Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chevrolet Silverado owners, lightly cleaned up (personal details are redacted by NHTSA).
On oct 13, 2004 my 2002 Chevy truck, 2500hd 4wd crew cab, was struck head on by another vehicle and a fire was started under the hood on the drivers side. This fire was extinguished several times by small extinguishers but kept coming back until there was no extinguisher left. The result was the total distruction of this vehicle. My family and I and a friend (4) were in this vehicle and fortunately got out prior to the truck being totally engulfed by fire. We recognize that if anyone of use were pinned in this vehicle more than we were, we would not be here today. The truck was totally burned up in 5-10 minutes before the fire department arrived. We are concerned that there is no safety mechanism to shut down the fuel pump after a head-on collision like this one. Everyone I talked to told me nothing could be done because you were not seriously burned. …
I had just driven 15 miles to on the expressway, I stopped at a store for a couple of minutes. When I went back to the truck, I didn't see the fluid under it, but got in and started the truck. At that time I was accelerating slowly to pull out of a parking spot. About that time a pedestrian stepped off the curb in front of me. I hit the break and it went to the floor! I missed the pedestrian and coasted to the end of the parking lot where I tried to apply the emergency break, that also failed! A concrete curb allowed me to stop the vehicle without incident. I had the vehicle towed to 2 garages before I could find one to repair it at a cost of just under $900.00.
Dt*: the contact stated while driving at no particular speed, the engine ran rough. The vehicle was taken to an independent repair shop for inspection and the mechanic determined the fuel injectors were blocked. The injectors were changed; however, the problem persisted. The vehicle was taken back to the repair shop where the injectors were cleaned. Again, the problem was apparent and the vehicle was taken back to the mechanic. During the last inspection, the mechanic determined the fuel lines were corroded due to road salt corrosion. The fuel lines were replaced and the problem was corrected.
Hi this is the second set of the fuel injector on this diesel engine,I talk to the different mechanic on dealers an privet shops and ask what is this problem and say is because the fuel,the used,how you drive,etc but no body say what is the reason, my problem is this injector set is not like replace like a set the spark plugs on gas engine is much money $5600, and I not the only person, I check online many trucks of this get this problems, please help as, the company make this truck whit this problems and people like me used for work and is not fear.
2002 Chevrolet 2500hd duramax fuel injector failure. Seems to be associated with leaking at 'test port' on injectors. Appears to be a global problem with this engine. Occurs at around 50-70,000 miles. Chevrolet will not answer as to whether they plan a recall or not. When the injectors leak, the diesel fuel enters the engine block, causing loss of oil pressure, loss of fuel mileage, oil leaks, loss of power, and significant amounts of diesel fuel leakage. Chevrolet has these parts back ordered as a result of the magnitude of the problem.
I had two inside door panel replaced already. These two things were fixed from the engine compartment, it gets worse when it is colder. Fuel gauge is inaccurate and jumps around when truck is not in a moving gear. I am very upset about the last two, because Chevy says the truck is working within "normal Chevy parameter". I have asked many mechanics and they say either one should be happening. The date below is an approximate time the last two started. I also have had it in twice for both of these problems.
Tl* the contact owns a 2002 Chevrolet Silverado. While driving at 65 MPH, the contact noticed that the vehicle would not accelerate forward. The vehicle was taken to the dealership where the contact was informed that the fuel injectors needed to be replaced. Five years prior to this failure, the contact had the fuel injectors replaced. The failure mileage was approximately 170,000. The current mileage was approximately 173,000.
On 26 September 2011 said vehicle had to have all brake lines and other brake parts replaced due to excessive rust/rusting out at 71,012 well maintained miles at a cost of $1300.00 plus. On 30 December 2014 said vehicle had to have all fuel lines and fuel filler tube replaced due to excessive rust/rusting out at 90,790 well maintained miles at a cost of $1800.oo plus.
Many of the problems took several times in the shop to fix. The castrophic failures in the engine & transmission have never been fixed. The truck has lunging, dead spots & surges & the transmission clunks (shifts hard, jerky) the auto May or May not accelerate on demand & will later accelerate when you need to apply the brakes.
Dt: consumer states: the fuel return lines and fuel rails when they come apart the diesel and oil mix together and shoots out and coats the rear windshield. Also, coats the sides of the truck and all over the tailgate in very large amounts. This was 3rd time that took the vehicle to dealer and had it fixed.
Related recalls
Fuel system, other › Delivery
Some 2wd and 4wd pickup trucks, converted to either dedicated or bi-fuel compressed natural gas (cng) fuel usage, were assembled with a throttle cable that can contact and rub through the flexible pressurized fuel line creating a pinhole leak of natural gas to the atmosphere.
Remedy: Dealers will secure the throttle cable to eliminate the possibility of contact with the cng fuel line. The cng fuel line, throttle cable, and cruise control cable are also to be inspected and replaced if necessary.
Fuel System complaints in other Silverado years
Frequently asked questions
How common are fuel system problems on the 2002 Chevrolet Silverado?
NHTSA has 23 complaints about the fuel & propulsion system of the 2002 Chevrolet Silverado, 3% of the model year's 710 complaints. The component named most often is fuel injection system (5 mentions).
Is there a recall for 2002 Chevrolet Silverado fuel system problems?
Yes — NHTSA recall 03V-435 (delivery, Nov 3, 2003). Recall repairs are free at authorized dealers.
At what mileage do 2002 Chevrolet Silverado fuel system problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 26% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 3 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.