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New for 2012

• New exterior color: Wheatland Yellow

Highlights

Chevrolet Express can haul up to 15 people and their cargo. It also serves as the foundation for conversion vans upfitted by a number of aftermarket manufacturers.

Express is available in regular (135-inch / 3,429-mm) and extended (155-inch / 3,937-mm) wheelbase lengths, and can accommodate eight, 12 or 15 people. The 1500 Series vans include light-duty models rated at 7,300 pounds (3,311 kg) GVWR. The 2500 Series includes heavy-duty models rated at 8,600 pounds (3,901 kg) GVWR. The heavy-duty 3500 Series includes full-bodied cargo/passenger vans rated at 9,600 pounds (4,354 kg) GVWR with the 6.0L gas V-8 and 9,900 pounds (4,490 kg) with the Duramax 6.6L diesel.

Passenger models are offered in LS and LT trim levels. A wide range of models and configurations – including numerous powertrain options – offers many competitive advantages, with standard and available features that include:

• Fuel-saving six-speed automatic transmissions
• All-wheel drive
• Available 6.6L Duramax turbo diesel engine with B20 biodiesel capability
• Available locking rear differential
• Trailer rating of up to 9,900 pounds (4,490 kg) on 3500 models
• StabiliTrak electronic stability control is standard on all cargo and passenger van models
• SiriusXM Satellite Radio is available
• A USB port is included with an available digital radio.

A unique Express 3500 passenger van model with the Duramax 6.6L turbo diesel complements the model’s people-hauling capability with exceptional towing capacity. With the diesel engine, long-wheelbase models boast a GVWR of 9,900 pounds (4,490 kg), a GCWR of 17,000 pounds (7,711 kg) and towing rating of 9,700 pounds (4,400 kg).

Express design and exterior features

• Chrome appearance package is standard on LT models and available on LS. It includes chrome front and rear bumpers and chrome grille with dual composite headlamps. Black-painted bumpers are standard on LS.
• Swing-out 60/40-split passenger-side doors are standard on all models.
• Sliding passenger-side door is available on all models.
• Heated power-adjustable outside folding mirrors are available on all models.
• Heated power-adjustable outside folding mirrors with turn signal indicators are available on all models.
• Sixteen-inch steel wheels are standard on three-quarter ton and one-ton models.
• Seventeen- steel wheels are standard on half-ton models and 17-inch aluminum wheels are available.
• Exterior colors include: Sandstone Metallic, Graystone Metallic, Dark Blue Metallic, Black, Dark Green Metallic, Summit White, Victory Red, Wheatland Yellow and Sheer Silver Metallic.

Express interior standard and available features

• Air conditioning (single-zone) is standard on all models.
• Rear air conditioning is standard on LT models and available on LS.
• A range of audio systems, including CD/MP3 capability and USB port, is available on all models. An AM/FM stereo is standard.
• SiriusXM Satellite Radio is available on all models.
• Child seat anchors are standard on LS and LT models and include four anchors and two tethers.
• Driver information center is standard on all models. A compass and outside temperature features are available.
• A rear auxiliary heater is standard on LT models and available on LS.
• Auxiliary 12-volt power outlets (two) are standard on all models and are located on the interior engine cover.
• Remote keyless entry is standard on LT and available on LS.
• Remove vehicle starter system is available on all models.
• Six-way power-adjustable driver’s seat is available on LT. A six-power power-adjustable passenger seat is also available on LT models.
• Leather-wrapped steering wheel and steering wheel audio controls are available on all models.
• Power windows are standard on LT and available on LS.
• LS and LT passenger-model seating is offered in eight-passenger, 12-passenger and 15-passenger configurations.
• Custom vinyl or cloth upholstery is offered on all models in Neutral or Medium Pewter colors.

Express powertrains – 6.6L Duramax diesel

The Duramax turbo-diesel V-8 is offered in some Express models, delivering best-in-class torque and horsepower. Known by its “LGH” engine code, it is rated at 260 horsepower (194 kW) and 525 lb.-ft. of torque (711 Nm).

Introduced for 2011, this updated Duramax is more fuel-efficient – up to 11-percent greater fuel economy than the previous model – reduces NOx emissions by up to 63 percent and helps enable exceptional towing capacity. Among its new and enhanced features are:

• Main bearing profiles changed to enhance oil film thickness
• Oil pump flow increased for more pressure at low speeds
• A revised turbocharger oil circuit for increased pressure at the turbo and faster oil delivery
• Connecting rod pin ends modified to provide increased piston support
• Higher-strength piston design

A 30,000-psi (2,000 bar) piezo-actuated fuel injection system – capable of operating on ASTM grade B20 biodiesel – tht ensures more precise fuel delivery, improving emission performance.

To meet the more stringent emissions requirements, the LGH Duramax was designed with a robust EGR cooling system, along with revised turbocharger tuning that helps enhance EGR performance. It also has a large-capacity selective catalytic reduction system. In fact, the engine features the latest in emission control technology, making it the cleanest Duramax engine ever produced. NOx emissions are reduced by at least 63 percent, compared to the 2010 model. NOx emissions are controlled via a Selective Catalyst Reduction aftertreatment system that uses urea-based Diesel (Emission) Exhaust Fluid (DEF). The DEF is housed in a 5.83-gallon (20 L) tank and needs to be replenished about every 5,000 miles (8,000 km). Electrically heated lines feed the DEF to the emission system to ensure adequate delivery in cold weather.

