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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!
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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

General Service Domestic Vehicles -> 2003-04 -> Precautions -> A/C Refrigerant Oil -> Battery Ground Cable -> Cleanliness -> Engine Coolant -> Exercise System -> General Service -> Product Compatibility -> R-134a -> Safety
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

Battery Ground Cable

Prior to service disconnect battery ground cable and isolate as required.

Product Compatibility

A/C Refrigerant Oil

Before replenishing refrigerant oil, ensure product compatibility with the system being serviced. Refer to "A/C Data," for specifications.

Engine Coolant

Before adding or replacing engine coolant, ensure product compatibility with the system being serviced. If using orange silicate-free coolant, do not mix with green silicated coolant. If mixed, premature engine, heater core or radiator corrosion may result.

...

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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Disc Brakes -> Delco Dual Piston Sliding Caliper -> Description
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

The caliper mounts in a way that allows the caliper to move laterally inboard as the brake pads wear. The caliper housing is a one piece casting with the inboard side containing the piston bore. The piston seal also acts as a return mechanism for the piston.

Applying the brake pedal causes the hydraulic pressure that moves the caliper piston. The piston then forces the inboard brake pad against the inboard braking surface of the rotor. Increasing the force against...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.

Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.

After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.

Engines Less Fuel Pressure ...

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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 6.6 V8 DIESEL

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 ...

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

Alternator, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

  • 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...

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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 6.6 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...

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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 6.6 V8 DIESEL

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+.

Remote Control Door Lock Receiver Diagram for 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESELRemote Control Door Lock Receiver Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

Components on diagram:
  • Instrument Panel
  • Remote Control Door Lock Receiver
  • Instrument Panel Carrier
  • Remote Control Door Lock Receiver Connector
  • Door Latch Assembly Diagram for 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESELDoor Latch Assembly Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    Components on diagram:
  • Door
  • Door Jamb Switch Connector
  • Door Handle Switch Connector
  • Door Lock Actuator 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  6.0 V8 GAS Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Body Control Module
  • Door Lock Switch Driver
  • Door Lock Switch Front Passenger
  • 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESEL Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Wiring Diagram

    Components on diagram:
  • Radio
  • Digital Radio Receiver
  • Rear Seat Entertainment Assembly
  • 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!

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    Source: Auto Body Parts Store

    $86.08

    Click here to view more details2003 Chevrolet Silverado 2500 HD Neutral Safety Switch, Blade type; 4-prong and 7-prong male terminals; A high quality, direct fit OE replacement neutral safety switch; With 2 years limited Trustbuilt warranty..

    Source: Auto Body Parts Store

    $37.58

    Click here to view more details1972 Chevrolet Nova Driver Side Head Light Mounting Ring, Driver Side Head Light Mounting Ring, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $29.50

    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 details2001 Chevrolet Silverado 2500 HD Used Upper Control Arm, Passenger Side, 6.6, AUTO, 4X2 R, Very Good.

    Source: Used Auto Parts Store

    $62.00

    Click here to view more details2001 Chevrolet Silverado 2500 HD Used Parking Lamp, Passenger Side, PLP/TURN SIGNAL, 15199559, Very Good.

    Source: Used Auto Parts Store

    $86.00
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