2004 Chevrolet Silverado 2500 HD Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Chevrolet Model: Silverado 2500 HD Year: 2004 Codes Platform: GMT800 (C/K Platform) 👋 Introduction Market Position Segment: Heavy-duty pickup truck, positioned for commercial, towing, and...

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Stichworte: 2004 Cars Chevrolet Misc Silverado 2500 HD Truck

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Beschreibung

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Silverado 2500 HD

Year:

Codes

Platform:

GMT800 (C/K Platform)

👋 Introduction

Market Position

Segment:

Heavy-duty pickup truck, positioned for commercial, towing, and heavy hauling applications.

Competitive Analysis

Competitors:

Ford F-250 Super Duty, Dodge Ram 2500 HD.

Key Features

Durability:

Renowned for robust construction, heavy-duty frames, and powerful drivetrain options.

Towing Capacity:

Class-leading towing and payload capabilities.

Engine Options:

Available with potent V8 gasoline engines and a highly regarded Duramax turbodiesel engine.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service and repair coverage for the 2004 Chevrolet Silverado 2500 HD.

Page Count

Estimated Page Count:

Thousands (as it's a comprehensive service manual).

Manual Type

Type:

Service and Repair Manual Software

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, and overhaul procedures for all gasoline and diesel engines offered in the 2500 HD.

Transmission:

Coverage for automatic (e.g., 4L80-E, Allison 1000) and manual transmissions, including removal, installation, overhaul, and troubleshooting.

Drivetrain:

Front and rear axle service, differential repair, propeller shaft and CV joint maintenance, four-wheel drive system operation and repair.

Suspension:

Front and rear suspension components, steering system, alignment specifications, component replacement.

Brakes:

Front and rear brake system service (disc/drum configurations), ABS system diagnostics and repair, brake fluid specifications.

Electrical:

Complete wiring diagrams, fuse/relay identification, lighting systems, power accessories, instrument cluster diagnostics, ignition system repair.

HVAC:

Climate control system diagnosis and repair, refrigerant handling, component replacement (compressor, evaporator, condenser).

Body And Frame:

Body panel repair, interior trim removal/installation, door and window mechanisms, frame straightening procedures (if applicable).

Fuel System:

Fuel tank service, fuel pump replacement, fuel filter replacement, fuel injection system diagnostics.

Exhaust System:

Exhaust manifold repair, catalytic converter replacement, muffler and pipe service.

Cooling System:

Radiator service, water pump replacement, thermostat replacement, coolant specifications.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for various vehicle issues.

Repair And Rebuild:

Step-by-step instructions for component removal, installation, repair, and complete overhauls.

Diagnostics:

Engine control module (ECM) diagnostics, sensor testing, actuator testing, OBD-II diagnostic procedures.

Torque Specifications:

Comprehensive list of torque values for critical fasteners across all vehicle systems.

Technical Depth

Depth:

Expert-level technical detail suitable for professional mechanics and advanced DIY enthusiasts.

Wiring Diagrams:

Detailed, system-specific electrical wiring diagrams with component locations.

Diagnostic Codes:

Coverage of common Diagnostic Trouble Codes (DTCs) and their troubleshooting procedures.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format).

Searchability:

Typically searchable text for quick access to specific information.

Print Quality

Quality:

High-resolution, printable pages for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download).

Paper Type

Paper Type:

N/A (Digital Download).

