2004 Chevrolet Express Fuel system Problems
- Complaints
- 4about this part
- Share
- 19%of 21 total for the year
- Median mileage
- 19,250miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 4 complaints about the fuel system of the 2004 Chevrolet Express, 19% of the 21 complaints for this model year. Where a mileage was given, the median is 19,250 miles. 1 recall campaign on record is filed under a similar system.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Our 2004 chevy Express van stalled serveral(12) times within a 14 mile distance on the interstate in denver, co. The wife was able to get it home, and we contacted the local chevy dealer (stevenson chevy, golden co.) the service advisor advised us that chevy is having a problem with fuel pumps overheating and is working the problem. No recall has been issued for the fuel pump problem from chevy. Yes, the fuel pump was replace at sevenson chevy in golden, co on 21 july. This is our second occurance of a fuel pump failure in a new chevy vehicle. …”
NHTSA complaint #10129686, filed 2005-07, 19,250 miles“Three times our vehicle engine has abruptly stopped running in crowded interstate traffic, endangering the lives of us and occupants of adjacent vehicles. The first was august 7, 2004 on interstate 40 near kingman az. Our first thought was that we ran out of gas, but the gauge registered !/4 full and when we added gas it took only 22.8 gallons (31 gallon tank). The second was may 23, 2005 on interstate 25 passing through colorado springs co. The gas tank was 3/4 full. Fortunately, we were able to coast into the right lane and off to the right shoulder without causing an accident. …”
NHTSA complaint #10127644, filed 2005-07, 10,875 miles“NHTSA Campaign Number: 12V388000. I have this problem. A leaking fuel line due to corrosion. I drive in the Cascade MT's of Washington state. my line now leaks excessively on fill up.”
NHTSA complaint #11454777, filed 2022-03“The contact owns a 2004 Chevrolet Express. While the vehicle was stationary, fuel spilled onto the ground. It was diagnosed that the filler neck was corroded. The vehicle was not repaired. The manufacturer was made aware of the issue. The failure mileage was 148,000. Updated 04/11/2017”
NHTSA complaint #10925238, filed 2016-11, 148,000 milesRelated recalls
- 12V388000Aug 8, 2012General Motors (GM) is recalling certain model year 2003-2004 Chevrolet Express and GMC Savana vehicles, equipped with a left side cargo door, and originally…Covers: Chevrolet Express 2003–2004, GMC Savana 2003–2004
Related service bulletins
- 11004761Jun 28, 2024This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or…
- 10209741Mar 22, 2022This service bulletin provides the technician with additional information on fuels, fuel additives and fuel management.
- 10209734Mar 22, 2022This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
- 10208027Jan 14, 2022This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester…
- 10199281May 25, 2021This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or…
- 10190437Mar 30, 2021This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible…
- 10176607May 8, 2020This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank…
- 10176310May 8, 2020This Preliminary information communicates the use of Winter grade fuel during the warm months of 2020 and the potential rivability issues that it can cause. The ongoing…
- 10171878Jan 2, 2020This informational bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended…
- 10160637Apr 4, 2019This Preliminary Information communication provides information to the technician about a customer?s request to remove or disable the Bi-Fuel Compressed Natural Gas system…
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2021 | 4 | 31% |
| 2020 | 1 | 6% |
| 2016 | 1 | 7% |
| 2015 | 1 | 13% |
| 2014 | 4 | 29% |
| 2013 | 4 | 18% |
| 2012 | 2 | 15% |
| 2011 | 3 | 25% |
| 2010 | 1 | 7% |
| 2008 | 2 | 14% |
| 2005 | 2 | 9% |
| 2004 | 4 | 19% |
| 2003 | 11 | 19% |
| 2002 | 5 | 9% |
| 2001 | 5 | 11% |
| 2000 | 5 | 6% |
| 1999 | 1 | 1% |
| 1998 | 2 | 9% |
| 1997 | 3 | 10% |
| 1996 | 3 | 20% |
Other parts of the 2004 Chevrolet Express
6 complaintsSeat belts
3 complaintsSteering
2 complaintsBody and structure
2 complaintsAir bags
1 complaintsElectrical system
1 complaintsEngine
1 complaintsEngine cooling
1 complaintsSuspension
1 complaintsTransmission and drivetrain
1 complaintsVisibility (wipers, defrost, mirrors)
1 complaints
← All problems reported for the 2004 Chevrolet Express
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology