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2004 GMC Sierra 2500 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: GMC Model: Sierra 2500 Year: 2004 Codes Platform: GMT880 Generation Generation: Second Generation (GMT800) 👋 Introduction Market Position Target Audience: DIY enthusiasts, Independent Repair Shops, Fleet Maintenance Personnel Competitive Analysis Advantages Over Print: Instant access, searchable content, cross-device compatibility, easier updates, often more cost-effective than multiple printed manuals. Key Features Content Source: Licensed information derived from OE (Original Equipment) materials by RepairSurge. Usability: User-friendly interface, push-button access to information, step-by-step procedures. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Additional Coverage: Maintenance, Diagnostics, Troubleshooting, Electrical Schematics, Component Replacement, Specifications Page Count Estimated Page Count: Varies by specific content, typically thousands of pages in OE equivalent Manual Type Manual Type: Software (Online Service and Repair Manual) Language Language: English Format Format: Digital Access (Web-based, PC/Laptop/Smartphone/Tablet compatible) 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engines (e.g., 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax Diesel) Transmission: Automatic transmissions (e.g., 4L80-E, Allison 1000), Manual transmissions (if applicable) Drivetrain: Front and Rear Axles, Differentials, Driveshafts, Transfer Case (4WD) Suspension: Front Independent Suspension (Torsion Bar), Rear Leaf Spring Suspension, Steering Components Brakes: Hydraulic Brake System, ABS, Parking Brake Electrical: Wiring Diagrams, Lighting, Power Accessories, Starting and Charging System, ECM/PCM Body And Chassis: Body Panels, Doors, Seats, Bumpers, Frame, Glass HVAC: Heating, Ventilation, and Air Conditioning (HVAC) System Fuel System: Fuel Pump, Injectors, Lines, Tank Cooling System: Radiator, Fan, Water Pump, Hoses, Thermostat Procedures Included Maintenance Procedures: Oil and Filter Changes, Fluid Top-offs, Tire Rotations, Spark Plug Replacement, Air Filter Replacement Diagnostic Procedures: Troubleshooting Charts, OBD-II Diagnostics, Component Testing Repair Procedures: Engine Mechanical Repairs, Transmission Overhauls, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Replacement Installation Procedures: Component Installation and Replacement (e.g., alternator, starter, water pump) Schematics: Detailed Electrical Wiring Diagrams for all systems Technical Depth Depth Of Coverage: Comprehensive, from basic scheduled maintenance to complete engine/transmission rebuilds and complex electrical diagnostics. Diagnostics Level: Advanced diagnostics including symptom-based troubleshooting and component testing with specifications. Rebuild Information: Detailed instructions for major component rebuilds, including torque specifications and clearances. 📊 Manual Specifications File Format Software Platform: Web Browser Access Accessibility: Accessible on any device with an internet connection and web browser. Print Quality Print Capability: Pages can be printed from the web interface, quality depends on user's printer. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Licensing Licensing Status: Officially Licensed, OE Material Derived Access Duration Subscription Period: 1 Year (with options for extension discounts) ⚙️ Engine Specifications Primary Engine Engine Options: 4.8L V8 Vortec, 5.3L V8 Vortec, 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax V8 Turbo Diesel (LB7) Performance Horse Power Range: Approx. 255-300 hp for gasoline, 300 hp for Duramax Torque Range: Approx. 285-330 lb-ft for gasoline, 520 lb-ft for Duramax Fuel System Fuel Delivery Gasoline: Multi-port Fuel Injection (MPFI) Fuel System Diesel: High-pressure Common Rail Injection (Duramax LB7) Ignition System Ignition Type: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) for Vortec engines 🔧 Transmission Standard Standard Transmission: 4-speed automatic (e.g., 4L60E for lighter duty 2500, 4L80E for heavy duty 2500) Optional Optional Transmission: 5-speed Allison 1000 automatic (primarily with Duramax diesel), 5-speed manual (less common) Features Transmission Features: Electronic controls, Tow/Haul mode (on automatics), Lock-up torque converter 📐 Dimensions Exterior Body Styles: Regular Cab, Extended Cab, Crew Cab Bed Lengths: Short Bed (approx. 6.5 ft), Long Bed (approx. 8 ft) Weights Curb Weight Range: Approx. 