⚙️ Engine Specifications

Primary Engine

Engine 1 Code:

Vortec 6.0L V8 (LQ4/LQ7)

Engine 1 Displacement:

5967 cc (364 ci)

Engine 1 Horsepower:

300-325 hp @ 4400-5200 rpm (depending on variant)

Engine 1 Torque:

370-375 lb-ft @ 3200-4000 rpm (depending on variant)

Diesel Engine

Engine 2 Code:

Duramax 6.6L V8 Turbo Diesel (LB7)

Engine 2 Displacement:

6599 cc (403 ci)

Engine 2 Horsepower:

300 hp @ 3100 rpm

Engine 2 Torque:

520 lb-ft @ 1600 rpm

Performance

Compression Ratio 6 0L:

9.4:1

Compression Ratio 6 6L Diesel:

18.0:1

Fuel System

Gasoline Injection:

Multi-point Fuel Injection (MPFI)

Diesel Injection:

Direct Injection, electronically controlled common rail

🔧 Transmission

Standard

Transmission Type Gasoline:

4-speed automatic (4L80-E)

Optional

Transmission Type Diesel:

5-speed Allison 1000 automatic

Manual Transmission Availability:

Rarely specified for HD models in this year, primarily automatic.

Features

Towing Mode:

Tow/Haul mode for optimized transmission shift points when towing.

Drivetrain Options:

Available in 2WD (RWD) and 4WD configurations.

📐 Dimensions

Exterior

Wheelbase Std Cab:

133.0 inches (3378 mm)

Wheelbase Ext Cab:

143.5 inches (3645 mm)

Bed Length Options:

6.5 ft (short bed), 8 ft (long bed)

Weights

Gvwr Range:

8,600 lbs to 10,000+ lbs (depending on configuration)

Curb Weight Range:

Approx. 5,500 - 6,500 lbs

Cargo

Payload Capacity:

Up to 4,000+ lbs (depending on configuration)

Max Towing Capacity:

Up to 12,000+ lbs (depending on configuration, typically with proper hitch and trailering package)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Driver:

Not rated or 4-star depending on specific configuration and test year.

NHTSA Frontal Crash Passenger:

Not rated or 4-star depending on specific configuration and test year.

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

Height-adjustable shoulder belts with pretensioners, three-point rear seatbelts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Bose premium audio system.

Navigation:

Optional dealer-installed or aftermarket navigation systems.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Onstar:

Optional OnStar telematics system.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000-7,500 miles or 6 months (refer to manual for specific conditions).

Oil Change Diesel:

Every 5,000-10,000 miles or 6-12 months (refer to manual for specific conditions).

Transmission Fluid Change Auto:

Every 30,000-100,000 miles depending on usage and fluid type (refer to manual).

Diesel Fuel Filter Replacement:

Every 15,000-30,000 miles.

Fluid Specifications

Engine Oil Gasoline:

SAE 5W-30 (API SM or higher, GM dexos1 approved is forward-compatible).

Engine Oil Diesel:

SAE 15W-40 or 5W-40 (API CJ-4 or equivalent for modern specs; check manual for original spec).

Transmission Fluid 4L80E:

Dexron III/VI Automatic Transmission Fluid (ATF).

Transmission Fluid Allison 1000:

TES 295 approved synthetic fluid (e.g., Allison Transynd).

Coolant:

Ethylene Glycol based coolant, typically orange or green (consult manual for specific type and mixture).

Known Issues

Duramax Lb7 Injectors:

Early LB7 Duramax engines are known for injector failures due to their location and exposure to fuel pressure.

Transfer Case Actuator:

Some models may experience issues with the automatic transfer case actuator.

Body Rust:

Like many trucks of this era, susceptible to rust in rocker panels, cab corners, and wheel wells, especially in rust-belt regions.

Fuel Pressure Regulator Diesel:

Potential issues with the fuel pressure regulator on Duramax models.

📚 Vehicle History

Brand Heritage

Heritage:

Chevrolet has a long-standing history in the truck market, with the Silverado nameplate succeeding the C/K series trucks.

Model Evolution

Generation:

Third generation of the GMT800 platform, which began in 1999.

Updates 2004:

Minor updates may have occurred for 2004, but it largely carried over the successful formula of previous years.

Production

Assembly Locations:

Fort Wayne, Indiana; Oshawa, Ontario, Canada; Silao, Mexico.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific 'Truck of the Year' awards for the 2004 model are not universally documented, the Silverado HD consistently received praise for its capabilities and powertrain.