Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1997CHEVY EXPRESS G3500, VAN CARGO EXTENDED, 5.7 RREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALSTARTERSTARTING SYSTEM (G SERIES)ON-VEHICLE TESTINGSOLENOID CLICKS, ENGINE DOES NOT CRANK
1997 Chevrolet Chevy Express G3500, Van Cargo Extended, 5.7 R
Solenoid Clicks, Engine Does Not Crank
1997 Chevrolet Chevy Express G3500, Van Cargo Extended, 5.7 RSECTION Solenoid Clicks, Engine Does Not Crank
- On diesel engines, remove fuel pump relay, located in underhood fuse-relay center. On gasoline engines, disconnect ignition coil connector, located at top right side of engine. Turn ignition switch to START position for 15 seconds. Using a DVOM, measure voltage between battery positive and negative terminals. If voltage is greater than 9.6 volts, go to next step. If voltage is 9.6 volts or less, perform battery load test. If battery fails load test, replace battery. If battery passes load test, repair or replace starter motor.
- Disconnect Black negative battery cable terminal from right engine compartment, near negative battery post. Turn ignition switch to START position. Using a DVOM, measure voltage between battery negative terminal and negative battery cable ground terminal connection located at left engine compartment, near fender well. If voltage is .5 volts or less, go to next step. If voltage is more than .5 volts, check for high resistance between negative battery terminal and negative battery cable ground connection terminal located at left engine compartment, near fender well. Repair as necessary and recheck symptom.
- Reconnect Black negative battery cable terminal to right engine compartment, near negative battery post. Disconnect Black negative battery cable from left engine compartment, near fender well. Turn ignition switch to START position. Using a DVOM, measure voltage between battery negative terminal and negative battery cable ground terminal connection located at right engine compartment, near negative battery post. If voltage is more than .5 volts, check for high resistance in Black negative battery cable, between battery negative terminal and negative battery cable terminal connection located right engine compartment, near negative battery post. Repair as necessary and recheck symptom.
- Reconnect Black negative battery cable from left engine compartment, near fender well. If vehicle has diesel engine, go to next step. If vehicle has gasoline engine, go to step 6).
- Turn ignition switch to START position. Using a DVOM, measure voltage between auxiliary battery negative terminal and ground terminal connection located at left frame rail near auxiliary battery. If voltage is .5 volts or less go to next step. If voltage is more than .5 volts, check for high resistance in Black negative battery cable between auxiliary battery negative terminal and auxiliary battery negative cable terminal connection located at left frame rail near auxiliary battery.
- Turn ignition switch to START position. Using a DVOM, measure voltage between starter solenoid terminal "B" (Black wire) and battery negative terminal. If voltage is more than 9.0 volts, repair or replace starter. If voltage is 9.0 volts or less, check open in Black wire between starter terminal "B" and positive battery terminal. Repair as necessary and recheck symptom.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.