Chevrolet Express 3500 Blower Motor and Check Engine Light Repair in Kirkland, WA: Melted Resistor Plug and a Plugged Vapor Canister

This 2012 Chevrolet Express 3500 van came into our Kirkland shop at 192,534 miles with two problems to check: the blower was inoperative and the check engine light was on. Each one came down to more than one failed part.

The blower

The blower motor would kick on, but it was noisy. We removed it and measured its resistance, which was excessive, and the bearing was making noise. The plug on the blower motor resistor was melting.

We replaced both the blower motor and the blower motor resistor (control module) with genuine GM parts. After that, the system operated as intended. More on our heating and A/C service.

The check engine light

We connected our diagnostic equipment and ran a fault survey. The faults were in the evaporative emissions (EVAP) system, which captures fuel vapor from the tank and feeds it back to the engine to burn.

The vent solenoid was loud and rattled. The purge valve was leaking into the intake instead of sealing. When we removed the vapor canister, it was plugged and not letting fuel fill properly.

We installed a new vapor canister, canister vent valve, purge valve and gas cap, cleared the codes, and drove the van to a fuel station. The tank filled to full with no problems. We also added fuel injector cleaner to the tank. See our engine diagnostics page for how we track down check engine lights.

The rest of the visit

Both rear shock absorbers were leaking, so we replaced them with KYB Gas-a-just shocks (steering and suspension repair). We serviced the rear differential: cover off, housing and gasket surface cleaned, new gasket, cover torqued to spec, and a fill of synthetic 75W-90 gear oil. The visit also included an oil and filter change with a tire rotation, brake check, fluid top-off and our multi-point inspection.

The work performed

• Blower motor and resistor: $350–$600.

• EVAP repair (canister, purge valve, vent valve, gas cap) with diagnosis: $700–$1,100.

• Rear shocks: $250–$450.

• Rear differential service: $150–$300.

• Oil service with inspection: $125–$225.

What else the inspection found

The inspection found the hydroboost (the brake booster that runs off power steering pressure) leaking. It wasn’t quoted or repaired on this visit.

The brake master cylinder and hydroboost area, where the inspection found the hydroboost leaking.

Everything else checked out: brakes 7mm front and 9mm rear, tires 6/32” front and 7 to 11/32” rear, and the battery tested good at 576 CCA against a 600 CCA spec.

What it cost

The visit landed in the $1,800–$2,600 range, completed October 2026. That covers the blower repair, the EVAP diagnosis and repair, the rear shocks, the differential service and the oil service.

That range reflects a completed historical project, not a current quote.

Questions about this job

Why replace the resistor if the blower motor was the bad part?

Both were bad. The motor had excessive resistance and a noisy bearing, and the resistor’s plug was melting.

Why replace three EVAP parts for one check engine light?

Each one failed its own check: the vent solenoid rattled, the purge valve leaked into the intake, and the canister was plugged. A full tank of fuel afterward went in without trouble.

Was the hydroboost leak fixed?

No. It was noted on the inspection but not quoted or repaired on this visit.

Do you work on commercial vans?

Yes. More on our Chevrolet repair in Kirkland.

Prepared from our job records for this vehicle: the repair order and technician notes, the multi-point inspection with photos, the parts list and the final invoice.