2003 Chevy Express and GMC Savana Built for Work
FOR RELEASE: March 6, 20022003 Chevy Express and GMC Savana Built for Work
New full-size vans offer major strong, smart and surprising features
When GM engineers embarked on redesigning the 2003 Chevy Express and GMC Savana full-size vans the mission was clear: Deliver More. With the addition of segment-busting features like all-wheel drive, a left-hand-side 60/40 entry/load door, and unique side access panels on Express Access and Savana Pro models, these vehicles will impress even the hardest-working commercial customer. And by leveraging proven technology from the Chevy Silverado and GMC Sierra full-size pickups, they’d further distance Express and Savana from the competition. “We’re delivering more by providing solutions to our customer’s individual business challenges,” said Dave Kanous, brand manager, commercial vans. “All-wheel drive allows more efficient travel to and from the job site, while left-hand door and unique side access provides improved on-the-job productivity.”
The 2003 Express and Savana also feature upgraded mechanical systems and powertrains to further enhance durability, dependability, work efficiency and safety.
2003 Chevrolet Express & GMC Savana | ||
Strong | Smart | Suprising |
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Strong
Upgraded Vortec ‘Gen III’ V8 Engines
The new lineup of “Gen III” V8 engines give the 2003 Chevrolet Express and GMC Savana more power and better performance, economy and reliability than previous small-block V8s, plus they top comparable rivals in either horsepower or acceleration capability – or both. The new V8 range includes a heavy-duty Vortec 4800, a spirited Vortec 5300, or the segment’s most powerful V8, the Vortec 6000.
With 275 horsepower, the Vortec 4800 V8 produces 50 more horsepower than the Vortec 5000 it replaces and is mated to a standard 4L80-E four-speed electronically controlled automatic transmission with overdrive. Rated at 275 hp @ 5200 rpm and 285 foot-pounds of torque @ 4000 rpm, this 4.8-liter engine is primarily used for heavy-duty service applications such as in 2500 Series regular- and extended-wheelbase cargo vans (8,600-pound GVW), or as the optional engine on 3500 Series commercial and motorhome cutaways (available with regular wheelbase only.)
Stepping up to 285 horses is the Vortec 5300, making 30 more ponies than the Vortec 5700 it replaces. Linked to a standard 4L60-E four-speed electronically controlled automatic transmission with overdrive, the 5.3-liter puts out its 285 hp @ 5200 rpm and delivers 325 foot-pounds of torque @ 4000 rpm. With the ability to provide segment-leading acceleration, it is used mostly for light-duty applications. It is the standard engine on the new AWD H1500 as well as 2500 Series models, and is optional in other select G1500 and G2500 regular/extended-length passenger/cargo vans, depending on GVW.
A more fuel-efficient replacement for the previous Vortec 8100, the new Vortec 6000 is the segment’s most powerful V8 – more than capable of handling any heavy-duty hauling/trailering requirements. Cranking out 300 horsepower @ 4400 rpm and a whopping 360 foot-pounds of torque @ 4000 rpm, the 6.0-liter comes standard with a 4L80-E four-speed electronic automatic transmission with overdrive for high levels of fuel-efficiency. This new powerplant is the standard engine for G2500/3500 regular- and extended-wheelbase passenger vans (8,600-pound GVW) as well as for the commercial and RV (motorhome) cutaway chassis.
A 200-hp Vortec 4300 V6 is now the base engine for light-duty G-Series vans in all 50 states, featuring new multi-point fuel injection for smoother, longer-life performance than the injection system previously used in the 49 states outside California. Engine calibration and exhaust system improvements also eliminate the need for an exhaust gas recirculation (EGR) unit, further enhancing long-term reliability. The 4.3-liter is a 90-degree, high-output six, with roller rocker arms and lifters, forged-steel connecting rods, cast-aluminum oil pan and extended-life platinum-tipped spark plugs. It makes its 200 hp @ 4400 rpm and delivers 250 foot-pounds of torque @ a down-low 2800 rpm. It mates to a standard 4L60-E four-speed electronic automatic transmission with overdrive.
