2004 Chevrolet Suburban 2500 Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Chevrolet Model: Suburban 2500 Year: 2004 Generation Generation Designation: GMT800 (Third Generation) Codes Chassis Code: GMT830 👋 Introduction Market Position Segment: Full-size SUV, positioned as a heavy-duty, versatile vehicle for families and commercial use. Competitive Analysis Competitors: Ford Expedition, Dodge Durango, Toyota Sequoia. Key Features Vehicle Strength: Robust construction, towing capacity, spacious interior, and proven powertrain options. Manual Advantage Convenience: Instant online access from any internet-connected device, offering superior convenience over traditional printed manuals. Cost Effectiveness: Saves significant costs associated with dealership repairs by empowering DIY maintenance and repairs. Licensing Licensing Status: Officially licensed, derived from OE (Original Equipment) materials, ensuring accuracy and authenticity. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service and repair for all major vehicle systems. Page Count Estimated Pages: Extensive, comparable to factory service manuals (specific count not provided but implied to be comprehensive). Manual Type Type: Service and Repair Manual Software Language Language: English Format Digital Format: PDF Download (Web-based access with one-year subscription) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair procedures, timing, cooling, lubrication, fuel, ignition, emissions, and component overhauls. Drivetrain: Front-wheel drive (FWD) and all-wheel drive (AWD) systems, front and rear differentials, axles, driveshafts, and related components. Transmission: Automatic transmission (e.g., 4L65-E, 4L80-E) repair, overhaul, diagnostics, fluid services, and electronic controls. Brakes: Hydraulic system, ABS, traction control, brake pads, rotors, calipers, lines, and bleeding procedures. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, and alignment specifications. Steering: Power steering system, steering gear, steering column, tie rods, and power steering fluid. Electrical: Wiring diagrams, fuse box locations, battery, charging system, starting system, lighting, power accessories, and diagnostic trouble codes (DTCs). HVAC: Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling, compressor, condenser, evaporator, and climate control modules. Body: Body panels, doors, windows, locks, interior trim, bumpers, and external trim components. Chassis: Frame structure, chassis components, and related systems. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspection procedures. Troubleshooting: Diagnostic flowcharts, common problem identification, and step-by-step troubleshooting guides for various systems. Repair: Component removal, installation, adjustment, rebuilding, and replacement procedures for all major systems. Diagnostics: On-board diagnostics (OBD-II) information, DTC interpretation, and use of diagnostic scan tools. Specifications: Torque specifications for critical fasteners, clearances, fluid capacities, electrical resistance values, and performance data. Technical Depth Depth: OE-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed component disassembly and reassembly. 📊 Manual Specifications File Format Format: Digital PDF accessed via web browser. Print Quality Scalability: Scalable vector graphics and high-resolution images for clear visibility on any device. Binding Type Access Method: Web-based subscription with year-long access. Paper Type Digital Content Type: Interactive digital content with searchable text and embedded diagrams. ⚙️ Engine Specifications Primary Engine Engine Code: LM7 Engine Type: 5.3L V8 OHV 16V Vortec 5300 Displacement: 5328 cc (325.1 cubic inches) Bore X Stroke: 3.78 in x 3.62 in (96 mm x 92 mm) Compression Ratio: 9.5:1 Horsepower: 285 hp @ 5200 rpm Torque: 325 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SFI) Fuel Type: Unleaded gasoline, 87 octane (minimum) Engine Management ECU Model: Delphi DRB-III (Diagnostic) / GM ECM Cooling System Coolant Type: GM DEX-COOL (Orange) Lubrication Oil Type: SAE 5W-30 Synthetic Blend or Full Synthetic Oil Capacity: 6.0 quarts (5.7 liters) with filter 🔧 Transmission Standard Type: 4-speed automatic overdrive Model Codes: 4L65-E Features Features: Electronic Transmission Control (ETC), Tow/Haul mode. Fluid Specifications Fluid Type: Dexron III/Mercon (or equivalent) Fluid Capacity Capacity: Approx. 11.7 quarts (11.1 liters) for the 4L65-E. 📐 Dimensions Exterior Length: 219.3 inches (5570 mm) Width: 78.5 inches (1994 mm) Height: 76.7 inches (1948 mm) Wheelbase: 130.0 inches (3302 mm) Weights Curb Weight: Approx. 5,550 - 5,900 lbs (2517 - 2676 kg) Gross Vehicle Weight Rating: 9,200 lbs (4173 kg) Towing Capacity: Up to 10,000 lbs (4536 kg) with proper equipment and configuration. Cargo Cargo Volume Behind 3Rd Row: Approx. 45.7 cu ft (1.3 cu m) Cargo Volume Behind 2Nd Row: Approx. 92.3 cu ft (2.6 cu m) Cargo Volume Behind 1St Row: Approx. 131.6 cu ft (3.7 cu m) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 4/5 Stars (specific rating may vary slightly by configuration) IIHS Frontal Offset Score: Good (for 2000-2006 models tested) Active Features ABS: Standard Anti-lock Braking System (ABS) on all four wheels. Traction Control: Available Traction Control System (TCS). Passive Features Airbags: Driver and front passenger airbags, available side-impact airbags. Seatbelts: Three-point seatbelts for all seating positions, front seat pretensioners. 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with CD player, optional Bose premium audio system, available rear-seat entertainment system. Driver Assistance Parking Assist: Available rear parking assist sensors. Connectivity Onstar: Available OnStar safety and communication system. 🔧 Maintenance Service Intervals...
Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, and alignment specifications.
Steering:
Power steering system, steering gear, steering column, tie rods, and power steering fluid.
