2009 Chevrolet Express 3500 Service and Repair Manual

This factory service and repair manual for the 2009 Chevrolet Express 3500 spans three overhead-valve V8s, a turbocharged 6.6L diesel of 403 cubic inches and naturally aspirated gasoline units of 6.0L and 4.8L, installed in any of seven bodies, from three-door standard cargo vans through four-door passenger vans to the bare two-door cutaway. Base, LS and LT set the equipment. Diesel and gasoline coverage stays separate throughout, since fuel handling, starting aids and emissions control have little in common between them.

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

Trims covered

• Base
• LS
• LT

Known issues on the 2009 Express 3500. The manual covers diesel injection and glow system testing, gasoline fuel and ignition diagnosis, transmission and rear axle overhaul, hydraulic and antilock brake service, heating and air conditioning work across the passenger and cargo shells, and the wiring diagrams, clearances and torque values that support all of it.