‘World-Class’ 4-Wheel Disc Brakes Standard
New world-class, four-wheel, power-disc, four-wheel ABS brake systems with the more efficient and durable HydroBoost® hydraulic-assist power-brake booster are standard on all vans. The new light- and heavy-duty systems also include GM’s Dynamic Rear Proportioning (DRP), which better accommodates changes in load variation by recognizing changes in wheel speed and adjusting the amount of pressure applied to the rear brakes. Beyond performance improvements such as better pedal feel, reduced pedal effort and travel, quieter operation and greatly improved durability and brake pad life, stopping distances have been decreased to outpace competitors on 60-, 70- and 80-mph-to-zero stops.
At the heart of the new systems are larger, vented front-brake rotors, new large, vented rear rotors (standard for the first time) and bigger pads. A larger-diameter brake master cylinder with a higher-capacity brake-fluid reservoir is also employed, with higher-friction front-brake linings providing more braking power with less pedal effort as well as greater wear resistance under heavy usage. Two light-duty and three heavy-duty systems match differently sized calipers, rotors and other foundation brake components to different GVW/brake-load requirements and help optimize performance. Low-drag, twin-piston calipers are used in the front and rear brakes on all models. Unlike single-piston calipers that apply pressure only to the center of the pad, the twin-piston calipers apply pressure evenly over the whole brake pad, helping to reduce wear and improve stopping performance.
Wheels are styled with bigger openings in order to feed more air to the larger rotors, thereby providing improved cooling. With increased surface area and ventilation at all four corners, brake pads are more effective at absorbing energy and dissipating heat during braking, making the system more fade-resistant than the previous generation.
Overall, GM test data shows that with normal operation, brake pads now last, at the very least, significantly longer and even twice as long in some models. Highly audible warning chimes now sound through the radio speakers to alert drivers of a failure or malfunction in the braking system and the need to get it repaired.
16-inch Wheels and Tires Standard
An upgrade to standard 16-inch tires with Chevrolet/GMC family-common wheels puts the Express and Savana vans in step with other full-size truck families. New 16 x 6.5-inch, six-bolt steel wheels are standard, with chrome-cladded and/or 16 x 7.0-inch aluminum wheels available on certain uplevel models. To take advantage of all the ride/handling improvements of the new vans, GM engineers sorted through a wide variety of available tire choices and matched them to the particular suspension and GVW rating. Tires range from P235/75R-16 standard and extra low blackwall (or white-outline-letter) all-season radials to LT225/75R-16D (or E) and LT245/75R-16E blackwall radials.
Stiffer Box Frames
Both light- and heavy-duty models now share redesigned, fully boxed three-piece frames, with 35,000-psi strength steel used for the front and rear section frame rails and 50,000-psi strength steel for the intermediate section rails. Frame rails have been straightened in the “torque box” area just behind the front suspension and two new front crossmembers have been added for extra strength. The increased torsional stiffness (up from 28 to 43 percent, depending on model) and full-frame beaming known as vertical stiffness (up 100 percent) helps to isolate road imperfections and improves ride and handling, especially under load. A sturdy frame also contributes to the new vans’ scoring the highest maximum payload rating (2,430 pounds) of any light-duty, base-model, full-size van on the market, as well as ensures better occupant protection and higher safety ratings in new government crash tests.
Improved Independent Front Suspensions
New independent front suspensions include larger diameter antiroll bars (33mm on light-duty vans, 35mm on heavy-duty) and new gas-pressurized shock absorbers with improved tuning, particularly aimed at providing more stable front-to-rear vehicle motion. Actually modified versions of the front suspensions used on GM’s highly successful full-size pickups, these beefy truck suspensions have been proven over millions of customer miles in the Chevrolet Silverado and GMC Sierra. As a matter of fact, except for its new cast-iron lower control arms, the independent front short/long arm (SLA) coil-spring suspension on new RWD (G-Series) vans is essentially the same as that of regular 2WD GM full-size pickups.
