2002 Chevrolet Van problems
The Chevrolet Van or Chevy Van (also known as the Chevrolet/GMC G-series vans and GMC Vandura) is a range of vans that was manufactured by General Motors from the 1964 to 1996 model years. Introduced as the successor for the rear-engine Corvair Corvan/Greenbrier, the model line also replaced the panel van configuration of the Chevrolet Suburban. The vehicle was sold both in passenger van and cargo van configurations as well as a cutaway van chassis that served as the basis for a variety of custom applications.
Produced across three generations (1964–66, 1967–70, and 1970–96), the model line was sold under a wide variety of model names under both the Chevrolet and GMC brands. The first two generations were forward control vehicles (with the engine placed between the seats); the third generation adopted a configuration placing the engine forward of the driver. The second and third generations shared powertrain commonality with the C/K pickup truck model line.
After the 1996 model year, GM retired the G-Series vans, replacing them with the GMT600-platform Chevrolet Express and GMC Savana.
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Common 2002 Chevrolet Van problems
Common Problems with the Chevrolet Van 2002:
- Fuel Filter Replacement: Some owners have found that replacing the fuel filter can help resolve starting issues. The fuel filter should be replaced approximately every 30,000 miles to ensure optimal performance and prevent issues with starting.
- Intake Manifold Gasket Leaks: Another common problem with the 2002 Chevrolet Express Van is leaking intake manifold gaskets. This issue can cause the engine to backfire and run roughly, especially after a tune-up. Replacing the intake manifold gasket can help resolve this problem, but it may require replacing other components, such as the distributor cap and rotor, plugs, wires, filters, and hoses.
- Computer Issues: Some owners have reported that their van's computer needs to be replaced after a tune-up, which can be expensive and time-consuming. In some cases, drilling holes in the computer deck can help resolve the issue, but this may not be a long-term solution.
- Fuel Pump Failure: The 1999 Chevrolet Express has the most overall complaints, with fuel pump failure being the most reported problem. The average cost to fix this issue is $3,000, with an average mileage of 25,000 miles when problems occur.
- Battery Corrosion: Corrosion on the battery can cause trouble starting the vehicle. Regular maintenance and inspection of the battery can help prevent this issue.
- Bad Timing Belt: A failed timing belt can cause engine failure, which could prevent the car from starting. Regular maintenance and inspection of the timing belt can help prevent this issue.
- Bad Starter Motor: A damaged ignition coil or bad starter motor can prevent the car from starting. Regular maintenance and inspection of these components can help prevent this issue.
In summary, the 2002 Chevrolet Express Van has several common problems, including starting issues, fuel filter replacement, intake manifold gasket leaks, computer issues, fuel pump failure, battery corrosion, bad timing belt, and bad starter motor. Regular maintenance and inspection of these components can help prevent these issues and ensure optimal performance of the vehicle.
Are Chevy Express vans reliable?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans. The average annual repair cost is $963 which means it has poor ownership costs.
How many miles do Chevy cargo vans last?
With proper maintenance, a used Chevy Express van will last up to 300 thousand miles on the original motor. There are four gasoline engines on the model to choose from: The most basic had a volume of 4.3 liters (200 hp). This is the only 6-cylinder unit for the Express model.
Why is my Chevy 1500 van not starting?
The most common reasons a Chevrolet Express 1500 won't start are a dead battery, an alternator problem, or failed starter.
How long is a 2002 Chevy Express van?
218.7 to 238.8″2002 Chevrolet Express / Length
Is Chevrolet van reliable?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans.
What is the mileage on a Chevy van?
According to Kelley Blue Book's review of the 2022 model year, the base engine for the Chevy Express is a 4.3-liter V6. This engine has an estimated EPA fuel economy rating of 16 miles per gallon (mpg) in the city and 20 mpg on the highway.
How many miles can a Chevy van last?
A well-maintained 2021 Chevy Express can last around 200,000 miles, which is similar to other full size vans like the Ford Transit. Regular annual maintenance costs are also average for a large van, at $870 per year, according to data provided by Repair Pal.
When did they stop making Chevy vans?
The Chevy Express has been around for 27 years; as of 2023, this vehicle replaced the Chevrolet van in 1996. General Motors has announced that there are plans in the work to revamp the Chevy Express for the 2027 model year. General Motors will keep this vehicle around since GM is transitioning to EV powertrains.
2002 Chevrolet Van car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Chevrolet Van problems, we found that the most common problems with these 2023 model year vehicles are:
- Tires problems
- Structure problems
- Service brakes problems
- Hydraulic problems
- Equipment problems
The graph below shows statistics for all 2002 Chevrolet Van vehicle components and the number of complaints received.
