2004 Chevrolet Express 2500 Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Express 2500 has four engines to keep apart, all overhead-valve and naturally aspirated: the 6.0L V8 of 364 cubic inches in gasoline or compressed natural gas form, the 5.3L V8 of 325, the 4.8L V8 of 294 and the 4.3L V6 of 262. The van is covered in standard and extended cargo and passenger bodies with Base and LS equipment. Displacement changes cooling, exhaust and calibration, so each engine carries its own specifications.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 5.3L V8 (325 cu in) — OHV, naturally aspirated, gasoline
• 4.8L V8 (294 cu in) — OHV, naturally aspirated, gasoline
• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline

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 2004 Express 2500. Seven recalls attach to this year. One covers seat belt buckle latches made brittle enough that they may not hold against the force a crash applies, so the belt cannot restrain the occupant as designed. Another involves a transmission shift cable that can separate, after which the lever position and the indicator no longer agree and the van can travel a direction its driver never selected. A third concerns a fuel filler pipe corroding badly enough to leak while the tank is being filled. Owner complaints number 57, fifteen of them on the service brakes and six each on fuel and steering.