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

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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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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!
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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

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 DIESELCamper Wiring Harness Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

Components on diagram:
  • Frame
  • Camper Wiring Harness
  • Vehicle Interface Unit Diagram for 2004 Chevrolet Silverado 2500 HD  8.1 V8 GASVehicle Interface Unit Diagram for 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

    Components on diagram:
  • Vehicle Interface Unit
  • I/P Panel
  • 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:
  • Clutch Pedal Position Switch
  • Engine Control Module
  • Turn Signal/Multifunction Switch
  • 2004 Chevrolet Silverado 2500 HD  6.0 V8 GAS Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Powertrain Control Module
  • 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: 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:
  • Diesel Engines
  • 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!

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