2009 Chevrolet Express 2500 Service and Repair Manual

This factory service and repair manual for the 2009 Chevrolet Express 2500 documents a 4.8L V8 of 294 cubic inches and a 6.0L V8 of 364, both naturally aspirated on gasoline, together with a turbocharged 6.6L diesel V8 of 403, across five body configurations and three trims. Cargo and passenger vans appear in standard and extended lengths, with four-door versions of each. Coverage moves system by system: engine mechanical, fuel and emissions, transmission and axles, brakes, steering and suspension, restraints, climate control and the body electrical diagrams.

Engines covered

• 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
• 4.8L V8 (294 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door extended cargo van
• 3-door standard cargo van
• 4-door standard passenger van
• 3-door standard passenger van
• 4-door standard cargo van

Trims covered

• Base
• LS
• LT

Known issues on the 2009 Express 2500. The manual covers engine mechanical clearances and pressures, diesel injection and turbocharger specifications, transmission and axle procedures with torque values, brake friction and hydraulic limits, and wiring diagrams for running an electrical fault down to a connector or ground.