeeEngine Compartment
Overview on page 5-14for
location of engine air
cleaner/®lter and change
indicator (if equipped).
When to Inspect
If your vehicle is equipped with a ®lter change indicator
it lets you know when the ®lter needs to be replaced.
Vehicles with a restriction indicator, inspect the air
cleaner/®lter at every oil change and replace the ®lter
when the indicator tells you to. Vehicles without a
change indicator, inspect the air cleaner/®lter at every
oil change and replace it at the ®rst oil change after
25,000 miles (40 000 km).
5-23

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission ¯uid
level is when the engine oil is changed.
Change both the ¯uid and ®lter every 50,000 miles
(83 000 km) if the vehicle's GVWR is over 8,600 or if
the vehicle is mainly driven under one or more of these
conditions:
·In heavy city traffic where the outside temperature
regularly reaches 90ÉF (32ÉC) or higher.
·In hilly or mountainous terrain.
·When doing frequent trailer towing.
·Uses such as found in taxi, police or delivery
service.
If your vehicle's GVWR is not over 8,600 and you do
not use your vehicle under any of these conditions,
change the ¯uid and ®lter every 100,000 miles
(166 000 km).
See
Part A: Scheduled Maintenance Services on
page 6-4.
How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little ¯uid can damage
your transmission. Too much can mean that some
of the ¯uid could come out and fall on hot engine
part or exhaust system parts, starting a ®re.
Too little ¯uid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission ¯uid.
Wait at least 30 minutes before checking the
transmission ¯uid level if you have been driving:
·When outside temperatures are above 90ÉF (32ÉC).
·At high speed for quite a while.
·In heavy traffic ± especially in hot weather.
·While pulling a trailer.
To get the right reading, the ¯uid should be at normal
operating temperature, which is 180ÉF to 200ÉF
(82ÉC to 93ÉC).
5-26

If No Steam Is Coming From Your
Engine
An overheat warning, along with a low coolant condition,
can indicate a serious problem. SeeLow CoolantunderDIC Warnings and Messages on page 3-64.
If you get an engine overheat warning with and do not
have a low coolant condition, but see or hear no steam,
the problem may not be too serious. Sometimes the
engine can get a little too hot when you:
·Climb a long hill on a hot day.
·Stop after high-speed driving.
·Idle for long periods in traffic.
·Tow a trailer. SeeTowing a Trailer on page 4-65.
If you get the overheat warning with no sign of steam, try
this for a minute or so:
1. In heavy traffic, let the engine idle in neutral while
stopped. If it is safe to do so, pull off the road. Shift
to park or neutral and let the engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn't come back on, you can drive
normally.
If the warning continues, pull over, stop, and park your
vehicle right away.
If there's still no sign of steam, you can push down the
accelerator until the engine speed is about twice as
fast as normal idle speed for at least three minutes while
you're parked. If you still have the warning,
turn off
the engine and get everyone out of the vehicleuntil it
cools down. Also, seeOverheated Engine Protection
Operating Modelisted previously in this section.
You may decide not to lift the hood but to get service
help right away.
5-35

The coolant level should
be at or above the FULL
COLD mark. If it isn't,
you may have a leak at the
pressure cap or in the
radiator hoses, heater
hoses, radiator, water
pump or somewhere else
in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine ®re, and you could be
burned. Get any leak ®xed before you drive the
vehicle.If there seems to be no leak, start the engine again.
The engine cooling fan speed should increase when idle
speed is doubled by pushing the accelerator pedal
down. If it doesn't, your vehicle needs service. Turn off
the engine.
Notice:Engine damage from running your engine
without coolant isn't covered by your warranty.
See ªOverheated Engine Protection Operating
Modeº in the Index for information on driving to a
safe place in an emergency.
Notice:When adding coolant, it is important that
you use only DEX-COOLž(silicate-free) coolant.
If coolant other than DEX-COOLžis added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the engine
coolant will require change sooner Ð at 30,000 miles
(50 000 km) or 24 months, whichever occurs ®rst.
Damage caused by the use of coolant other
than DEX-COOL
žis not covered by your new vehicle
warranty.
5-37

Notice:
·Using the wrong ¯uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system parts so
badly that they will have to be replaced. Do not
let someone put in the wrong kind of ¯uid.
·If you spill brake ¯uid on your vehicle's painted
surfaces, the paint ®nish can be damaged. Be
careful not to spill brake ¯uid on your vehicle. If
you do, wash it off immediately. See
Appearance
Care on page 5-99.
Brake Wear
Your vehicle has four-wheel disc brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving (except when you are pushing on the
brake pedal ®rmly).
{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are ®rst applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque speci®cations.
Brake linings should always be replaced as complete
axle sets.
See
Brake System Inspection on page 6-17.
5-47