Chevrolet Express 2500 Problems

RepairPal has identified the most common problems with the 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
×
Choose your vehicle
21
Known Problems

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.

The EVAP canister vent valve or valve solenoid wiring may fail causing illumination of the check engine light, setting code P0446, and problems filling the tank with fuel.

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.

The 2000-2002 Chevrolet Express 2500 has a known issue with the air pump check valve which causes illumination of the check engine light. There are no notable symptoms, but the vehicle will not pass state inspection or smog testing. 

When the valve fails, it sticks closed, and the computer sets the code P1416. Replacement of the check valve is the only fix, as the valve is not serviceable. 

This page can provide more information about the air pump check valve. 

The throttle position sensor (TPS) on the Chevrolet Express 2500 is notorious for failure which causes:

This issue is related to the throttle position sensor, and can be caused by faulty wiring to the TPS, bad connection at the TPS, or a failed TPS.

To correct this issue, the wiring harness, connector, and throttle position sensor must be inspected, tested, and/or replaced. The most common cause is a faulty TPS.

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

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.

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

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.

A Loose or worn gas cap may cause Check Engine Light to illuminate.

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.

The spark plugs should be replaced every 100,000 miles. Our technicians recommend replacing the spark plug wires also at this time.

Vehicles equipped whit a 4 speed automatic transmission may develop a harsh 1-2 shift and/or illumination of the Check Engine Light with code P1870 stored. This can be caused by wear of the bore for the TCC isolator and regulator valves in the valve body. This condition does not commonly occur until the transmission reaches normal operating temperature. If the valve body is worn, replacement will be necessary to correct this concern.

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

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.

Extended life coolant may become contaminated and require cooling system service before the recommended 100,000 miles.