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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 INSTRUCTIONSSTARTER MOTOR 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 Starter Motor & Bolts
    GM1874075Courtesy of GENERAL MOTORS CORP.
  1. Install the starter motor.
    2. NOTE: Refer to Fastener Notice .
  2. Install the starter motor bolts (1).

    Tighten:  Tighten the bolts to 85 N.m (63 lb ft).

  3. Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) .
    4. Fig 2: View Of Starter Solenoid Cable Terminal, Bracket & Bolts
    GM1874038Courtesy of GENERAL MOTORS CORP.
  4. Install the engine wiring harness lead (2) to the starter motor.
  5. Install the engine wiring harness lead nut (3).

    Tighten:  Tighten the nut to 3.4 N.m (30 lb in).

    6. Fig 3: View Of Starter Solenoid Cable & Components
    GM1874037Courtesy of GENERAL MOTORS CORP.
  6. Install the starter solenoid cable (7) to the starter.
  7. Install the starter solenoid cable nut (6) to the starter.

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

  8. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (GMC) or Front Wheelhouse Liner Replacement - Right Side (Chevrolet) .
  9. 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.