2009 GMC Sierra 3500 HD Service and Repair Manual

This factory service and repair manual for the 2009 GMC Sierra 3500 HD is built around two engines that share little beyond their overhead-valve layout: the 6.6L turbocharged diesel V8 at 403 cubic inches, and the naturally aspirated 6.0L gasoline V8 at 364. Buyers picked from five bodies, including four-door crew and extended cab pickups, a two-door standard cab pickup and cab and chassis versions in both door counts, and from three trims, SLE, SLT and WT. Torque values and diagnostics are separated by system.

Engines covered

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

Body styles covered

• 4-door crew cab pickup
• 4-door cab & chassis
• 2-door cab & chassis
• 4-door extended cab pickup
• 2-door standard cab pickup

Trims covered

• SLE
• SLT
• WT

Known issues on the 2009 Sierra 3500 HD. Five recalls are recorded for this model year. Three cover passenger frontal air bag inflators whose propellant can break down in humid service and rupture the housing, throwing metal fragments at occupants. A fourth concerns a supplied fire extinguisher that can clog and fail to discharge, and the fifth the auxiliary battery circuit, where current pulled through the trailer harness melts a fusible link and risks a fire. Forty-two complaints split evenly between air bags and the electrical system, with structure third — all systems this manual diagrams and tests.