On several occasions with the truck there have been significant amounts of smoke bellowing from the exhaust. In some cases, other autos believe the vehicle was on fire. Injectors have been found to be faulty on three occasions requiring replacement at significant costs. Smoke from the exhaust is due to the faulty injectors not allowing fuel into the engine so as a result the engine is burning only oil and no diesel fuel. Engine is exposed to excessive heat and could start on fire.
The worst 2004 Chevrolet W4500 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Fuel system1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Fuel system1
Recalls 1
Fuel system, diesel: storage: tank assembly
- What is wrong
- On certain trucks equipped with rpo ik9, due to insufficient durability and testing, the fuel switching manifold solenoids lack water or salt intrusion resistance, which can lead to failure of one or more solenoids. Fuel switching manifold solenoid failure will cause incorrect fuel delivery resulting in fuel overflow from the fuel filler neck.
- Risk
- Overflow fuel may result in high amount of diesel fuel leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
- Remedy
- Dealers will replace the solenoid valve assembly with an improved assembly including additional detection circuit and enhanced water resistance free of charge. The recall began on october 27, 2005. Owners may contact isuzu at 1‑800‑255‑6727.
Recall number 05V168000 · Recall details
Technical service bulletins for the 2004 Chevrolet W4500 80
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- Unknown or other
- Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles
- GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities
- This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves...
- This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as...
- This Warranty Administration bulletin provides retail and wholesale service personnel with the...
- This bulletin provides information for electrical ground repairs using new General Motors replacement...
- This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake...
- This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil...
What 2004 Chevrolet W4500 owners say
Most recent owner complaints, unedited.
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Questions about the 2004 Chevrolet W4500
Is the 2004 Chevrolet W4500 reliable?
Owners have filed 1 complaint about the 2004 Chevrolet W4500, close to a typical W4500 model year.
What is the most common problem with the 2004 Chevrolet W4500?
Fuel and propulsion system, with 1 complaint.
How many recalls does the 2004 Chevrolet W4500 have?
1 recall, covering fuel system, diesel.
Was there a recall on the 2004 Chevrolet W4500 fuel system?
Yes, 1 recall: 05V168000. Check your VIN to see if your car still needs the free repair.
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