Three problems related to manifold/header/muffler/tail pipe have been reported for the 2002 Chevrolet Suburban. The most recently reported issues are listed below.
After so long ignoring the smell in my cab, I decided to get it checked out at benny's exhaust in bristol, TN, and found that exhaust manifold head bolts broke off on both sides of engine. 1st bolt initially then second bolt next to it broke as well. No work has been done to motor or aftermarket parts added that would affect this part and create failure. Exhaust gas enters the underhood area sometime can be smelled inside passenger cab area. The exhaust makes a black plume up side of motor on both sides. This vehicle can not be registered in any state that has emissions testing, because it will not pass. I am forced to register it to non-testing states. Why isn't there a recall on this matter. It appears that this affects all years. What is wrong with gm, why won't they take care of this matter. After someone spends several tens of thousands on a vehicle, why isn't safety the standard gm should measure itself up too. Engineers, are you making sure planned obsolescence is built into all your vehicles. I won't buy gm no more after owning gm all my life.
Exhaust manifold bolts breaking leaving studs in the heads, heating up engine compartments, releases carbon monoxide, affects O2 sensor and catalytic converter. Will not pass emissions in some states. Gm not standing behind this 1999-2008 issue. It is a safety issue and is expensive to fix. Gm mechanics denying any such issues. Please check- in to this. Our whole fleet and our personal trucks affected by this.
Left-side engine manifold bolts broke off, causing exhaust gas to escape into the engine compartment on the opposite side of the firewall from the driver. The escaping exhaust causes a 'ticking' noise, which is what brought this to the attention of the owner (me). The vehicle is well-maintained and is never used in harsh or demanding conditions. Primary use is transporting family in urban area. There has been no prior service work that required manifold to be removed. The manifold bolts are defective. This is a serious safety and epa issue due to exhaust gases being released in the engine compartment, and the possibility of the heat from the exhaust negatively affecting sensors and other vital engine components.