2004 Chevrolet W4500 Tiltmaster Service and Repair Manual
This factory service and repair manual for the 2004 Chevrolet W4500 Tiltmaster works with a pair of engines at opposite ends of the range: the naturally aspirated 6.0L overhead-valve V8 of 364 cubic inches on gasoline, and the turbocharged 4.8L inline-four of 290 cubic inches on diesel. There are two bodies, the low crew cab and the low tilt straight truck, both carrying the W4S042 build code. Engine sections split by fuel type; frame, driveline, brake and body sections apply to every truck listed.
Engines covered
- 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
- 4.8L inline-four (290 cu in) — turbocharged, diesel
Body styles covered
- Straight truck, low crew cab
- Straight truck, low tilt
Trims covered
- W4S042
Known issues on the 2004 W4500 Tiltmaster. The federal record carries one recall for this year. Trucks with the fuel switching manifold had solenoids that could not resist water or salt getting in; when a solenoid quits, fuel is routed incorrectly and overflows at the filler neck, and leaking diesel near a heat or spark source can start a fire. The one owner complaint logged for the year is a fuel system report as well. Fuel storage, transfer, delivery and their wiring are covered here in procedure and specification form.