New all-wheel-drive model (H-Series) vans employ an independent front torsion-bar suspension, unique for full-size vans. With torsion bars absorbing the suspension movements and halfshafts driving each front wheel, ride and handling are vastly improved over solid-axle 4WD designs. Yet apart from geometry changes, the front suspension system used on H-Series vans is practically identical to that of GM’s K1500 full-size pickups, including using identical upper and lower control arms.
All rear suspensions use a solid axle, with semi-elliptic variable-rate, two-stage multi-leaf springs and gas-charged shocks to provide a smooth ride under loaded and unloaded conditions. Specific systems, including spring and shock sizes and rates, are uniquely matched to the vehicle’s load-carrying requirement and body configuration.
A Choice of Wheelbase Lengths
The Chevrolet Express and GMC Savana passenger vans continue to be available in both regular (135-inch) and extended (155-inch) wheelbase lengths, and can provide eight-, 12- or 15-person carrying capability. Cargo vans, available in the same wheelbase lengths, offer seating for two. The cutaways, which can be converted to various commercial, School Bus and RV requirements, are available in 139-inch, 159-inch and 177-inch wheelbase lengths. The 1500 Series vans include light-duty models rated at 6,200 and 7,200 pounds GVW. The 2500 Series includes light-duties rated at 7,300 and 8,500 GVW (in CNG and bi-fuel only,) and heavy-duty models rated at 8,600 pounds GVW. The heavy-duty 3500 Series includes full-bodied cargo/passenger vans rated at 9,600 pounds GVW, and commercial and RV cutaway chassis, with GVW ratings of 8,600-12,300 pounds.
Protective ‘Halo’ and Improved Structural Supports
To help keep Express and Savana work vans looking newer longer is an exterior ‘halo’ made of a dent-resistant composite material that allows ladders and pipes to be loaded and unloaded without the body damage that may occur to sheet metal. And more supports have been added to lend more stability and quietness to the front-end structure. A diagonal brace, running from the front tie-bar back to the inner fender, increases overall stiffness, while the radiator support structure, which also holds the hood latch and locates and holds the front lamps and grille, has been completely redesigned and strengthened with the addition of a vertical supporting member.
… And More on “Strong”
Higher quality rear axles across the line are quieter and more durable. Rear axles in 1500 Series G- and H-Vans (rated at 6,200/7,200-pounds GVWR and equipped with 4.3- or 5.3-liter engines) are wider for increased stability and feature larger, 8.6-inch ring gears using a new synthetic lube to reduce operating temperatures when trailering and hauling for better dependability. The 2500 Series vans have a new semi-float rear axle, with a larger 9.75-inch ring gear to handle higher torque loads from the heavy-duty Gen III V8s. And while the new 3500 Series retains a full-float rear axle with a 10.5-inch ring gear, it has been upgraded with new design features and is manufactured with more precision for improved NVH and enhanced durability.
Meanwhile, all new van models feature improved propshafts. Regular length G-Vans and Cutaways use a new aluminum propshaft to help reduce driveline noise. Extended length G-Vans and Cutaways have a more precisely welded, Slip-In-Tube® two-piece unit with a supporting center ring for improved propshaft balance. And strong yet light one-piece steel propshafts drive both the front and rear axles of the new AWD H-Vans.
Revised engine mounts help contribute to a smoother, quieter ride. Larger, thicker pad-style mounts replacing the previous bushing type provide quieter engine idle and better down-the-road feel in the steering wheel by more effectively isolating engine vibration. Manufacturing revisions also improve the engine mounts’ durability and assembly.
Full-bodied passenger/cargo vans also get composite fuel tanks, and all models have more robust turbine fuel pumps and greater vapor-leak detection capability. A 31-gallon capacity tank is standard on all but Cutaway cab chassis, which comes with a standard 35-gallon tank and optional rear-mounted 55-gallon tank. The new fuel pumps’ turbine propellers do not have parts (like a roller vane or G-rotor used with the previous design) that can wear out. The high-pressure pumps also have an increased capability to handle contaminants and are more sensitive to potential fuel vapor leaks, thanks to improved on-board diagnostic (OBDII) calibration enhancements.
