2004 Chevrolet Express 2500 Problems
RepairPal has identified the most common problems with the 2004 Chevrolet Express 2500 as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.Refine by vehicle
The fuel pump may fail causing the engine to stall and not restart.
The 2004-2007 Chevrolet Express 2500 has known issues with the EVAP system, a part of your emission control system.
To correct the issue, the EVAP canister vent valve, solenoid, and wiring must be inspected. The most common fix is replacement of the wiring connector or replacement of the vent valve assembly.
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.
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.
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.
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.