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2009 Chevrolet Express AWD

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2009 Express AWD.

Transmission Automatic 4-spd

The 2009 Chevrolet Express AWD is a full-size van equipped with a 5W-30 API engine requiring 4.5 quarts of oil, paired with a 4-speed automatic transmission and achieving EPA fuel economy of 13 city, 16 highway, and 14 combined mpg. Within the model’s complaint history spanning 1995 through 2026, the 2009 model year sits well below the peak of 127 complaints recorded for 2003 and far above the single complaint for 1995, placing it in a moderate reliability position that researchers should consider when evaluating this generation’s overall durability.

Model year2014 2009

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque140 ft-lbsOEM · verified

EPA fuel economy13/16/14 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 78 · 600 CCA battery, OE oil filter 12690386. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 78 · 600 CCAOEM · verified

OE service part numbers OEM · verified

Engine oil filter	12690386 alt 12731175
Engine air filter	22909882
Spark plug	12621258 alt 12680072
Front wiper blades	15214346
Serpentine belt	19210691 alt 12626222
Thermostat	89018168 alt 12632948

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

Transmission

Automatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length	224 in
Overall width	79.5 in
Overall height	81.5 in
Wheelbase	135 in
Curb weight	5381 lb
Track (front / rear)	68.1 / 67.7 in
Weight distribution (front / rear)	53/47

Ratings & economy EPA / vPIC

EPA city / highway / combined	13 / 16 / 14 mpg
Drivetrain	4-Wheel or All-Wheel Drive
Recommended fuel	Regular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil, SAE 75W · SYNTHETIC in the differential, DOT 3 brake fluid. Torque lug nuts to 140 ft-lbs, the oil drain plug to 62.0 ft-lbs. The firing order is 1-8-7-2-6-5-4-3. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission Fluid	ATF
Automatic Transmission Fluid Capacity	7.4
Brake Fluid	DOT 3
Differential Gear Oil	SAE 75W · SYNTHETIC
Differential Gear Oil Capacity	6.6 qt
Differential Gear Oil	SAE 75W · SYNTHETIC
Differential Gear Oil Capacity	4.4 qt
Engine Coolant	DEX-COOL OR EQUIVALENT

Engine torques

Intake Manifold to Engine Bolts	18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	42 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Oil Pan Drain Plug	62.0 ft-lbs
Engine Valve Cover Bolts	9.0 ft-lbs
Engine Valve Cover Bolts	16.0 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)	103.0 ft-lbs
Leaf Spring to Chassis Bracket	107.0 ft-lbs
Leaf Spring to Rear Shackle	66.0 ft-lbs
Leaf Spring Rear Shackle to Chassis Bracket	66.0 ft-lbs
Lug Nuts	140 ft-lbs
Transfer Case Fill Plug	18.0 ft-lbs
Transfer Case Drain Plug	18.0 ft-lbs
Front Wheel Hub	155 ft-lbs

Ignition

Cylinder Firing Order	1-8-7-2-6-5-4-3
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.060 in
Spark Plug Torque	11 ft-lbs
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.040 in
Spark Plug Torque	11.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Oil Group	PAG
Oil Type	46
Standard BCI Group Number	78
Standard BCI Cranking Performance	600 cca
Standard BCI Group Number	78
Standard BCI Cranking Performance	600 cca
Standard BCI Group Number	78

Service checks

Pressure Test	15 psi
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	195 °F
Pressure Test	15 psi
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	195 °F
Pressure Test	15 psi
Radiator Cap Pressure Relief	15 psi

Brakes

Torque Caliper to Bracket	80 ft-lbs
Torque to Knuckle	129 ft-lbs
Torque Caliper to Bracket	80 ft-lbs
Torque to Knuckle	129 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.001 in
Rotor Runout Limit	0.005 in
Rotor Nominal Thickness From	1.142 in / 1.181 in / 1.496 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

70 ft. lbs., step 2: 95 ft. lbs.

70 ft. lbs

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

74 ft. lbs., step 2: 100 ft. lbs., step 3: 105 degrees.

