2004 Chevrolet Suburban 2500 Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Suburban 2500 covers the LS and LT versions of the four-door sport utility with either of two overhead-valve gasoline V8s ahead of the firewall: the naturally aspirated 6.0L of 364 cubic inches or the naturally aspirated 8.1L of 496 cubic inches. Each is treated as its own engine through the mechanical, fuel, ignition, cooling and emissions material, while the chassis, brake, steering and body electrical sections that follow apply to the vehicle in either form.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
• 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• LS
• LT

Known issues on the 2004 Suburban 2500. Six recalls sit on the federal record for this year, and two of them land on the same brake booster. The hydraulic brake booster accumulator can crack and part from its assembly, letting fluid escape from the booster circuit; a relief valve bore machined out of specification in that same booster housing can fracture its seal and raise the pedal effort needed for a given stop. A third recall covers a fuel rail damper retainer clip on the 8.1L that can break and let the damper loosen into a fuel leak. Complaints total 406: 146 electrical, 82 brakes, 29 steering.