2002 Chevrolet G30

The 2002 Chevrolet G30, part of the G-series vans, was a workhorse known for its reliability and spaciousness, making it popular for conversions into RVs, ambulances, and work vans. The 2002 model year came with several engine options including a 4.3L V6, a 5.0L V8, a 5.7L V8, and a 7.4L V8. The 5.7L V8 produced approximately 255 horsepower and 330 lb-ft of torque. Owners generally appreciated the G30’s robust build and simple mechanics, making it relatively easy to maintain and repair. However, some common complaints included issues with rust, particularly in areas prone to salt exposure, and the van’s somewhat dated interior and fuel economy compared to more modern vehicles.

Engine

5.7L V8 (L31)

• Intake Manifold Gasket Leaks
  • Description/Symptoms: Coolant leaks externally around the intake manifold, sometimes causing overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found
• Fuel Injector Failure (Specifically, the Multec Fuel Injectors)
  • Description/Symptoms: Rough idling, misfires, poor fuel economy, and difficulty starting. Can be more pronounced when the engine is warm.
  • Solution: Replace the failed fuel injector(s) with updated injectors. Replacing all injectors is recommended for preventative maintenance.
  • Estimated Cost to Fix: $100 - $300+ per injector (parts and labor)
  • Recalls: None Found

7.4L V8 (L29)

• Distributor Issues
  • Description/Symptoms: Rough running, misfires, and stalling due to worn distributor gear or a faulty distributor module.
  • Solution: Replace the distributor gear or the entire distributor assembly.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Transmission

4L80E (All Engines)

• Shifting Problems
  • Description/Symptoms: Harsh shifting, slipping between gears, failure to shift, and general erratic behavior, primarily when hot.
  • Solution: A complete transmission rebuild or replacement is the ultimate fix. In some cases, a valve body replacement may resolve the problem.
  • Estimated Cost to Fix: $1500 - $3500+ (for rebuild or replacement), $500 - $1000+ (for valve body replacement)
  • Recalls: None Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking or rattling noises from the front end, especially when going over bumps or turning. Uneven tire wear.
  • Solution: Replace the worn ball joints. It is recommended to replace them in pairs (both upper or both lower).
  • Estimated Cost to Fix: $200 - $500+ per ball joint (parts and labor)
  • Recalls: None Found
• Leaf Spring Sagging/Breakage
  • Description/Symptoms: The rear of the van sits lower than normal. Reduced ride quality and handling. Broken or cracked leaf springs are visible.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $400 - $1000+ per side (parts and labor)
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, slow cranking, battery light on the dashboard, and eventually, the vehicle won’t start.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found
• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights not working, gauges malfunctioning, or the engine cutting out. Caused by corrosion or damaged wiring, particularly in areas exposed to the elements.
  • Solution: Inspect and repair or replace damaged sections of the wiring harness.
  • Estimated Cost to Fix: Highly variable, depending on the extent of the damage. $100 - $1000+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust along the rocker panels, wheel wells, door bottoms, and frame. Common in areas with road salt.
  • Solution: Rust repair or panel replacement. Preventative measures like rustproofing can help slow down the process.
  • Estimated Cost to Fix: Highly variable, depending on the severity and location of the rust. $200 - $2000+ per area
  • Recalls: None Found

Interior

• Dashboard Cracks
  • Description/Symptoms: Cracks appearing on the dashboard due to age and sun exposure.
  • Solution: Dashboard replacement or installation of a dashboard cover.
  • Estimated Cost to Fix: $200 - $800+ (for replacement), $50 - $200+ (for cover)
  • Recalls: None Found
• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaching from the backing board and sagging down.
  • Solution: Headliner replacement.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2002 Chevrolet G30 is generally a reliable van, but like any vehicle of that age, it is prone to certain issues. Engine problems such as intake manifold gasket leaks and fuel injector failures in the 5.7L and distributor issues in the 7.4L V8 are common, and can range from a few hundred to over a thousand dollars to repair. Transmission issues with the 4L80E can be very costly, potentially requiring a complete rebuild or replacement. Rust is also a significant concern, especially in areas with harsh winter conditions. Overall, while the G30 is a capable vehicle, potential buyers should be prepared for the possibility of repairs, especially given its age. Addressing these common problems can help keep the van running smoothly for many years.