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2004 Chevrolet Suburban 2500 Service & Repair Manual Software PDF Download
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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,...
Type: Cars
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Sku: 47151
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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 | |
| 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. |