2004 Chevrolet Silverado 2500 HD REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

Auto Parts Search


2004 Chevrolet Silverado 2500 HD CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

Help me findSearch

Select Section

Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Chevrolet Silverado 2500 HD car and truck repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Chevrolet Silverado 2500 HD automobile. Try the Automotix DIY solution today!
DIY REPAIR SAMPLES > CONTINUE EXPLORING >
Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Chevrolet mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 2004 Chevrolet Silverado 2500 HD vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Component Replacement & Adjustment -> Sierra & Silverado -> Technical Service Bulletins -> 2003 Sierra & Silverado -> 2003-04 Sierra & Silverado -> 2004 Sierra & Silverado -> Air Conditioning Inoperative/Intermittent, Blows Warm Air -> Blower Motor Runs Continuously After Vehicle is Turned Off -> Underhood Rattle Noise Heard On Acceleration
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

Underhood Rattle Noise Heard On Acceleration

2003-04 Sierra & Silverado

On some of these models there may be an underhood rattle noise heard on acceleration or a sudden loss of air condition system performance.

This condition may be caused by liquid slugging of compressor. This condition may cause an internal failure in compressor.

To correct this condition, proceed as follows:

  • Open hood and inspect compressor for damage and to see if it is seized.
  • Ensure serpentine belt is not damaged or missing.
  • If com...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD A/C & HEATER SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Power Brake Units -> Delco Brake Booster -> Power Brake Unit, Replace -> Astro, Avalanche, Escalade EXT, Safari, Sierra, Silverado & SSR -> Aztek & Rendezvous -> Blazer, Bravada, Envoy, Jimmy, Rainier & Trailblazer -> Canyon, Colorado, Sonoma & S10 -> Equinox & Torrent -> Escalade, HHR, Suburban, Tahoe & Yukon -> Express & Savana -> Hummer H2 -> Hummer H3 -> Montana, Silhouette & Venture -> Relay, Terraza, SV6 & Uplander -> SRX -> Vue
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Aztek & Rendezvous

  • Remove coolant reservoir, then relieve fuel system pressure as follows:
    • Loosen fuel filler cap to discharge tank pressure.
    • Connect fuel pressure gauge tool No. J-34730-1A, or equivalent, to fuel pressure connection. Wrap shop towel around connection while connecting fuel pressure gauge in order to avoid fuel spillage.
    • Install bleed hose into an approved container and open valve in order to bleed fuel system pressure.
    • Drain any fuel remaining in fuel pressure gauge into suitable container.
  • Remove cruise control cable from module, then disconnect electrical ...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD BRAKE SERVICE PROCEDURES

FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 2004-06 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

Light Duty Emissions

Normal Service

Service as required

Severe Ser...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD FUEL FILTER REPLACEMENT PROCEDURES

DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.

Disassemble

  • Support propeller shaft in a line horizontal with table of a press.
  • Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
  • On models equipped with external snap ring retainers, proceed as follows:
    • Disassemble snap rings by ...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES

STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Starter, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

  • Disconnect battery ground cable.
  • Remove mounting bolts and engine shield, if required.
  • Remove mounting bolts and oil pan skid plate, if required.
  • Remove righthand transmission cover bolt.
  • Remove front axle mounting bracket nut, then position front axle mounting bracket bolt until tip is flush with support bushing. Do not remove bolt.
  • Remove mounting bolts and slide starter forward until it clears transmission.
  • Disconnect oil level sensor electrical connector.
  • Remove start...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD STARTER & ALTERNATOR REPLACEMENT PROCEDURES

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...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES

MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

General Motors Corp./Saturn Trucks -> Change Oil, Change Oil Now Or Change Oil Soon Lamp & Messages -> 2001-04 Sierra & Silverado
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

These models are equipped with an oiling system indicator lamp which will flash if the oil level drops below a safe point or will remain lit when the oil and filter are ready to be changed.