74 ft. lbs

Cylinder Head — tightening sequence 3 stages

Prep Do not reuse old bolts. Do not allow oil on cylinder head or head bolt bosses · M11 Bolts:

1	22.0 ft. lbs.	22 ft. lbs
2	90 degrees	90 degrees
3	70 degrees; M8 Bolts:	70 degrees
1	22.0 ft. lbs.	22 ft. lbs
2	22.0 ft. lbs	22 ft. lbs

Cylinder Head — tightening sequence 4 stages

Prep M12 Bolts:

1	37.0 ft. lbs.	37 ft. lbs
2	59 ft. lbs.	59 ft. lbs
3	60 degrees	60 degrees
4	90 degrees; M8 Bolts:	90 degrees
1	18.0 ft. lbs.	18 ft. lbs

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3.7 ft. lbs., step 2: 7.4

3.7 ft. lbs

Exhaust Manifold to Cylinder Head Bolts — tightening sequence 1 stages

11 ft. lbs., step 2: 15

11 ft. lbs

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3.7 ft. lbs., step 2: 7.4

3.7 ft. lbs

Exhaust Manifold to Cylinder Head Bolts — tightening sequence 1 stages

11 ft. lbs., step 2: 18

11 ft. lbs

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3.7 ft. lbs., step 2: 7.4

3.7 ft. lbs

Exhaust Manifold to Cylinder Head Bolts — tightening sequence 1 stages

11 ft. lbs., step 2: 15

11 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the spark plugs every 100,000 mi; coolant at 150,000 mi. The big-interval services (at 150,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 20,000 mi	Fuel Filter (replace)
Every 25,000 mi	Exhaust System (Complete) (inspect) · Fuel System (inspect)
Every 50,000 mi	Engine Air Filter Element (replace) · Fuel Evaporative Emission Control System (inspect)
Every 100,000 mi	Spark Plug Wires (inspect) · Spark Plugs (replace) · Transfer Case Assembly (drain & refill) · Transmission Fluid & Filter (replace)
At 150,000 mi	Accessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Open recalls

NHTSA campaigns

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

Owner complaints

0 involved a crash · 0 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’95 ’96 ’97 ’98 ’99 ’00 ’01 ’02 ’03 ’04 ’05 ’06 ’07 ’23 ’24 ’26

No owner complaints on record with NHTSA for this vehicle.

Recalls NHTSA · verified

Showing 2 of 7 campaigns on record for this vehicle.

18V267000EquipmentReported 26/04/2018

General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana… Remedy: GM will notify owners, instructing them to contact Kidde to get a replacement fire extinguisher, free of charge. The recall began June 11, 2018. Owners may contact Chevrolet…

14V117000Air Bags:FrontalReported 17/03/2014

General Motors LLC (GM) is recalling certain model year 2009-2014 Chevrolet Express and GMC Savana vans manufactured January 27, 2009, through March 7, 2014 with a gross vehicle weight rating of 10,000 pounds and less… Remedy: GM will notify owners, and dealers will modify the passenger instrument panel free of charge. Notices to the owners of the heavy duty vans were mailed on April 28, 2014. The…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Express AWD. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 78 battery Vehicles taking 4.5 qt Engine oil filter 12690386 Engine air filter 22909882 Spark plug 12621258 Front wiper blades 15214346

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2009 Express AWD take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 2009 Express AWD have open recalls?

NHTSA lists 7 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Express AWD get?

EPA figures are 13 city / 16 highway / 14 combined mpg.

2009 Chevrolet Express AWD

Quick specs

Fitment & sizes

OE service part numbers OEM · verified

Full specifications

Engine & drivetrain NHTSA vPIC

Dimensions & weight NHTSA vPIC

Ratings & economy EPA / vPIC

Service quick specs OEM factory data

Lubricants & capacities

Engine torques

Chassis torques

Ignition

Battery & A/C

Service checks

Brakes

Multi-step torque procedures OEM · verified

Factory maintenance schedule OEM · verified

Reliability & federal safety record

No owner complaints on record with NHTSA for this vehicle.

Recalls NHTSA · verified

Common OBD-II trouble codes

VIN tools

Vehicles with shared specs

Reference guides

Related vehicles

Other years

Frequently asked