Smart
Advanced Class II Electrical System
New wiring architecture takes multiplexing technology – where a common wire replaces individual wires to send information between electrical modules – to a new level. This highly integrated system features distributed computing and numerous zone modules, all connected by a serial data network. By replacing copper wires with integrated circuits at every opportunity, GM engineers greatly increased processing power and reduced the number of wires, splices and connectors for improved dependability. Additional diagnostic capability designed into the electronic control modules themselves also makes for quicker, easier servicing and lower warranty costs.
The new electrical system’s leaner, cleaner design also simplifies vehicle assembly, reduces components and weight and improves reliability – all contributing to quality enhancements that reduce bottom-line servicing and warranty expense. When servicing is required, many of the system’s control modules are flash programmable, allowing technicians to quickly re-program a module, if need be, to reset it instead of replace it or to incorporate upgrades and service diagnostics, using a serial data link connector.
Oil Life Monitor
The new Class II electrical system supports monitoring and reporting on more than 20 vehicle system conditions. There are actually 16 alerts on the new instrument cluster, but some, like “Check Gauges” and “Service Oil,” are used to report on more than one service condition. “Check Gauges,” for example, provides an alert both for rising temperature and low oil pressure. A new Oil Life Monitor takes the guesswork out of routine engine service intervals. When the “Service Oil” light remains on, it signals that an oil change is required; a flashing light signals that the oil level is low.
Battery Run-down Protection
The Battery Run-down Protection feature, not previously available on full-size vans, guards against the interior lights and/or headlamps and parking lamps from draining the battery if they are accidentally left on for a long period of time. The system automatically turns off any lamps inadvertently left on after 10 minutes.
Retained Accessory Power
Another convenient new feature is Retained Accessory Power, or the ability to operate power accessories such as the radio without having to turn the ignition on with a key.
Lock-out Protection
Frequent entry and exit can sometimes lead to inadvertently locking the van with the key still in the ignition by manually tripping the power door-lock switch. Part of the remote keyless entry control subsystem, Lock-out Protection prevents tripping the power locks while the key is still in the ignition, preventing a lockout situation.
Tow/Haul Switch
All new Express/Savana vans not only come standard with a four-speed automatic transmission with overdrive – but also offer for the first time GM’s unique Tow/Haul Mode feature, which assists drivers in pulling a heavy trailer or large or heavy load. Engaging the Tow/Haul mode by pushing a button reduces the frequency and improves the predictability of transmission shifts during heavy hauling and trailering. It also provides for improved control of vehicle speed by requiring less throttle activity when pulling a heavy trailer or large load.
Air Filter Monitor
New air induction systems incorporating a mass airflow sensor for the new line of Vortec V8s make for quieter engine operation and reduced operating costs. A redesigned air cleaner system with a built-in filter monitor actually discharges most of the dirt that would be trapped in a conventional filter. The design can extend air-filter life up to 80,000 miles before replacement is required – more than twice the typical 30,000-mile change-interval in most vehicles. This offers big potential savings for large fleet and commercial operators. The air cleaner unit separates dirt and water inside the cleaner and discharges debris into a valve located in the air cleaner cover. As the engine pulsates, it opens and closes the valve to clear any debris that is accumulated. A filter restriction indicator inside the engine compartment, which turns from “green” to “red” when the filter needs changing, eliminates the cost of unnecessary filter replacements.
New ABS system standard
All new models feature a smaller, quieter and more-efficient three-channel ABS unit. A “closed-loop” motor control in the ABS varies pump speed so that fluid is pumped at maximum pressure when required, for harder full-speed vehicle stops. This improves durability, as well as efficiency and also helps reduce noise level during normal stops.
