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 MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISENGINE MECHANICALSTARTERBATTERY, CHARGING SYSTEM AND STARTING SYSTEMREPAIR INSTRUCTIONSBATTERY POSITIVE CABLE EXTENSION CABLE JUNCTION BLOCK REPLACEMENTINSTALLATION PROCEDURE

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure

Fig 1: View Of Auxiliary Positive Battery Cable At Starter Stud

Courtesy of GENERAL MOTORS CORP.

Install the auxiliary positive battery cable.
Install the auxiliary positive battery cable to the starter stud.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Install the starter lead nut.
Tighten: Tighten the nut to 9 N.m (80 lb in).

Fig 2: View Of Auxiliary Cable Clip Bolt At Frame

Courtesy of GENERAL MOTORS CORP.

Install the auxiliary cable clip bolt to the frame.
Tighten: Tighten the bolt to 10 N.m (89 lb in).
Lower the vehicle.

Fig 3: Auxiliary Positive Cable At Junction Block

Courtesy of GENERAL MOTORS CORP.

Install the auxiliary positive battery cable to the junction block.
Install the auxiliary positive battery cable nut to the junction block.
Tighten: Tighten the nut to 8 N.m (71 lb in).
Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .

RENDER: 1.0x

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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.