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2009 Chevrolet SILVERADO 2500-3500 4WD Service Repair Manual
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Basic Information Identification Make: Chevrolet Model: Silverado 2500HD/3500HD Year: 2009 Drive Type: 4WD Codes Platform: GMT900 (GMT912 for 2500HD, GMT932 for 3500HD) Introduction Market Position Segment: Heavy-duty pickup truck Target...
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| Basic Information | |
| Identification | |
| Make: | Chevrolet |
| Model: | Silverado 2500HD/3500HD |
| Year: | 2009 |
| Drive Type: | 4WD |
| Codes | |
| Platform: | GMT900 (GMT912 for 2500HD, GMT932 for 3500HD) |
| Introduction | |
| Market Position | |
| Segment: | Heavy-duty pickup truck |
| Target Audience: | Owners and professional mechanics of 2009 Chevrolet Silverado 2500HD/3500HD 4WD trucks, seeking detailed repair and maintenance information. |
| Competitive Analysis | |
| Competitors: | Ford F-Series Super Duty, Dodge Ram Heavy Duty. |
| Key Features | |
| Content Strength: | Comprehensive, detailed, step-by-step instructions, high-quality diagrams and illustrations, technical specifications, troubleshooting guides. |
| Delivery Method: | Instant digital download for immediate access. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | 2009 Chevrolet Silverado 2500HD/3500HD 4WD |
| Page Count | |
| Estimated Page Count: | 2000+ pages (typical for comprehensive service manuals) |
| Manual Type | |
| Type: | Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Diagnosis, repair, and overhaul of gasoline and diesel engines, including cooling, lubrication, fuel, ignition/pre-ignition, and emissions systems. |
| Drivetrain: | Front and rear axle assemblies, transfer case (NVG 246, NVG 261 HD, NVG 263 HD), driveshafts, differentials, and hub assemblies. |
| Transmission: | Repair and overhaul of automatic transmissions (e.g., 4L70E, 4L80E, Allison 1000/2000) including torque converter, valve body, and electronic controls. |
| Brakes: | Hydraulic brake system (ABS, EBD), disc brake component inspection and replacement, drum brake service (if applicable), parking brake system. |
| Steering: | Power steering system, steering gear box, steering linkage, wheel alignment specifications. |
| Suspension: | Front independent suspension (torsion bar), rear leaf spring suspension, shock absorbers, ball joints, control arms, stabilizer bars. |
| Electrical: | Battery, charging system, starting system, lighting, instrumentation, power accessories, fuses, relays, wiring diagrams for all systems. |
| Body: | Body panels, doors, hood, tailgate, bumpers, glass, interior trim, seat mechanisms, HVAC system (heater, A/C). |
| Diagnostics: | On-Board Diagnostics (OBD-II), Diagnostic Trouble Codes (DTCs), guided troubleshooting procedures, component testing. |
| Procedures Included | |
| Maintenance: | Scheduled maintenance tasks including oil changes, filter replacements, fluid checks and top-offs, lubrication, brake inspection, tire rotation. |
| Repair: | Step-by-step repair instructions for virtually all mechanical and electrical components, from minor adjustments to complete component overhauls. |
| Troubleshooting: | Systematic diagnostic approaches for identifying and resolving common and uncommon faults, symptom-based troubleshooting trees. |
| Specifications: | Torque values, fluid types and capacities, electrical specifications, diagnostic data, wear limits, and alignment settings. |
| Disassembly Reassembly: | Detailed instructions for the removal, inspection, and installation of all major components and sub-assemblies. |
| Technical Depth | |
| Depth: | Comprehensive, covering from basic maintenance to advanced diagnostics and complete component rebuilds, suitable for professional technicians and advanced DIY enthusiasts. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Print Quality | |
| Image Resolution: | High-quality diagrams and illustrations designed for clear display and printing. |
| Binding Type | |
| Binding: | Digital download (no physical binding) |
| Paper Type | |
| Paper Quality: | N/A (Digital PDF format) |
| Engine Specifications | |
| Primary Engine | |
| Gasoline Engine 1: | 6.0L V8 Vortec (L96/LQ4) |
| Gasoline Engine 1 Hp: | Approx. 360 hp @ 5400 rpm |
| Gasoline Engine 1 Torque: | Approx. 380 lb-ft @ 4200 rpm |
| Diesel Engine 1: | 6.6L V8 Duramax Turbodiesel (LMM) |
| Diesel Engine 1 Hp: | Approx. 365 hp @ 3200 rpm |
