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2004 Chevrolet Silverado 2500 HD CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Air Bag System Precautions -> General Motors Corp. -> Disarming -> 1990 -> 1990-93 -> 1990-95 -> 1990-97 -> 1991 -> 1991-93 -> 1991-94 -> 1991-95 -> 1992-93 -> 1992-99 -> 1993-2002 -> 1993-94 -> 1993-98 -> 1994 -> 1994-2002 -> 1994-95 -> 1994-96 -> 1994-98 -> 1995-2002 -> 1995-96 -> 1995-97 -> 1995-98 -> 1995-99 -> 1996 -> 1996-2001 -> 1996-97 -> 1997 -> 1997-2002 -> 1997-98 -> 1997-99 -> 1998-2000 -> 1998-2002 -> 1998-99 -> 1999 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 2000-02 -> 2001-02 -> 2002 -> 2003 -> 2003-04 -> 2003-04 Except Malibu Maxx -> Achieva & Skylark -> Alero -> Astro & Safari -> Aurora -> Avalanche -> Aveo -> Aztek & Rendezvous -> Beretta & Corsica -> Blazer, Jimmy, Sonoma & S-10 -> Bonneville, Eighty-Eight, LeSabre, LSS, Ninety-Eight & Regency -> Bravada, Envoy, Rainier, SSR & TrailBlazer -> C/K Series -> Camaro & Firebird -> Canyon & Colorado -> Caprice, Custom Cruiser & Roadmaster -> Catera -> Cavalier & Sunfire -> Century -> Corvette -> Coupe -> CTS -> Cutlass -> Cutlass Ciera & Cruiser -> Cutlass Supreme -> DeVille -> Eldorado -> Escalade -> Express, G Series & Savana -> Fleetwood -> Grand Am -> Grand Prix & Intrigue -> Impala -> ION -> L-Series -> Light Trucks & Vans -> Lumina -> Lumina APV, Montana, Silhouette, Trans Sport & Venture -> Malibu -> Malibu Maxx -> Metro -> Monte Carlo -> Park Avenue -> Passenger Cars -> Prizm -> Reatta, Toronado & Trofeo -> Regal -> Riviera -> S-Series -> Sedan -> Seville -> Sierra & Silverado -> SRX -> Storm -> Suburban, Tahoe, Yukon & Yukon XL -> Tracker -> Vibe -> VUE -> XLR -> Zone 1 -> Zone 10 -> Zone 12 -> Zone 2 -> Zone 3 -> Zone 4 -> Zone 5 -> Zone 6 -> Zone 7 -> Zone 8 -> Zone 9 -> Zones 1 & 7 -> Zones 2 & 6 -> Zones 5 & 9 -> Zones 7 & 9
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
Passenger Cars
The Sensing and Diagnostic Module (SDM) can maintain enough voltage to cause air bag deployment for up to 10 minutes after the ignition is turned Off and the battery is disconnected. Servicing the Supplemental air bag (SIR) system during this period may result in accidental deployment and personal injury.
Achieva & Skylark
1994-96
- Ensure front wheels are in straight-ahead position.
- Turn ignition switch to LOCK position.
- Remove AIR BAG fuse from fuse block.
- On 1995 models, remove lefthand sound insulator panel to ac...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Power Brake Units -> Delco Brake Booster -> Power Brake Unit Service
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
The power brake unit is n...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Gasoline Engines Except Equinox, Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Uplander & Vue (2004-06) & 2004-06 Envoy, Rainier & TrailBlazer -> Returnless Fuel System
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS
Returnless Fuel System
On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Pri...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
DRIVESHAFT, Replace -> Front -> Rear
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
Front
Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the propeller shafts, wheel drive shafts, pinion flanges and output shafts
Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly.
- Raise and support vehicle.
- Remove transfer case shield, if equipped.
- If equipped with double clamp style boot, remove clamp at transfer case by prying up ex...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Starter, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Disconnect starter battery positive cable and wiring harness.
- Remove starter motor mounting bolts, washers, shims, starter and heat shield from vehicle.
- Rever...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 1999-2007 Silverado, Sierra, 2000-07 Denali, Suburban, Tahoe, Yukon, Yukon XL, 2001-07 Escalade & 2002-07 Avalanche
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Remove the righthand instrument panel hush panel.
- Remove the A/C and heater modul...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
General Motors Corp./Saturn Trucks -> Check Fuel Cap Lamp ->
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. I...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS
- Drain radiator coolant into suitable container.
- Remove upper and lower radiator hoses.
- Remove mounting bolts and lower fan shroud.
- Remove engine vent hose and surge take hose.
- Disconnect eng...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL
- Rotate tensioner to release belt tension using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley, then remove belt.
- Route be...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
Component location diagrams for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1990+.
Camper Wiring Harness Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Components on diagram: |
Vehicle Interface Unit Diagram for 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S.
2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Wiring Diagram Components on diagram: |
2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
OEM TSB listings for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1985+.
Document: 6.6L LB7, LLY Duramax Diesel Engine Cylinder Head Gasket Missing Thickness Grade Markings-Inspect Block for Stampings Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Auto Systems: |
Document: Information on 6.6L LBZ, LB7, LLY Duramax Diesel Engine Cylinder Head Gasket Design Change-New Head Gasket Part Numbers and Head Bolt Torque Specifications Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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