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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

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!

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    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

    Manual Air Conditioning & Heater System Diagnosis & Testing -> Technical Service Bulletins -> Poor Air Conditioning Performance -- Will Not Blow Cold Enough -> 2003 Sierra & Silverado
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

    2003 Sierra & Silverado

    On some of these models equipped with 6.6L diesel engine the air conditioning performance is less than desirable, especially when ambient temperature is more than 90°F.

    To correct this condition perform system inspects as follow:

    • Calibrate actuators
    • Inspect lower condenser deflector for proper installation. Deflector should be positioned at lower part of condenser and extend forward into top of front bumper and below two fresh air intake holes.
    • Inspect engine coo...

    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 8.1 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 -> Component Locations -> 1999-06 Silverado & Sierra
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    Refer ...

    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

    CV AXLE SHAFT, Replace
    Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

    • Raise and support vehicle.
    • Remove wheel and tire assembly.
    • Remove drive axle center cap, if equipped.
    • Insert a drift or large screwdriver through brake caliper into one of the brake rotor vanes in order to prevent drive axle wheel drive shaft from turning.
    • Remove nut and washer from hub. Do not reuse nut. A new nut must be used when installing wheel drive shaft.
    • Using J 45859 or equivalent, press wheel drive shaft from hub.
    • Remove bolts securing wheel drive shaft ...

    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

    Alternator, Replace
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    • Disconnect battery ground cable.
    • Remove air inlet duct, if required.
    • Disconnect terminal plug and battery lead connections from back of alternator.
    • Remove upper fan shroud mounting bolts and fan shroud.
    • Remove accessory drive belt using suitable 3/8 i...

    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 6.6 V8 DIESEL

    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 -> Air Cleaner Restriction Indicator ->
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    An air cleaner restriction indicator, Fig. , is located in the intake duct between the MAF sensor and the air cleaner assembly.

    If the window shows green, no service is required at this time. However, if...

    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

    Radiator, Replace
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    • Drain coolant into a suitable container.
    • Remove radiator air upper baffle retainers, then upper air baffle, Fig. .
    • Remove inlet and outlet hoses from radiator.
    • Lift lower fan shroud upward to disengage from clips, then remove lower fan shroud from vehicle.
    • Remove surge tank hose from radiator
    • Remove and discard radiator quick connect fittings as follows:
      • Pull caps back along pipe, then holding one leg o...

    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 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...

    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+.

    PCM Location Diagram for 2004 Chevrolet Silverado 2500 HD  6.0 V8 GASPCM Location Diagram for 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

    Components on diagram:
  • Powertrain Control Module
  • Left Frame Rail
  • Throttle Actuator Control Module Diagram for 2004 Chevrolet Silverado 2500 HD  8.1 V8 GASThrottle Actuator Control Module Diagram for 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

    Components on diagram:
  • Throttle Actuator Control Module
  • Throttle Actuator Control Connector
  • 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  6.0 V8 CNG Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.0 V8 CNG Wiring Diagram

    Components on diagram:
  • Radio
  • Audio Amplifier
  • 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 2003 Chevrolet Silverado 2500 HD Door Handle, Front, Passenger Side2003 Chevrolet Silverado 2500 HD Door Handle, Front, Passenger Side, With keyhole; A high quality, OE replacement door handle; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $14.34

    Click here to view more details2008 Chevrolet Silverado 2500 HD Mirror, Passenger Side, Convex glass; Non-folding; Telescopic type; With plate; Without glass; A high quality, direct fit OE replacement mirror; Backed by 2-year Kool Vue limited warranty..

    Source: Auto Body Parts Store

    $99.26

    Click here to view more details2010 Chevrolet Express Van 16" X 6.5" Steel Wheel, STEEL WHEEL, 16 X 6.5, 8 STUDS/LUGS, 6.5" BOLT DIA, SOLID DISC, BLACK, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $64.45

    Click here to view more details1995 Pontiac Bonneville Sse V6, 3.8 L, 231 CID Rebuilt Engine, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,969.00

    Click here to view more details2004 Chevrolet Silverado 2500 HD Used Exhaust Manifold, R., Very Good.

    Source: Used Auto Parts Store

    $96.00

    Click here to view more details2008 Chevrolet Silverado 2500 HD Used Engine Computer, Elec Cont Unit (ECU); (L. Fr eng comp), 3.5L, Very Good.

    Source: Used Auto Parts Store

    $105.00
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