The Duramax also includes GM’s second-generation diesel particulate filter system. Unlike most competitors, the Duramax regenerates its diesel particulate filter using a downstream injection of diesel fuel directly into the exhaust stream and can travel up to 700 miles (1,125 km) between regenerations – a 300-mile (482 km) increase over the previous Duramax engine. The use of downstream injection also helps improve engine life by eliminating concerns surrounding the possibility of diesel fuel contaminating engine oil, which can happen when fuel used for regeneration is introduced directly into the cylinder. 

The Duramax also provides outstanding cold-weather performance, with  microprocessor-controlled glow plugs capable of gas engine-like start performance in less than three seconds in temperatures as low as -20 degrees F (-29 C), without a block heater. The engine has been developed to operate for at least 200,000 miles (322,000 km) on a rough-duty cycle without the need for a major overhaul; and it is backed with a five-year/100,000-mile powertrain warranty.

A fuel-operated heater (FOH) also is available for vans equipped with the Duramax 6.6L to quickly provide heat to the vehicle interior in cold weather. The seamlessly integrated system is designed into the Express chassis, saving customers the time and labor of upfitting an aftermarket system. The electronically controlled, fuel-operated heater operates automatically, turning on and off within parameters that include outside air temperature, fuel level, coolant temperature and whether the engine is running. It features a self-contained, pressurized auxiliary coolant heater (with a surge tank) that uses diesel fuel to generate up to 17,200 Btu/h (5 kW) of heating energy.

The Duramax engine is backed by GM’s Hydra-Matic 6L90 heavy-duty six-speed automatic transmission.

Express powertrains – gas/FlexFuel engines

Chevrolet Express offers a choice of four engines. Standard on 2500 passenger and cargo vans is a 4.8L V-8 that cranks out 279 horsepower (208 kW) and 294 lb.-ft. of torque (398 Nm).

G1500 and H1500 passenger models and H1500 cargo and conversion models, meanwhile, are powered by the 5.3L V-8. It delivers 310 horsepower (231 kW) and 334 lb.-ft. of torque (453 Nm), providing segment-leading acceleration.

A FlexFuel E85 version of the 5.3L V-8 is available. It delivers the same horsepower and torque as its gasoline counterpart, while running on E85 ethanol fuel or a mixture of E85 and gasoline. E85 comprises of 85 percent ethanol, a renewable fuel produced domestically. 

Those seeking more power can opt for the 6.0L V-8 – the segment’s most powerful V-8. It delivers 323 horsepower (241 kW) and 373 lb.-ft. of torque (505 Nm), and for 2011 features a fast-idle option, making it easier to run a host of accessories while idling at a worksite.

The 4.8L, 5.3L and 6.0L engines are part of GM’s Gen IV small-block V-8 engine family. Designed for quiet operation, these engines include:

• Special friction-reducing polymer coating on piston skirts
• Full-floating piston pins
• Damping patch on the oil pan (externally mounted)
• Timing chain tensioner
• Quieter alternator

Backing the engines’ quietness is the assurance of long-lasting performance. The engine family was validated under extreme conditions, with the 6.0L engine dynamometer-tested to the equivalent of 200,000 miles – 50,000 miles more than other engines in the family. The engines also feature many long-life engine components that can reduce maintenance intervals and costs. The iridium-tip spark plugs, engine coolant, accessory drive belt and sealing gaskets are some of these items.

Some of the stringent durability testing included cycling engines between the peak torque and peak horsepower rpm points – the equivalent of towing a heavy trailer up a steep grade – for 600 straight hours.

The Gen IV V-8 is also engineered to meet stringent emissions standards. In fact, compared to truck engines of a decade ago, the Gen IV engine family is approximately 90-percent cleaner. Cast iron exhaust manifolds matched with dual close-coupled catalytic converters help reduce cold-start emissions, which is the largest source of vehicle emissions.

Models equipped with 4.8L and 5.3L engines are matched with the Hydra-Matic 4L60 four-speed automatic transmission. The 6.0L V-8 is backed by the Hydra-Matic 6L90 six-speed automatic.

Express chassis and suspension

The Express is built on a strong, ladder-type full frame architecture. The frame features fully boxed sections for greater strength and rigidity, while extended and tapered front frame rails are used for improved crashworthiness. Also, additional tubular frame cross members are used to increase torsional stiffness.

All models feature an independent short-long arm (SLA) front suspension. A 33mm front stabilizer bar is featured on 1500-series models and a 35mm bar is used on 2500 and 3500 models. Two-stage semi-elliptic multi-leaf springs are used in the rear suspension and help locate a semi-floating axle.

Additional chassis and suspension features include:

• Power-assisted rack-and-pinion steering is featured on 1500 models.
• Hydroboost four-wheel disc brakes with ABS and dynamic rear proportioning are standard on all models.
• StabiliTrak electronic stability control is standard on all models.
• A locking rear differential is available on all models.
• 31-gallon (117.3 L) fuel tank is standard on all models (except for dedicated compressed natural gas package)
• 7,300-pound GVWR on 1500 passenger models.
• 8,600-pound GVWR on 2500 models.
• 9,600-pound GVWR on 3500 models.

Express safety and crash avoidance features

Express is equipped with a host of safety features, including head curtain side air bags. They’re standard on all passenger vans and provide a higher level of protection in the event of a side impact or a vehicle rollover. Also standard on 12- and 15-passenger models is Enhanced Technology Glass (ETG) for superior occupant retention. Additional safety features include:

• StabiliTrak is standard on all cargo and passenger models. 
• Tire pressure monitoring system is standard on all cargo and passenger models.
• Flat and convex exterior mirrors for a wider field of vision are standard on all cargo and passenger models.
• Lap and shoulder belts for the center seats are standard on all passenger models.
• Four-wheel anti-lock disc brake system with Hydroboost is standard on all models.
• Driver and front passenger air bags are standard on all models.
• Daytime Running Lamps are standard on all models.