2009 Chevrolet Express 3500 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Chevrolet Model: Express 3500 Year: 2009 Generation Generation Designation: Second Generation (GMT610) Generation Years: 2003-Present Codes Platform Code: GMT610 👋 Introduction Market Position Vehicle Segment:...

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标签: 2009 Cars Chevrolet Express Express 3500 Truck

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Express 3500

Year:

Generation

Generation Designation:

Second Generation (GMT610)

Generation Years:

2003-Present

Codes

Platform Code:

GMT610

👋 Introduction

Market Position

Vehicle Segment:

Full-size Van / Commercial Van

Target Audience:

Businesses, tradespeople, fleet owners, DIY enthusiasts requiring reliable van service information

Competitive Analysis

Competitors:

Ford E-Series, Mercedes-Benz Sprinter (in certain configurations), Ram ProMaster

Key Features

Vendor Description:

Officially licensed, OE-derived information from RepairSurge

Convenience:

Instant online access, replaces bulky printed manuals

Value Proposition:

Cost savings through DIY repairs and maintenance

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for 2009 Chevrolet Express 3500

Body Styles Covered:

All body configurations of the Express 3500

Page Count

Estimated Page Count:

Thousands (as it's a software/database)

Manual Type

Type:

Service and Repair Manual Software

Language

Language:

English

Format

Format:

Digital Download (PDF/Proprietary Software)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel, lubrication, cooling, ignition, exhaust, engine management, automatic transmission, driveline

Chassis:

Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels and tires

Electrical:

Starting and charging system, lighting, instruments and indicators, body electrical, power distribution, infotainment, comfort and convenience features

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair

Body:

Body construction, doors, windows, interior trim, exterior trim, bumpers, locks and latches

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, inspections

Diagnostics:

Troubleshooting guides, symptom analysis, diagnostic trouble codes (DTCs) interpretation

Repair:

Component removal, installation, overhaul, and adjustment procedures

Adjustment:

Wheel alignment, steering linkage adjustment, brake adjustments

Wiring Diagrams:

Complete electrical system wiring diagrams with component identification

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and experienced DIYers

Diagnostic Tools:

Information on diagnostic tool usage (e.g., OBD-II scanners) and diagnostic procedures

Torque Specs:

Detailed torque specifications for all fasteners

Schematics:

Component diagrams, system schematics

📊 Manual Specifications

File Format

Digital Format:

Downloadable PDF

Print Quality

Print Readability:

High-resolution for clear printing and on-screen viewing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Software Features

Searchability:

Fully searchable text for quick information retrieval

Compatibility:

Compatible with PC, laptop, smartphone, tablet via web browser

Access Duration:

1-Year access, with discounts for extensions

⚙️ Engine Specifications

Primary Engine

Engine Options 2009:

4.3L V6 Vortec (LU3), 5.3L V8 Vortec (LMG/LY5), 6.0L V8 Vortec (LY6), 6.6L Duramax V8 Turbo-Diesel (LLY/LBZ variants might be present in some chassis configurations)

Engine Displacement 4.3L V6:

4.3 Liters / 262 cubic inches

Engine Horsepower 4.3L V6:

Approx. 195 hp @ 4500 rpm

Engine Torque 4.3L V6:

Approx. 260 lb-ft @ 2800 rpm

Engine Displacement 5.3L V8:

5.3 Liters / 323 cubic inches

Engine Horsepower 5.3L V8:

Approx. 301 hp @ 5200 rpm

Engine Torque 5.3L V8:

Approx. 325 lb-ft @ 4400 rpm

Engine Displacement 6.0L V8:

6.0 Liters / 364 cubic inches

Engine Horsepower 6.0L V8:

Approx. 300-310 hp @ 4800-5200 rpm

Engine Torque 6.0L V8:

Approx. 360-370 lb-ft @ 4000-4400 rpm

Engine Displacement 6.6L Duramax V8:

6.6 Liters / 403 cubic inches

Engine Horsepower 6.6L Duramax V8:

Approx. 250-300 hp (depending on specific LLY/LBZ variant)

Engine Torque 6.6L Duramax V8:

Approx. 450-520 lb-ft (depending on specific LLY/LBZ variant)

Performance

Induction Type V8:

Naturally Aspirated (Vortec) / Turbocharged (Duramax)

Fuel System

Fuel Delivery Vortec:

Sequential Fuel Injection (SFI)

Fuel Type Gasoline:

87 Octane Unleaded (recommended)

Fuel Type Diesel:

Diesel Fuel

🔧 Transmission

Standard

Transmission Type V6:

4-Speed Automatic (4L60-E)

Transmission Type V8 Gas:

4-Speed Automatic (4L60-E for 5.3L, 4L80-E for 6.0L)

Transmission Type V8 Diesel:

4-Speed Automatic (4L80-E or specific Allison variants)

Optional

Optional Transmission:

5-Speed Manual Transmission (less common on 3500, primarily for 2500 models or specific vocational packages)

Features

Transmission Fluid Spec:

Dexron VI Automatic Transmission Fluid (ATF)

📐 Dimensions

Exterior

Wheelbase Options:

135-inch and 155-inch

Overall Length 135In Wb:

Approx. 224 inches

Overall Length 155In Wb:

Approx. 244 inches

Overall Width:

Approx. 79.4 inches

Overall Height:

Approx. 81.5-84.1 inches (depending on roof height)

Cargo

Max Cargo Volume Behind First Row:

Variable, significantly exceeding 200 cubic feet

Weights

Gvwr Options:

Up to 9,600 lbs, 10,000 lbs, 11,000 lbs, 12,300 lbs (depending on configuration)

Curb Weight:

Approx. 4,700 - 5,500 lbs (highly variable based on configuration)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star (typical for vans of this era, check VIN specific)

IIHS Ratings:

Not typically tested by IIHS in the same way as passenger cars; focus is on structural integrity for commercial use.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point seat belts with pretensioners

💡 Technology Features

Infotainment

Infotainment System 2009:

Available CD player with AM/FM, optional satellite radio, optional navigation system, and available rear-seat entertainment systems for passenger variants.

Driver Assistance

Driver Assistance Features:

Basic features like power windows, power locks, cruise control. Advanced driver assistance systems (ADAS) were not common on this model year.

Connectivity

Connectivity Options:

Optional OnStar system (service subscription required)

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 7,500 miles or 6 months, or as indicated by oil life monitor

Oil Change Interval Diesel:

Every 5,000 miles or 6 months (or as per severe duty schedule)

Tire Rotation:

Every 7,500 miles

Fluid Specifications

Engine Oil Viscosity Gasoline:

SAE 5W-30 (GM dexos1 Gen 2 approved recommended)

Engine Oil Capacity 4.3L V6:

Approx. 4.5 quarts (with filter)

Engine Oil Capacity 5.3L V8:

Approx. 6.0 quarts (with filter)

Engine Oil Capacity 6.0L V8:

Approx. 6.0 quarts (with filter)

Engine Oil Viscosity Diesel:

SAE 15W-40 (API CJ-4 or CK-4 approved)

Engine Oil Capacity 6.6L Duramax:

Approx. 10.0 quarts (with filter)

Coolant Type:

GM P/N 12346290 or equivalent Orange Coolant (Extended Life)

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items:

Brake pads/rotors, ball joints, tie rod ends, exhaust components, fuel pumps (especially on E85 models)

Engine Issues Duramax:

Glow plug issues, injector problems (depending on specific LLY/LBZ variant's common faults)

Transmission Issues:

Overheating in heavy-duty applications, solenoid pack failures in older 4L60E units.

📚 Vehicle History

Brand Heritage

Chevrolet Light Commercial Vehicles:

Long history of producing robust commercial vehicles and vans.

Model Evolution

Express Platform History:

Based on the GMT600 platform, evolving into the GMT610 for the second generation (introduced in 2003). Minimal visual changes since 2003, with mechanical updates and new powertrains over the years.

Production

Assembly Locations:

Historically assembled in Wentzville, Missouri, USA

🏆 Awards & Recognition

Recognitions

Commercial Van Awards:

Often cited for its workhorse capability and versatility in commercial applications. Specific awards vary by year and publication.