2005 Chevrolet Express 2500 Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2005 Chevrolet Express 2500

2005 Chevrolet Express 2500 Problems

Fuel Level Sensor Failure

It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.

Leaking Water Pump May Cause Coolant Loss and Overheating

A coolant leak may develop from the water pump. This can result in an engine overheating condition. A leaking water pump will require replacement.

Check Engine Light Due to Restricted Secondary Air Injection Check Valves

One or both secondary air injection check valves may become restricted causing poor air flow resulting in illumination of the Check Engine Light. It is often recommend to replace both check valves even if a fault code is set for only one bank of cylinders. Replacing only one valve may result in a return trip to the repair shop.

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2005 Chevrolet Express 2500 Recalls

Seat Belts May Not Latch or Unlatch

On certain vans, the front and rear seat belts will not latch or unlatch. In a crash, the risk of injury is increased if the seat occupant is not properly restrained. Dealers will inspect the seat belt buckles, and will replace the buckle assembly if the buckle is found to be inoperative. If the buckle is found to function, only the upper buckle cover will be replaced. The recall began March 15, 2006. The GM recall number is 05113.

Hydraulic Brake Booster May Fail

On vehicles equipped with the Bosch hydraulic brake booster, the boost pressure accumulator may crack and break away from the hydro-boost assembly during normal operation. If this were to happen while the hood is open, fragments from the accumulator could injure people standing in the immediate area. The loss of fluid while driving would cause increased steering and braking effort and a crash could occur without warning. Dealers will test the hydro-boost assembly for function of the two-function valve. If the hydro-boost assembly fails the test, it will be replaced free of charge. The recall began March 23, 2005. The GM recall number is 05006.

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