Chevrolet Express 2500 Repair and Maintenance

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

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 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.

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Certain vehicles equipped to run on compressed natural gas are being recalled because the high pressure natural gas regulator could develop a leak, increasing the risk of a fire or explosion. Dealers will replace the natural gas regulator to correct this concern.

Certain vehicles are being recalled because if a crash were to occur not requiring deployment of the front airbags, the head of an unbelted front seat passenger could hit the instrument panel, resulting in personal injury because the panel may not sufficiently absorb the impact. As of this writing, General Motors is still working on a remedy for this concern.

IMPCO Technologies installed a compressed natural gas (CNG) fuel system as original equipment on certain 2011-2013 full size GM vans. These vans are being recalled because the electrical connector on the fuel shut off solenoid can corrode, causing the connector to overheat, increasing the risk of a fire. Both dealers and fleet operators will be performing the necessary updates to correct this concern. The corrections include: replacing the fuel shut off solenoid, fuel pump fuse, and adjusting the wiring routing.

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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...

I have the Diesel version and get almost 20 mpg empty on the highway and 16 mpg highway when towing our 7000# work trailer. The vent control on the heating system would not change from vent to defrost. The dealer said it was the vacuum pump which was repaired but is now making strange noises. Of course it started at 36,000 miles right after the bumper to bumper warranty expired. Only other ...

have 115000 miles not one problem

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