2002 Chevrolet Express 2500 Problem Reports

Most Reported 2002 Chevrolet Express 2500 Problem Reports

Report A Problem
View:Most ReportedNewestRepairPal Verified

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.

Various electrical components under the front carpet/rubber mat may become damaged if excess water is used to clean the rear cargo area.

The tail light wiring harness in the cargo area is not protected very well. As a result it may become damaged due to normal wear a tear. This damage can causing some or all of the rear lights to stop working.

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Running the engine with a coolant/oil mix may result in engine damage. Replacing the intake manifold gasket should correct this issue.

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

The fuel pump may fail causing the engine to stall and not restart. Our technicians recommend replacing the fuel filter every 30,000 miles to help prevent undue strain on the fuel pump.

The engine may develop a misfire due to worn valve seats. This fault will cause the Check Engine Light to illuminate. Our technicians tell us the misfire may or may not be felt while driving. They further recommend that both cylinder heads be removed and thoroughly inspected and repaired as necessary.

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.

A loose or worn gas cap could be cause the Check Engine Light to illuminate.

The alternator may fail causing the battery to go dead. The charge light on the dash may or may not illuminate. The alternator may also develop an abnormal noise. A failed alternator will require replacement.