2005 Chevrolet Express 2500 Service and Repair Manual

This factory service and repair manual for the 2005 Chevrolet Express 2500 covers the working end of the range, the cargo and passenger vans in both lengths, offered as Base or LS, with a 6.0L V8 of 364 cubic inches running gasoline or compressed natural gas at the top of a lineup that also includes the 5.3L and 4.8L V8s and the 4.3L V6. All four are overhead-valve and naturally aspirated, and the suspension, brake and driveline specifications are given at the ratings this chassis is built to carry.

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 2005 Express 2500. Eight recalls appear for this model year, most of them tied to equipment added after the van left the factory. Platform wheelchair lifts account for the bulk: interlocks and threshold sensors that fail to register a user let the lift move or fold away while someone is on it. A stop lamp lens on converted vans passes too little light for following traffic to read the braking. Belt buckles that will not latch or unlatch are also listed. Owner complaints number 59, the body structure drawing nine of them, the service brakes eight and the tires six.