Chevrolet Express 3500 Problems
RepairPal has identified the most common problems with the Chevrolet Express 3500 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 2004-2007 Chevrolet Express 3500 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.
The 2000-2002 Chevrolet Express 3500 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.
The throttle position sensor (TPS) on the Chevrolet Express 3500 is notorious for failure which causes:
- Check engine light
- Reduced Power message
- OBD trouble code P2135
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.
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 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.
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.
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.
A coolant leak may develop from the water pump. This can result in an engine overheating condition. A leaking water pump will require replacement.
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.
A Loose or worn gas cap may cause Check Engine Light to illuminate.
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.
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 fuel pump may fail causing the engine to stall and not restart.