2004 Chevrolet Express 2500 Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2004 Chevrolet Express 2500

2004 Chevrolet Express 2500 Problems

"No start" Caused By Failed Fuel Pump

The fuel pump may fail causing the engine to stall and not restart.

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.

Check Engine Light and Misfire Due to Stuck Fuel Injectors

One or more fuel injectors may become stuck closed causing an engine misfire  and the Check Engine Light to illuminate. Our technicians tell us that this problem can be caused by some fuel additives. There are special procedures which may be able to restore the affected injector. If this fails the affected injector must be replaced.

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2004 Chevrolet Express 2500 Questions

Where is the thermostat located and even further, how do you change the thermostat? (2 answers)

Van has been over heating on an irregular basis with pools of coolant sporadically being left under van. Pretty sure it's a bad thermostat but fearful it's also the water pump.

I got crank with no start. (1 answer)

Changed tank and sender as well as the crank shaft sensor still crank with no start. Not sure where o look next

p0300 misfire on 2004 express 4.8l 140k. Tried about everything. Any suggestions (1 answer)

2004 Express van 4.8l with 140k miles.

Past couple years:
Hard to start after fuel fill up.
Random miss and hesitation when accelerating. Pumping throttle would cure. Then randomly again from 30 min to 7 days between.

Lately:
Missing most of the time, especially when hot. Rough idle and...

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2004 Chevrolet Express 2500 Recalls

Fuel Leak Due to Corrosion in Area Near Gas Cap

On vehicles equipped with a left side cargo door, water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe, which can cause the pipe to corrode. Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source, this could cause a fire. Dealers will install a new fuel filler neck to correct this concern. The General Motors recall number is 12166.

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.

High Mount Brake Light May Not Be Bright Enough on Van Conversions

On two vehicles, the high mount (third) brake lens may not reflect enough light to meet Federal standards. Following vehicles may not adequately see the brake lamps, increasing the risk of a rear-end crash. Quality Coaches is working with Audiovox to replace the center high-mounted brake lamp assembly. The recall began November 23, 2005. The Quality/ASA recall number is VCCBLCHV.

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2004 Chevrolet Express 2500 Reviews

GREAT PASSENGER VAN WITH OVER 100K. HAVE HAD TO REPLACE WATER PUMP TWICE. NOT SO CHEAP. ELECTRICAL WIRING SYSTEM POORLY DESIGNED ACCESS. INTERIOR LIGHT SWITCH PROBLEM ALONG WITH REAR BACK-UP LIGHT FAILURE. I REALLY LIKE THIS VAN. WITH ITS SMALL PROBLEMS.
I have had several Express vans over the years. This one and the others all had problems with the rear a/c lines leaking due to the way they are mounted. The other main problem is the side door hinges seize up due to rust, and yes I kept them lubricated. Both of these problems have been occurring for several years and are expensive repairs if completed at a dealer. These design problems sho...

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