| Diesel Engine 1 Torque: | Approx. 725 lb-ft @ 1600 rpm |
| Performance | |
| Emission Control: | Includes procedures for catalytic converters, EGR systems (Duramax), particulate filters (Duramax), and oxygen sensors. |
| Fuel System | |
| Gasoline Fuel System: | Sequential Fuel Injection (SFI), electronic throttle control (ETC). |
| Diesel Fuel System: | Common Rail Diesel Injection (CRDI), high-pressure fuel pump, injectors, glow plug system. |
| Transmission | |
| Standard | |
| 2500Hd Gas: | 4-speed automatic (4L70E) |
| 2500Hd Diesel: | 6-speed automatic (Allison 1000) |
| 3500Hd: | 6-speed automatic (Allison 1000/2000) |
| Optional | |
| Manual Transmission: | No manual transmission offered for 4WD models in this configuration. |
| Features | |
| Tow Haul Mode: | Includes operation and diagnostics for Tow/Haul mode. |
| Transfer Case Type: | Electronic shift transfer case (e.g., NVG 246, NVG 261 HD, NVG 263 HD depending on model/configuration). |
| Dimensions | |
| Exterior | |
| Wheelbase Options: | Approx. 143.5 in (Regular Cab), 153.0 in (Extended Cab), 167.7 in (Crew Cab) for 2500HD; 167.7 in (Crew Cab) for 3500HD. |
| Bed Length Options: | Approx. 6.5 ft (short box) and 8.0 ft (long box). |
| Weights | |
| Curb Weight Range: | Approx. 6,000 - 7,500 lbs (varies by configuration). |
| Max Gvw: | Up to 11,500 lbs (2500HD) and 12,300 lbs (3500HD single rear wheel) or 14,300 lbs (3500HD dually). |
| Safety Features | |
| Ratings | |
| NHTSA Rollover Resistance: | Typically 4 out of 5 stars for 4WD models. |
| Active Features | |
| ABS: | Standard Anti-lock Braking System (ABS) with electronic brake force distribution (EBD). |
| Traction Control: | Standard electronic traction control. |
| Passive Features | |
| Airbags: | Front airbags for driver and passenger, available side-curtain airbags. |
| Technology Features | |
| Infotainment | |
| Audio Options: | Available AM/FM/CD/MP3 player, with options for Bose premium audio, satellite radio, and integrated navigation. |
| Connectivity: | Auxiliary input jack, available Bluetooth hands-free phone connectivity. |
| Driver Assistance | |
| Cruise Control: | Standard cruise control. |
| Parking Assist: | Available rear parking assist sensors. |
| Maintenance | |
| Service Intervals | |
| Oil Change Gas: | Every 5,000 - 7,500 miles or 6 months (check oil life monitor). |
| Oil Change Diesel: | Every 5,000 - 7,500 miles or 6 months (check oil life monitor), especially under heavy use. |
| Transmission Fluid Service: | Inspect fluid condition at regular intervals. Replace fluid and filter typically every 50,000 - 100,000 miles, depending on usage and manufacturer recommendation. |
| Fluid Specifications | |
| Engine Oil Gas 6.0L: | SAE 5W-30 synthetic blend or full synthetic. |
| Engine Oil Diesel 6.6L: | SAE 15W-40 or 5W-40 synthetic diesel engine oil meeting API CJ-4 specification. |
| Transmission Fluid 4L70E: | Dexron VI Automatic Transmission Fluid. |
| Transmission Fluid Allison: | TES 295 approved synthetic fluid (e.g., Mobil Delvac Synthetic Transmission Fluid 727, Allison Transmission Fluid). |
| Coolant: | GM Dex-Cool (Orange) 50/50 coolant/water mixture. |
| Known Issues | |
| Duramax Egr: | EGR cooler failures and clogging are common issues requiring cleaning or replacement. |
| Duramax Dpf: | Diesel Particulate Filter (DPF) regeneration issues and clogging can occur, especially with short trips. |
| Transfer Case Actuator: | Potential failure of the electronic transfer case actuator, leading to 4WD engagement issues. |
| Brake Wear: | Front brake pad and rotor wear can be accelerated due to the vehicle's weight and towing/hauling duties. |
| Vehicle History | |
| Brand Heritage | |
| Chevrolet Trucks: | Chevrolet has a long-standing reputation for building durable and capable trucks, dating back to the early 20th century. |
| Model Evolution | |
| Silverado Hd Generation: | The 2009 model is part of the second generation GMT900 platform (2007-2013), representing significant updates in styling, interior, and powertrain over previous generations. |
| Production | |
| Assembly Locations: | Fort Wayne, Indiana; Oshawa, Ontario, Canada. |
| Awards & Recognition | |
| Recognitions | |
| Automotive Press Awards: | While specific awards for the 2009 model year might vary, the Silverado HD line has historically been recognized for its towing and hauling capabilities, often earning praise from automotive publications for its workhorse nature. |