Electrical:
Wiring diagrams, fuse box locations, battery, charging system, starting system, lighting, power accessories, and diagnostic trouble codes (DTCs).
HVAC:
Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling, compressor, condenser, evaporator, and climate control modules.
Body:
Body panels, doors, windows, locks, interior trim, bumpers, and external trim components.
Chassis:
Frame structure, chassis components, and related systems.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspection procedures.
Troubleshooting:
Diagnostic flowcharts, common problem identification, and step-by-step troubleshooting guides for various systems.
Repair:
Component removal, installation, adjustment, rebuilding, and replacement procedures for all major systems.
Diagnostics:
On-board diagnostics (OBD-II) information, DTC interpretation, and use of diagnostic scan tools.
Specifications:
Torque specifications for critical fasteners, clearances, fluid capacities, electrical resistance values, and performance data.
Technical Depth
Depth:
OE-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed component disassembly and reassembly.
📊 Manual Specifications
File Format
Format:
Digital PDF accessed via web browser.
Print Quality
Scalability:
Scalable vector graphics and high-resolution images for clear visibility on any device.
Binding Type
Access Method:
Web-based subscription with year-long access.
Paper Type
Digital Content Type:
Interactive digital content with searchable text and embedded diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Code:
LM7
Engine Type:
5.3L V8 OHV 16V Vortec 5300
Displacement:
5328 cc (325.1 cubic inches)
Bore X Stroke:
3.78 in x 3.62 in (96 mm x 92 mm)
Compression Ratio:
9.5:1
Horsepower:
285 hp @ 5200 rpm
Torque:
325 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SFI)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Engine Management
ECU Model:
Delphi DRB-III (Diagnostic) / GM ECM
Cooling System
Coolant Type:
GM DEX-COOL (Orange)
Lubrication
Oil Type:
SAE 5W-30 Synthetic Blend or Full Synthetic
Oil Capacity:
6.0 quarts (5.7 liters) with filter
🔧 Transmission
Standard
Type:
4-speed automatic overdrive
Model Codes:
4L65-E
Features
Features:
Electronic Transmission Control (ETC), Tow/Haul mode.
Fluid Specifications
Fluid Type:
Dexron III/Mercon (or equivalent)
Fluid Capacity
Capacity:
Approx. 11.7 quarts (11.1 liters) for the 4L65-E.
📐 Dimensions
Exterior
Length:
219.3 inches (5570 mm)
Width:
78.5 inches (1994 mm)
Height:
76.7 inches (1948 mm)
Wheelbase:
130.0 inches (3302 mm)
Weights
Curb Weight:
Approx. 5,550 - 5,900 lbs (2517 - 2676 kg)
Gross Vehicle Weight Rating:
9,200 lbs (4173 kg)
Towing Capacity:
Up to 10,000 lbs (4536 kg) with proper equipment and configuration.
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 45.7 cu ft (1.3 cu m)
Cargo Volume Behind 2Nd Row:
Approx. 92.3 cu ft (2.6 cu m)
Cargo Volume Behind 1St Row:
Approx. 131.6 cu ft (3.7 cu m)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4/5 Stars (specific rating may vary slightly by configuration)
IIHS Frontal Offset Score:
Good (for 2000-2006 models tested)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all four wheels.
Traction Control:
Available Traction Control System (TCS).
Passive Features
Airbags:
Driver and front passenger airbags, available side-impact airbags.
Seatbelts:
Three-point seatbelts for all seating positions, front seat pretensioners.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player, optional Bose premium audio system, available rear-seat entertainment system.
Driver Assistance
Parking Assist:
Available rear parking assist sensors.
Connectivity
Onstar:
Available OnStar safety and communication system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).
Tire Rotation Interval:
Every 7,500 miles (12,000 km).
Transmission Fluid Service:
Check at every oil change; change approximately every 50,000-100,000 miles (80,000-160,000 km) or as per manual recommendations.
Coolant Flush Interval:
Initial flush at 5 years or 100,000 miles (160,000 km), then every 2 years or 50,000 miles (80,000 km) thereafter (using DEX-COOL).
Fluid Specifications
Brake Fluid:
DOT 3 (GM P/N 12378476 or equivalent)
Power Steering Fluid:
Dexron III/Mercon ATF (GM P/N 12378515 or equivalent)
Differential Fluid Rear:
SAE 75W-90 Synthetic Gear Lubricant (GM P/N 10522777 or equivalent), with limited-slip additive if equipped.
Differential Fluid Front:
SAE 75W-90 Synthetic Gear Lubricant (GM P/N 10522777 or equivalent).
Known Issues
Common Problem 1:
Rear main seal leaks.
Common Problem 2:
Coolant leaks from intake manifold gaskets or heater core.
Common Problem 3:
Transmission solenoid issues or hard shifts in the 4L65-E.
Common Problem 4:
Front hub bearing failure.
Common Problem 5:
Dashboard cracking or warping due to sun exposure.
📚 Vehicle History
Brand Heritage
Manufacturer:
Chevrolet, a division of General Motors (GM).
Model Evolution
Generation Timeline:
The 2004 Suburban is part of the GMT800 platform, which debuted in 1999 and represented a significant redesign with improved aerodynamics, interior, and safety features over the previous generation. This generation ran until 2006.
Production
Assembly Locations:
Janesville, Wisconsin, USA; Silao, Mexico.
🏆 Awards & Recognition
Recognitions
Recognition Example:
The GMT800 platform vehicles, including the Suburban, were generally well-regarded for their capability and space, often appearing on 'best of' lists for large SUVs and trucks during their production run.
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