Daytime Running Lights
Like other GM vehicles, new full-size vans also provide standard Daytime Running Lamps (DRL), which allow other drivers to easily see them on the road. The DRLs are integrated with the park/turn signals; a dual filament bulb provides the lighting for both.
… And More on “Smart”
New catalytic converter systems, with improved oxygen sensors and catalysts moved closer to their engines for improved cold-start performance, are now common for all 50 states and provide LEV capability in California. In some systems, NOX emissions have been reduced by 70 percent by reformulating catalyst content and remapping engine controls. Together with advances in engine calibration, the new systems meet emission standards with 82 percent less precious metal used in converters than the previous vans.
Also new for 2003 is expanded Alternative Fuel options for fleet and commercial use. No less than 10 different models equipped with a Vortec 6000 V8 now have alternative fuel capability, each offering a choice of a fully converted, dedicated compressed natural gas (CNG) system or a bi-fuel system using either CNG or gasoline. Both alternative fuel systems are designed to meet the most stringent federal and California emissions standards as well as allow fleet and commercial customers to qualify for special credits provided by the government’s Energy Policy Act (EPACT). All alt-fuel systems have the same 3-year, 36,000-mile warranty as on base gasoline vans (5-year, 50,000-miles on emissions-related components), and regular Chevrolet and GMC dealers can handle any warranty work.
Surprising
Segment-exclusive Optional Left-hand Door
Another “industry-first,” a 60/40 left-hand-side hinged door, is now available on regular-length passenger and cargo vans, offering the segment’s most flexible passenger entry/cargo loading capability. The same innovative access feature that won “must-have” status in the minivan segment is now available to the full-size customer, with complete driver’s-side access to the second-row seat/cargo compartment and third-row seat/rear compartment. Hinged and sliding passenger/cargo doors continue to be available on the right-hand side. (The right-side hinged door is available without the optional left-side door, but the new left-side door requires customers to get the same hinged-type door on the right-hand side.) Side window options, including a choice of stationary (fixed) or swing-out windows with standard light-tinted Solar Ray® glass or deep-tinted glass, are the same for both sides. Rear cargo doors also continue to offer a choice of stationary or pop-up windows.
Pro / Access panels
Innovative side access doors with remote release on new Chevy Express and GMC Savana Pro models allow contractors street-side access to tools and parts, saving time and steps. These panels cover the cutouts where passenger-van side glass would normally be installed, and are body-colored to match the vehicle. Any number of specially designed interior storage systems are also available from the factory to help professional tradesmen increase their work efficiency.
Industry-first All Wheel Drive Models
Three new all-wheel-drive “H-model” cargo and passenger vans have been added to the 2WD “G-model” lineup, employing a full-time viscous-coupled transfer case to offer the best on-road, wet- or dry-pavement handling traction ever engineered into full-size van. Their full-time AWD system is always “on” and fully operational, automatically and seamlessly transferring torque from slipping wheels to those with a firmer grip. The viscous coupling (a torque-biasing device) has a series of opposing discs attached to the front and rear output shafts in a strong, lightweight magnesium housing mounted directly to the 4L60-E automatic transmission. One set of the discs turns with the front axle, the other set of discs with the rear axle. The discs are surrounded by a high-viscosity silicone fluid which, when deformed, transfers power from the faster rotating discs (or the slipping wheels) to those rotating more slowly (the wheels with grip). A 35-percent to 65-percent front-to-rear power split is used under normal operating conditions, while up to 100 percent of the engine’s torque can be transferred to the wheels with traction. If climbing a hill or steep grade, for example, the differential will send more torque to the rear wheels to compensate for the extra weight being transferred to them. The AWD also accommodates for speed differences that naturally occur when a vehicle travels around a corner on dry pavement, and adds superior cornering capabilities. The system also provides better durability than a rear-drive system because torque is continually shared between the front and rear axles.
