1996 Chevrolet Express 2500 Service and Repair Manual

This factory service and repair manual for the 1996 Chevrolet Express 2500 has a diesel in it, which changes the character of the book. Alongside the gasoline 4.3L V6 and the 5.0L and 5.7L V8s sits a turbocharged 6.5L V8 of 395 cubic inches, with its own injection, glow plug and boost-related procedures. Four bodies are covered, cargo and passenger vans in standard and extended lengths, in Base and LS trim, and the load-bearing hardware is specified at the ratings this chassis carries.

Engines covered

• 5.0L V8 (305 cu in) — OHV, naturally aspirated, gasoline
• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
• 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
• 6.5L V8 (395 cu in) — OHV, turbocharged, diesel

Body styles covered

• 3-door extended cargo van
• 3-door standard cargo van
• 3-door extended passenger van
• 3-door standard passenger van

Trims covered

• Base
• LS

Known issues on the 1996 Express 2500. Three recalls are recorded for this model year. The most serious concerns a rear axle U-bolt that can break, allowing a leaf spring to lift away from the axle during rebound, braking or cornering and taking control of the van with it. A second covers passenger vans that emit fuel odors or leak fuel, a fire risk near any ignition source. The third reaches aftermarket corner and bumper lamps lacking amber side reflectors. Fifteen complaints follow, led by engine and engine cooling at three, then the electrical system and steering at two each.