2005 GMC Sierra 2500 HD Service and Repair Manual

This factory service and repair manual for the 2005 GMC Sierra 2500 HD spans the widest engine spread the truck offered, from the 6.6L turbocharged diesel V8 of 403 cubic inches through the 6.0L gasoline or CNG V8 of 364 cubic inches to the 8.1L gasoline V8 of 496 cubic inches. Four trims are listed, Base, SLE, SLT and WT, over a 4-door crew cab pickup, a 2-door standard cab pickup and a 4-door extended cab pickup. Procedures, specifications, torque values, wiring diagrams and diagnostics are organized by system for all of it.

Engines covered

• 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 4-door crew cab pickup
• 2-door standard cab pickup
• 4-door extended cab pickup

Trims covered

• Base
• SLE
• SLT
• WT

Known issues on the 2005 Sierra 2500 HD. Eight recalls are on the federal record. One concerns a shift lever position indicator that may not light at startup, so the truck can move in an unintended direction. Another concerns a power steering hose built off specification that can fracture at full lock while braking, costing steering and hydro-boost brake assist. A third concerns fuel rail crossover tube retainer screws that were made out of specification and can break, letting fuel leak. Owners logged 448 complaints, led by 122 on the electrical system and 118 on service brakes. Steering, fuel and cluster diagnostics all appear here.