OnStar & RDS Radio System Availability
Select audio options now allow for the security and convenience of GM’s next-generation, factory-installed OnStar® system, available in full-size vans for the first time. The OnStar® system uses Global Positioning Satellites (GPS) to locate a vehicle and provide a hands-free cellular phone communications link for convenience and emergency aid. The optional OnStar® system has a microphone located in the headliner, with three-button controls integrated into the inside rearview mirror assembly. Also new for ’03 is Radio Data System (RDS) capability, available on all except the base-model and Upfitter package radios. Based on signals from FM or civil broadcast stations, RDS allows the radio to display a variety of text descriptions, including traffic information, construction updates, music type (i.e., “classic,” “rock,” “country” etc.), station call letters – even song and artist information. The new vans continue to offer a wide selection of high quality audio system choices, including AM/FM stereo, Seek/Scan, clock, cassette, single CD player or 6-disc CD changer.
Truck-like Styling
Bold, new front-end styling – including grille, bumper, fascia, fenders and hood – not only lends a strong family resemblance to other GM trucks, but its underlying structure also improves occupant protection and crashworthiness and reduces repair costs. The extended front-end includes a 3.9-inch longer hood with new power-dome design, 3.9-inch longer/5.1-inch higher fenders, a bigger engine compartment and a larger, wraparound bumper system. Uplevel quad Parabolic reflector optic halogen headlamps and larger, revamped taillamps enhance visibility and add an extra measure of safety. The Express features Chevrolet’s trademark rectangular “egg-crate” shaped grille with a horizontal chrome mid-band on uplevel models and gold bowtie emblem. Savana now has GMC’s signature, louvered center-port grille with a chrome surround on uplevel models. Distinctive new badging is also family-common with other full-size trucks. All vans feature cleaner, molding-free bodysides and a smoother, more aerodynamic roof halo. Painted halos, available as an option on all cargo/passenger models, are available in seven matching body colors. New exterior color choices include Sandalwood Metallic, Dark Spiral Gray Metallic, and Berry Red Metallic.
Outstanding Ride, Handling and Steering
The new full-size vans continue to improve upon previous best-in-class features, like the widest rear cargo-door openings, lowest step-in heights and segment-leading ride-and-handling dynamics. The new wheels, suspensions and brakes have raised the bar even further in driving in ride compliance and smooth cornering. And light-duty models now benefit from standard power rack-and-pinion steering, providing even more nimble performance. The 17.3:1 steering ratio is quicker, with a more responsive feel than the previous integral recirculating-ball system. The steering gear itself also features a segment-unique mounting system for improved reliability. Heavy-duty models employ an upgraded version of their previous integral power recirculating-ball variable-ratio (13-15:1) steering gear to meet rigorous demands, but a completely new steering linkage with new attachment design is used to improve durability.
… And More on “Surprising”
Improved functionality and convenience is also evident with safer, more comfortable interiors. More supportive front seats, better lighting, higher quality fit-and-finish on panels, safer trim and an improved headliner have been added, as well as an upgraded heating, ventilation and air conditioning (HVAC) system, and more integrated armrests, door pull handles, window and lock control switches and mirrors. Front doors include integral storage pockets. An added storage tray, twin trip odometers, a second power point, a third console cupholder, loop-style coat hooks and more durable 12-ounce carpeting is also provided.
New front-seat dual-stage airbags are now standard in all light-duty models (up to 8,600 pounds GVW), which tailor inflation speed to crash severity to minimize the risk of injury to smaller occupants during low-speed crashes. Driver and front-passenger belts feature pre-tensioners and energy-absorbing retractors, while three-point lap-and-shoulder belts are provided in all first- and second-row seating positions, including a new center-position all-belts-to-seat system and a child-seat tether type restraint anchorage system in passenger vans. There are even new rearview mirrors available on some models, which can be ordered with integrated turn signals, along with their remote control, electrically heated, manually folding design features.
Strong, Smart and Surprising in many other ways, the 2003 Chevrolet Express and GMC Savana will be available in dealer showrooms in the 3rd quarter of 2002.
All product information is based on the latest information at time of production and is subject to change without notice.