5,500 - 7,000 lbs (depending on configuration) Gross Vehicle Weight Rating Gvwr: Up to 8,600 lbs (2500 series, depending on configuration) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 4-Star (Driver), 5-Star (Passenger) - Check specific configurations IIHS Front Offset Crash Test: Good (for models tested, typically up to 2003 for this generation, 2004 data may vary) Active Features Active Safety: Anti-lock Braking System (ABS), Available StabiliTrak (on some models) Passive Features Passive Safety: Driver and Passenger Front Airbags, Available Side Curtain Airbags (on some models) 💡 Technology Features Infotainment Infotainment System: Base AM/FM stereo, Optional CD player, available premium audio systems. Limited integrated technology compared to modern vehicles. Driver Assistance Driver Assistance Features: Cruise Control, Optional Park Assist (rear ultrasonic sensors). Connectivity Connectivity Options: Not applicable in the modern sense; primarily basic audio system connections. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact specs) Transmission Fluid Change: Recommended every 30,000-50,000 miles for heavy-duty use (refer to manual for exact specs) Coolant Flush: Every 50,000-100,000 miles or 2-5 years, depending on coolant type (refer to manual) Fluid Specifications Engine Oil Specification: SAE 5W-30 or 10W-30 (API Certified) for gasoline engines; SAE 15W-40 (API CJ-4) for Duramax diesel. Consult manual for precise grade. Transmission Fluid Type: Dexron III/VI for automatic transmissions; Allison approved fluid for Allison...
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2004 GMC Sierra 2500 Service & Repair Manual Software
🏷️ Basic Information
Identification
Make:
GMC
Model:
Sierra 2500
Year:
2004
Codes
Platform:
GMT880
Generation
Generation:
Second Generation (GMT800)
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, Independent Repair Shops, Fleet Maintenance Personnel
Competitive Analysis
Advantages Over Print:
Instant access, searchable content, cross-device compatibility, easier updates, often more cost-effective than multiple printed manuals.
Key Features
Content Source:
Licensed information derived from OE (Original Equipment) materials by RepairSurge.
Usability:
User-friendly interface, push-button access to information, step-by-step procedures.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Additional Coverage:
Maintenance, Diagnostics, Troubleshooting, Electrical Schematics, Component Replacement, Specifications
Page Count
Estimated Page Count:
Varies by specific content, typically thousands of pages in OE equivalent
Manual Type
Manual Type:
Software (Online Service and Repair Manual)
Language
Language:
English
Format
Format:
Digital Access (Web-based, PC/Laptop/Smartphone/Tablet compatible)
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engines (e.g., 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax Diesel)
Transmission:
Automatic transmissions (e.g., 4L80-E, Allison 1000), Manual transmissions (if applicable)
Drivetrain:
Front and Rear Axles, Differentials, Driveshafts, Transfer Case (4WD)
Suspension:
Front Independent Suspension (Torsion Bar), Rear Leaf Spring Suspension, Steering Components
Brakes:
Hydraulic Brake System, ABS, Parking Brake
Electrical:
Wiring Diagrams, Lighting, Power Accessories, Starting and Charging System, ECM/PCM
Body And Chassis:
Body Panels, Doors, Seats, Bumpers, Frame, Glass
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) System
Fuel System:
Fuel Pump, Injectors, Lines, Tank
Cooling System:
Radiator, Fan, Water Pump, Hoses, Thermostat
Procedures Included
Maintenance Procedures:
Oil and Filter Changes, Fluid Top-offs, Tire Rotations, Spark Plug Replacement, Air Filter Replacement
Diagnostic Procedures:
Troubleshooting Charts, OBD-II Diagnostics, Component Testing
Repair Procedures:
Engine Mechanical Repairs, Transmission Overhauls, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Replacement
Installation Procedures:
Component Installation and Replacement (e.g., alternator, starter, water pump)
Schematics:
Detailed Electrical Wiring Diagrams for all systems
Technical Depth
Depth Of Coverage:
Comprehensive, from basic scheduled maintenance to complete engine/transmission rebuilds and complex electrical diagnostics.
Diagnostics Level:
Advanced diagnostics including symptom-based troubleshooting and component testing with specifications.
Rebuild Information:
Detailed instructions for major component rebuilds, including torque specifications and clearances.
