2009 Chevrolet Express 4500 Service and Repair Manual

This factory service and repair manual for the 2009 Chevrolet Express 4500 concerns a vehicle that is only half a vehicle when it ships: a two-door cutaway, cab and chassis, sold in a single Base specification for a body builder to complete. Two engines are documented, a turbocharged 6.6L diesel V8 of 403 cubic inches and a naturally aspirated 6.0L gasoline V8 of 364. Everything behind the cab is someone else's work, so the manual concentrates on what Chevrolet actually built.

Engines covered

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

Body styles covered

• 2-door cutaway

Trims covered

• Base

Known issues on the 2009 Express 4500. A lone complaint is on record, concerning the fuel and propulsion system, far too little to characterize the year. The fuel coverage here is detailed nonetheless, treating the diesel's injection, filtration and pressure control apart from the gasoline V8's pump, injector and evaporative hardware. Around that sit engine mechanical procedures, transmission and rear axle service, brake and steering specifications, and the wiring diagrams for the cab and chassis circuits an upfitter later ties into.