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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 POSITIVE CABLE REPLACEMENT (6.6L)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 Positive Battery Cable Clips
    GM1873919Courtesy of GENERAL MOTORS CORP.
  1. Install the positive battery cable to the vehicle.
  2. Install the positive battery cable clips (1) onto the studs on the plenum front panel.
    3. Fig 2: View Of Positive Battery Cable Clip & Nuts
    GM1873918Courtesy of GENERAL MOTORS CORP.
  3. Install the positive battery cable clip (1) onto the stud on the plenum front panel.
    4. NOTE: Refer to Fastener Notice .
  4. Install the positive battery cable clip nuts (2) to the studs on the plenum front panel.

    Tighten:  Tighten the nuts to 3 N.m (27 lb in).

    5. Fig 3: View Of Mega Fuse Nuts
    GM1873917Courtesy of GENERAL MOTORS CORP.
  5. Install the positive battery cable terminals onto the mega fuse studs.
  6. Install the positive battery cable to mega fuse nuts (1).

    Tighten:  Tighten the nuts to 7.5 N.m (66 lb in).

    7. Fig 4: View Of Mega Fuse Cover
    GM1873916Courtesy of GENERAL MOTORS CORP.
  7. Install the mega fuse cover.
    8. Fig 5: View Of Positive Battery Cable
    GM1873915Courtesy of GENERAL MOTORS CORP.
  8. Connect the positive battery cable (1) to the glow plug control module.
    9. Fig 6: View Of Positive Battery Cable Connector & (UBEC)
    GM1702797Courtesy of GENERAL MOTORS CORP.
  9. Install the positive battery cable connector (1) to the UBEC.
    10. Fig 7: View Of Junction Block & Retainers
    GM1702795Courtesy of GENERAL MOTORS CORP.
  10. Ensure that the junction block retainers are in the open position (1).
  11. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3).
    12. Fig 8: View Of Under Hood Junction Block Cover
    GM1702793Courtesy of GENERAL MOTORS CORP.
  12. Install the underhood junction block cover.
  13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  14. 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.