📊 Manual Specifications
File Format
Software Platform:
Web Browser Access
Accessibility:
Accessible on any device with an internet connection and web browser.
Print Quality
Print Capability:
Pages can be printed from the web interface, quality depends on user's printer.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Licensing
Licensing Status:
Officially Licensed, OE Material Derived
Access Duration
Subscription Period:
1 Year (with options for extension discounts)
⚙️ Engine Specifications
Primary Engine
Engine Options:
4.8L V8 Vortec, 5.3L V8 Vortec, 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax V8 Turbo Diesel (LB7)
Performance
Horse Power Range:
Approx. 255-300 hp for gasoline, 300 hp for Duramax
Torque Range:
Approx. 285-330 lb-ft for gasoline, 520 lb-ft for Duramax
Fuel System
Fuel Delivery Gasoline:
Multi-port Fuel Injection (MPFI)
Fuel System Diesel:
High-pressure Common Rail Injection (Duramax LB7)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) for Vortec engines
🔧 Transmission
Standard
Standard Transmission:
4-speed automatic (e.g., 4L60E for lighter duty 2500, 4L80E for heavy duty 2500)
Optional
Optional Transmission:
5-speed Allison 1000 automatic (primarily with Duramax diesel), 5-speed manual (less common)
Features
Transmission Features:
Electronic controls, Tow/Haul mode (on automatics), Lock-up torque converter
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Extended Cab, Crew Cab
Bed Lengths:
Short Bed (approx. 6.5 ft), Long Bed (approx. 8 ft)
Weights
Curb Weight Range:
Approx. 5,500 - 7,000 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Up to 8,600 lbs (2500 series, depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-Star (Driver), 5-Star (Passenger) - Check specific configurations
IIHS Front Offset Crash Test:
Good (for models tested, typically up to 2003 for this generation, 2004 data may vary)
Active Features
Active Safety:
Anti-lock Braking System (ABS), Available StabiliTrak (on some models)
Passive Features
Passive Safety:
Driver and Passenger Front Airbags, Available Side Curtain Airbags (on some models)
💡 Technology Features
Infotainment
Infotainment System:
Base AM/FM stereo, Optional CD player, available premium audio systems. Limited integrated technology compared to modern vehicles.
Driver Assistance
Driver Assistance Features:
Cruise Control, Optional Park Assist (rear ultrasonic sensors).
Connectivity
Connectivity Options:
Not applicable in the modern sense; primarily basic audio system connections.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact specs)
Transmission Fluid Change:
Recommended every 30,000-50,000 miles for heavy-duty use (refer to manual for exact specs)
Coolant Flush:
Every 50,000-100,000 miles or 2-5 years, depending on coolant type (refer to manual)
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 10W-30 (API Certified) for gasoline engines; SAE 15W-40 (API CJ-4) for Duramax diesel. Consult manual for precise grade.
Transmission Fluid Type:
Dexron III/VI for automatic transmissions; Allison approved fluid for Allison 1000. Consult manual for exact type.
Coolant Type:
GM P/N 12346340 (Orange, silicate-free, long-life) or equivalent. Consult manual for exact specification.
Known Issues
Common Duramax Issues:
Injectors (LB7), Glow Plugs, Fuel Filter Water Separator Issues
Common Gasoline Engine Issues:
Intake manifold gaskets, PCV valve issues, exhaust manifold leaks (4.8L/5.3L)
Common Transmission Issues:
Torque converter shudder (4L80E), transmission fluid leaks
Common Suspension Issues:
Ball joint wear, tie rod end wear, shock absorber/strut wear
📚 Vehicle History
Brand Heritage
Gmc Truck Legacy:
GMC has a long history of producing robust and capable trucks, emphasizing professional-grade performance.
Model Evolution
Sierra Lineage:
The Sierra nameplate replaced the C/K series in 1999. The 2004 model year falls within the first generation of the Sierra, known for its significant redesign and introduction of advanced features like the Duramax diesel.
Production
Manufacturing Locations:
Fort Wayne, Indiana; Oshawa, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Duramax Diesel Recognition:
The 6.6L Duramax diesel engine was highly regarded for its power, torque, and durability, contributing to the Sierra's reputation as a capable workhorse.
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