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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1221 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSBATTERY NEGATIVE CABLE REPLACEMENT (4.3L)INSTALLATION 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
WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Negative Battery Cable
    GM1877203Courtesy of GENERAL MOTORS CORP.
  1. If the negative battery cable was replaced, install the battery current sensor. Refer to Battery Current Sensor Replacement (4.3L)  or Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) .
  2. Install the negative battery cable to the vehicle.
    3. Fig 2: View Of Battery Cable Clips
    GM1877179Courtesy of GENERAL MOTORS CORP.
  3. Install the negative battery cable clip (2) to the right wheelhouse liner.
  4. Raise and support the vehicle.
  5. Install the negative battery cable clip (1) to the chassis harness.
    6. Fig 3: View Of Negative Battery Cable Terminal, Forward Lamp Wiring Harness Terminal & Ground Bolt
    GM1702546Courtesy of GENERAL MOTORS CORP.
  6. Route the negative battery cable terminal (3) through the opening between the radiator support and frame.
  7. Ensure that the negative battery cable is positioned behind the forward lamp harness.
  8. Install the forward lamp wiring harness terminal (2) to the frame. Ensure that the anti-rotation tab is inserted into the hole in the frame.
  9. Install the forward lamp wiring harness ground bolt (1).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    10. Fig 4: View Of Battery Cable Terminal, Battery Cable Bolt & Wiring Harness Terminal
    GM1877177Courtesy of GENERAL MOTORS CORP.
  10. Position the engine wiring harness terminal (3) against the engine block and position the negative battery cable terminal (1) on top of the engine wiring harness terminal.
  11. Install the negative battery cable bolt (2) to the front of the engine block.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    12. Fig 5: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  12. Position the oil pan skid plate and install the bolts, if equipped.

    Tighten:  Tighten the bolt to 28 N.m (21 lb ft).

  13. Lower the vehicle.
    14. Fig 6: View Of Battery Cable Components
    GM1702504Courtesy of GENERAL MOTORS CORP.
  14. Install the battery current sensor (3) clip to the battery tray.
    15. Fig 7: View Of Engine Harness Electrical Connector & Battery Current Sensor
    GM1702507Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine wiring harness electrical connector (1) to the battery current sensor.
  16. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (w/Single Battery)  or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery)  or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .
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.