2002 Chevrolet Van complaints
The NHTSA has received 11 complaints about various vehicle components related to the 2002 Chevrolet Van.
SERVICE BRAKES, HYDRAULIC PROBLEM
- Date Of Incident: 2011-02-01
- VIN: 1GNEL19W01B
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: 2002 ASTRO VAN BECOMES DIFFICULT TO STOP . FEELS LIKE THE HYDRAULIC BOOSTER FAILS TO ENGAGE, NECESSITATING EXTREME PRESSURE TO BE APPLIED TO THE BRAKE PEDDLE TO STOP THE VEHICLE. THIS SITUATION TOOK PLACE FAIRLY OFTEN. AFTER REMOVING THE ABS FUSE THE BRAKES ARE WORKING FINE. *TR
EQUIPMENT PROBLEM
- Date Of Incident: 2007-03-26
- VIN: 1GNDV03E72D
- Components: EQUIPMENT
- Summary: I OWN A 2002 CHEVROLET VENTURE AWD. RECENTLY, I NOTICED AN OILY SUBSTANCE COMING FROM THE RIGHT, PASSENGER SIDE OF THE VAN. UPON FURTHER INVESTIGATION, I DISCOVERED THAT THE OIL WAS COMING FROM THE AIR CONDITIONER (A/C ) CONDENSER, DETERMINING THAT THE AIR CONDITIONER DID NOT WORK. IT WORKED FINE UNTIL THIS TIME. I CALLED REPAIR SHOPS, AND FOUND OUT THAT THE REPLACEMENT A/C CONDENSER WAS DESIGNED A LITTLE DIFFERENT, AND/OR THE WAY OF MOUNTING IT HAS BEEN UPGRADED. ALSO, I HAVE BEEN TOLD THAT THIS WAS COMMON ON THE PONTIAC MONTANA VANS. THE COST TO FIX IT WAS ANYWHERE FROM $975.00 TO $1175.00. NOW, IF THIS WAS A FLAW IN THE DESIGN, AND IT' WAS ILLEGAL TO VENT R-134A FREON INTO THE AIR, WHY HASN'T THIS BEEN ADDRESSED?*AK
SUSPENSION PROBLEM
- Date Of Incident: 2006-11-08
- VIN: 1GNEL19X22B
- Components: SUSPENSION
- Summary: CORROSION IN FRONT HUB BEARINGS LEADING TO PREMATURE AND ERRATIC ABS SENSOR PROBLEMS AND PULLING OF VEHICLE TO THE RIGHT. THIS OCCURS AT SLOW SPEED. GM HAS RECOGNIZED THIS PROBLEM AND HAS SELCTIVELY RECALLED CERTAIN MAKES OF AUTOMOBILES IN CERTAIN STATES. MY CHEVY ASTRO WAS NOT RECALLED. THE MECHANIC WHO REPAIRED THE PROBLEM (COST $1081) SAID THERE IS NO QUESTION IT IS THE SAME PROBLEM THAT THE RECALLED VEHICLES HAVE (INCLUDING HIS!). GM IS STONEWALLING IN ORDER TO SAVE MONEY. THIS PROBLEM HAS BEEN SHOWING UP FOR THE PAST COUPLE OF MONTHS AND WAS GETTING WORSE. *NM
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 2005-09-20
- VIN: 1GNDU23E22D
- Components: FUEL SYSTEM, GASOLINE
- Summary: ON SEPTEMBER 15, 2005 I FILLED MY GAS TANK UP FOR THE NEXT WEEK. ON SATURDAY SEPTEMBER 17,2005 I WENT TO GO TO THE STORE AND SMELLED GAS. MY HUSBAND LOOKED UNDER THE VAN AND STATED THAT GAS WAS LEAKING. I CALLED OUR MECHANIC MONDAY SEPTEMBER 19,2005 TOLD THEM WHAT WAS GOING ON. DROPPED THE VAN OFF TO THE MECHANIC TUESDAY SEPTEMBER 20,2005. UPON INSPECTION THEY NOTICED THAT THE FILL A NECK HOSE TO THE TANK AND ATTACHING HOSE IN CRACKED 80% AROUND. TO CORRECT THE PROBLEM THEY HAVE TO DROP MY ALMOST FULL TANK OF GAS AND REPLACE THE TANK AND ATTACHING PIECES. *NM
SEAT BELTS PROBLEM
- Date Of Incident: 2005-03-26
- Number Of Injuries: 5
- Crash: 1
- VIN: 1GNEL19X52B
- Components: SEAT BELTS
