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2004 Chevrolet Suburban 2500 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
- Tire Pressure Monitoring System
- 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 Suburban 2500 AUTOMOBILES
Component Replacement & Adjustment -> Avalanche, Escalade, Suburban, Tahoe & Yukon -> Evaporator Core, Replace -> Delphi -> Escalade ESV, Suburban & Yukon XL -> Escalade, Tahoe & Yukon -> Front -> Rear -> Visteon
Vehicle: 2004 Chevrolet Suburban 2500 8.1 V8 GAS
Front
Delphi
- Remove HVAC module as outlined in "Heating, Ventilation & Air Condition (HVAC) Module, Replace."
- Remove heat stakes using suitable screw driver and a hammer.
- Remove mounting screws and evaporator cowl gasket.
- Separate HVAC module upper and lower assemblies.
- Remove evaporator core.
- Reverse procedure to install. Torque HVAC module mounting screws to 18 inch lbs.
Visteon
- Remove HVAC module as outlined in "Heating, Ventilation & Air Condition (HVAC) Module, Replace."
- Disconnect recircula...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Disc Brakes -> Delco Dual Piston Sliding Caliper -> Caliper Service -> Assemble -> Disassemble -> Inspection -> Installation -> Removal
Vehicle: 2004 Chevrolet Suburban 2500 8.1 V8 GAS
Removal
- Siphon 2/3 of the brake fluid from master cylinder.
- Raise and support vehicle.
- Remove tire and wheel assembly.
- Compress caliper pistons until they bottom in bores using suitable clamp, Fig. .
- Disconnect brake hose at caliper by removing inlet fitting bolt.
- Remove mounting bolts and caliper.
Inspection
Should it become required to remove the caliper for installation of new components, clean components in denatured alcohol, wipe dry using lint-free cloths. Blow out drilled passages and holes using compressed air. Inspect dust boots for punctures or tears. If punctures or tears are...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Suburban 2500 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 Suburban 2500 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 Suburban 2500 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Chevrolet Suburban 2500 6.0 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 ...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Wiring Diagrams -> Wire Color Code Identification
Vehicle: 2004 Chevrolet Suburban 2500 8.1 V8 GAS
Refer to Fig. for wirin...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Chevrolet Suburban 2500 6.0 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 Suburban 2500 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 Suburban 2500 8.1 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 Suburban 2500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Change Oil, Change Oil Now Or Change Oil Soon Lamp & Messages -> 2001-04 Denali, Suburban, Tahoe, Yukon, Yukon XL, 2002-04 Avalanche
Vehicle: 2004 Chevrolet Suburban 2500 8.1 V8 GAS
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 proceedin...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Chevrolet Suburban 2500 8.1 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Remove heater and surge tank hoses from mounting clip.
- Reposition surge tank outlet hose clamp at surge tank.
- Remove surge tank outlet hose from surge tank.
- Reposition hose clamp from water pump housing.
- Remove radiator outlet hose from water pump housing.
- Reposition hose clamp from ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Suburban 2500 6.0 V8 GAS
- Rotate tensioner clockwise to release belt tension using suitable wrench, then remove belt.
- Route belt over pulleys excep...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
Component location diagrams for most 2004 Chevrolet Suburban 2500 cars and light trucks sold in the U.S. from 1990+.
PCM Location Diagram for 2004 Chevrolet Suburban 2500 6.0 V8 GAS Components on diagram: |
Theft Deterrent Control Module Diagram for 2004 Chevrolet Suburban 2500 6.0 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Chevrolet Suburban 2500 cars and light trucks sold in the U.S.
2004 Chevrolet Suburban 2500 6.0 V8 GAS Wiring Diagram Components on diagram: |
2004 Chevrolet Suburban 2500 6.0 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
OEM TSB listings for most 2004 Chevrolet Suburban 2500 cars and light trucks sold in the U.S. from 1985+.
Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Suburban 2500 6.0 V8 GAS Auto Systems: |
Document: Power Folding Mirrors Will Not Fold Inward Vehicle: 2004 Chevrolet Suburban 2500 6.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Suburban 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Suburban 2500 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 Suburban 2500 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 Suburban 2500 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 Suburban 2500 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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