After changing the oil and filter, reset the monitor by proceeding as fol...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD MAINTENANCE LAMP RESET PROCEDURES

RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Lower

  • Drain cooling system into a suitable container.
  • Separate mass airflow (MAF)/intake air temperature (IAT) sensor assembly and air inlet tube by loosening hose clamp.
  • Disconnect radiator inlet hose clip from air cleaner outlet duct.
  • Remove air cleaner outlet duct.
  • Reposition radiator outlet hose clamp at radiator.
  • Remove radiator outlet hose from radiator.
  • Reposition hose clamp from water pump.
  • Remove radiator outlet hose from water pump and from vehicle.
  • Reverse procedure to install.

Upper

  • D...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD RADIATOR & HOSE REPLACEMENT PROCEDURES

SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

  • Rotate tensioner counterclockwise, using suitab...

CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD SERPENTINE BELT SERVICE PROCEDURES

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+.

Sunload Sensor/Daytime Running Lamp,Ambient Light Sensor Diagram for 2004 Chevrolet Silverado 2500 HD  6.0 V8 GASSunload Sensor/Daytime Running Lamp,Ambient Light Sensor Diagram for 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Components on diagram:
  • Sunload Sensor
  • License Lamps w/o Bumper Diagram for 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESELLicense Lamps w/o Bumper Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    Components on diagram:
  • License Lamp
  • Frame
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD PARTS/COMPONENTS LOCATION DIAGRAMS!

    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 Diagram2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Wiring Diagram

    Components on diagram:
  • Generator
  • Auxiliary Battery Relay
  • 2004 Chevrolet Silverado 2500 HD  8.1 V8 GAS Wiring Diagram2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS Wiring Diagram

    Components on diagram:
  • Instrument Panel Cluster
  • Inflatable Restraint Sensing And Diagnostic Module
  • Seat Belt Switch Driver
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD WIRING DIAGRAMS!

    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:
  • Diesel Engines
  • Document: Revised General Motors New Vehicle Tire Warranty Program
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Wheels, Tires, Wheel Bearings, Seals, Hubs
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD TECHNICAL SERVICE BULLETINS!

    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

    CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD SPECIFICATIONS DATA!

    Shop online for auto body parts, engines, wheels, lights...

    Click here to view more details about 2002 Chevrolet Silverado 2500 HD Bumper, Front2002 Chevrolet Silverado 2500 HD Bumper, Front.

    Source: Auto Body Parts Store

    $184.34

    Click here to view more details about 2005 Chevrolet Silverado 2500 HD Mirror, Driver Side2005 Chevrolet Silverado 2500 HD Mirror, Driver Side.

    Source: Auto Body Parts Store

    $76.67

    Click here to view more details1972 Chevrolet Chevelle Door Mirror LH Or RH, Door Mirror Driver Side Or Passenger Side; With Mount Kit Without Bowtie, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $23.50

    Click here to view more details about 1985 Chevrolet C20 Pickup V8, 5.7 L, 350 CID Rebuilt Engine1985 Chevrolet C20 Pickup V8, 5.7 L, 350 CID Rebuilt Engine, Flat lifters, 4-bolt main., Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,187.00

    Click here to view more details2011 Chevrolet Silverado 2500 HD Used Air Cleaner Assembly, 6.0, AUTO, 4X4 6.0L, Very Good.

    Source: Used Auto Parts Store

    $150.00

    Click here to view more details2010 Chevrolet Silverado 2500 HD Used Air Flow Meter/Sensor, 4.3, AUTO, 4X2, Very Good.

    Source: Used Auto Parts Store

    $61.00
    More parts
    Help me findSearch
    Auto Repair Quick Search
    Help me find
    Search DIY repair manuals by VIN...
    Vehicle Identification Number is a unique serial number used by the automotive industry to identify individual motor vehicles

    Find out what info we have for your vehicle

    Get the Complete Technical Service Bulletins!
    Get the Complete Technical Service Bulletins!Access diagrams and repair information such as wiring diagrams, diagnosis and repair charts, manufacturer service bulletins, and OEM Part numbers of your 2004 Chevrolet Silverado 2500 HD vehicle.
    Access the Complete guide!
    Need To Fix Your Car or Truck?
    Save Money With Free Car Insurance Quote
    FREE car insurance quote
    Enter Zip Code:
    Auto Repair Quick Search
    Help me find