- Summary: WE WERE INVOLVED IN A CRASH, A DRUNK DRIVER HIT OUR 2002 CHEVY ASTRO VAN IN THE FRONT LEFT SIDE BY A DODGE DAKOTA. WE WERE TRAVELING 35 MPH, OTHER VEHICLE SPEED UNKNOWN. THERE WERE 5 RESTRAINED PASSENGERS IN THE VEHICLE, THE 2ND ROW RIGHT PASSENGER'S SEAT BELT DID NOT RESTRAIN HER DURING THE ENTIRE CRASH. SHE HAD BRUSES ON HER LEFT HIP, RIGHT BREAST, RIGHT SHOULDER AND RIGHT ARM. (THE AIR BAGS DID NOT DEPLOY). SHE WOULD UP ON THE FLOOR BETWEEN THE BUCKET SEATS WITH HER LEGS UNDERNEATH HER. THE SEAT BELTS ARE BEING REPLACED (4 ARE COMPLETE, 1 THE CHEVY DEALER IS HAVING TROUBLE GETTING THE RIGHT PART). I HAVE THE OLD PARTS IN MY POSSESSION. WE WERE UNABLE TO DRIVE THE VEHICLE FROM THE CRASH SITE, THE DAMAGES WERE APPROXIMATELY $8,000
TIRES PROBLEM
- Date Of Incident: 2003-05-12
- VIN: 1GAHG39R921
- Components: TIRES
- Summary: DRIVING CHEVROLET E3500 VAN WHEN LEFT REAR ORIGINAL EQUIPMENT FIRESTONE STEELTEX RADIAL R4S SEPARATED AND DAMAGED VAN. BODY DAMAGE TO VAN. RIGHT REAR TIRE HAS CRACK AROUND TREAD LIKE FIRESTONE WILDERNESS. *NLM
VISIBILITY PROBLEM
- Date Of Incident: 2002-09-13
- Components: VISIBILITY
- Summary: CONSUMER WANTED TO KNOW THE STATUS OF A VEHICLE OWNER'S QUESTIONNAIRE. *DT THE VEHICLE EXPERIENCED A PROBLEM WITH THE MIRRORS.*JB
TIRES PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1GNDM19W4VB
- Components: TIRES
- Summary: WHILE TRAVELING ABOUT 60MPH ON HIGHWAY, VEHICLE STARTED TO VIBRATE. CONSUMER WAS ABLE TO PULL OVER TO THE SHOULDER. RIGHT REAR TIRE TREAD SEPARATED FROM WHEEL. FIRESTONE, P215/70R DEALERSHIP IS AWARE OF PROBLEM.*AK FIRESTONE REPLACED ALL FOUR TIRES. *SLC
STRUCTURE PROBLEM
- Date Of Incident: 2002-07-20
- VIN: 1GNDV13E020
- Components: STRUCTURE
- Summary: THE DRIVER SIDE SLIDING DOOR OPENED ALL THE WAY PASS THE GAS TANK OPENING. *YH
STRUCTURE,LATCHES/LOCKS/LINKAGES PROBLEM
- Date Of Incident: 2002-04-14
- Number Of Injuries: 1
- Components: STRUCTURE,LATCHES/LOCKS/LINKAGES
- Summary: THE PASSENGER WAS SITTING ON THE RIGHT SIDE OF THE CAR, IN THE SECOND ROW, SHE WENT TO OPEN THE SIDE DOOR AND HER HAND WAS ON THE HANDLE, THE ELECTRIC DOOR OPENED, LODGING HER ELBOW INTO THE BACK OF THE OPENING OF THE DOOR, SHE BROKE HER WRIST IN THREE PLACES. DEALER FOUND A MALFUNCTION. *YD
TIRES PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 3GNEK13T92G
- Components: TIRES
- Summary: CARS ARE BEING SHIPPED FROM FACTORY WITH 17" TIRES AND ONLY 16"SPARES. I BELIEVE THIS TO BE A SERIOUS SAFETY ISSUE. USING THE SPARE TIRE ( ROTATING AT A FASTER SPEED THAN THE OTHER TIRES ) COULD CAUSE AN ACCIDENT. ALL OTHER MANUFACTURERS USE THE SAME SIZE SPARE AS ALL OTHER TIRES ON THE VEHICLE!
Additional sources
More sources of information about 2002 Chevrolet Van problems:
Q&A: Common Problems with 2002 Chevy Express 3500 (5.7 Engine)
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Mar 10, 2023 ... I'm working on my new (to me) 2002 Astro right now - right blinker is double fast, but both front and back blinkers are blinking. Left is fine.
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