2004 GMC Sierra 3500 Service and Repair Manual
2004 GMC Sierra 3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.
Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.
What’s included
- Step-by-step repair procedures and service information
- Specifications and reference data (where provided)
- Wiring diagrams and electrical sections
- Powertrain, brakes, steering, suspension, HVAC and more
Trims covered
- WT Crew Cab Pickup 4-Door
- Base Standard Cab Pickup 2-Door
- SLT Crew Cab Pickup 4-Door
- Base Extended Cab Pickup 4-Door
- WT Extended Cab Pickup 4-Door
- Base Crew Cab Pickup 4-Door
- Base Cab & Chassis 4-Door
- Base Cab & Chassis 2-Door
- SLE Extended Cab Pickup 4-Door
- WT Cab & Chassis 4-Door
- SLE Cab & Chassis 4-Door
- WT Cab & Chassis 2-Door
- SLE Cab & Chassis 2-Door
- SLE Crew Cab Pickup 4-Door
- SLT Extended Cab Pickup 4-Door
- WT Standard Cab Pickup 2-Door
- SLE Standard Cab Pickup 2-Door
Engines covered
- 6.6L 6599CC 403Cu. In. V8 DIESEL OHV Turbocharged
- 6.0L 5967CC 364Cu. In. V8 GAS OHV Naturally Aspirated
- 8.1L 496Cu. In. V8 GAS OHV Naturally Aspirated
- 6.0L 5967CC 364Cu. In. V8 CNG OHV Naturally Aspirated
Index / Table of contents
- Body
- Brakes
- Chassis Electrical
- Driveline
- Engine Cooling
- Engine Electrical
- Engine Mechanical
- Engine Performance & Emission Controls
- Fuel System
- General Information & Identification
- Heating, Ventilation, & Air Conditioning
- Hybrid & Electric Vehicle Systems
- Steering
- Suspension
- Transmission, Clutch, & Transfer Case
- Wiring Diagrams
CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURE
THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. I
HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOB
This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo
Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo
GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal
This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should
Showing the 8 most recent of 109 technical service bulletins on file with NHTSA.
FUSE BOX UNDER HOOD CAUGHT FIRE WHILE PARKED. *TR
TL*THE CONTACT OWNS A 2004 GMC SIERRA DORMAX DIESEL (NA). THE CONTACT STATED THAT THE FUEL INJECTORS PRODUCE WHITE SMOKE. OCASSIONALLY, THE VEHICLE BECOMES DIFFICULT TO START. THE CONTACT SERVICED
The fan for the heater doesnt work on all speeds properly, stopped working entirely
WHILE PULLING A CAMPER-TRAILER, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR. I WAS ABLE TO STOP UTILIZING THE BRAKES ON THE TRAILER. I WAS ONLY A SHORT DISTANCE FROM HOME AND I W
I WAS TRAVELING ON THE INTERSTATE TOWING A 5TH WHEEL TRAILER AND TRAFFIC CAME TO AN ABRUPT STOP. I APPLIED MY BRAKES AND HAD BRAKES THAN THE PEDAL WENT TO THE FLOOR AND I LOST BRAKING POWER. I LET OFF
Showing the 5 most serious of 29 complaints filed with NHTSA.
