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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 SOLENOID 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 Starter Solenoid Cable
    GM1874042Courtesy of GENERAL MOTORS CORP.
  1. Install the starter solenoid cable to the vehicle.
    2. Fig 2: View Of Battery Components
    GM1873941Courtesy of GENERAL MOTORS CORP.
  2. Install the starter solenoid cable (5) to the battery positive post.
    3. NOTE: Refer to Fastener Notice .
  3. Tighten the starter solenoid cable nut (2).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  4. Close the starter solenoid cable positive battery post cover (1).
    5. Fig 3: View Of Negative Battery Cable & Components
    GM1873940Courtesy of GENERAL MOTORS CORP.
  5. Install the starter solenoid cable to the battery positive post.
  6. Tighten the starter solenoid cable nut (1).

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

  7. Close the starter solenoid cable positive battery post cover.
  8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
    9. Fig 4: View Of Starter Solenoid Cable Channel Bolts
    GM1874040Courtesy of GENERAL MOTORS CORP.
  9. Position the starter solenoid cable to the oil pan and install the starter solenoid cable channel bolts (1).

    Tighten:  Tighten the bolts to 12 N.m (106 lb in).

    10. Fig 5: View Of Starter Solenoid Cable Terminal, Bracket & Bolts
    GM1874038Courtesy of GENERAL MOTORS CORP.
  10. Reposition the starter solenoid cable bracket (1) and install the engine wiring harness to the clips on the rear of the bracket.
    11. Fig 6: View Of Starter Solenoid Cable & Components
    GM1874037Courtesy of GENERAL MOTORS CORP.
  11. Position the starter solenoid cable clip to the frame and install the bolt (4).

    Tighten:  Tighten the bolt to 16 N.m (12 lb ft).

  12. Install the starter solenoid cable bracket onto the stud and install the nut (5).

    Tighten:  Tighten the nut to 8 N.m (71 lb in)

  13. Position the engine wiring harness ground terminal (1) behind the starter solenoid cable terminal (2) and against the engine block.
  14. Install the starter solenoid cable bolt (3) to the engine block.

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

  15. Install the starter solenoid cable (7) onto the starter.
  16. Install the starter solenoid cable nut (6) to the starter.

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

    17. Fig 7: View Of Coolant Heater Cord
    GM1874035Courtesy of GENERAL MOTORS CORP.
  17. Connect the coolant heater cord (1) to the coolant heater.
    18. Fig 8: View Of Starter Solenoid Cable At Frame
    GM1874033Courtesy of GENERAL MOTORS CORP.
  18. Position the starter solenoid cable (1) to the frame.
  19. Install the starter solenoid cable bolt to the frame.

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

    20. Fig 9: View Of Engine Wiring Harness Clips
    GM1874031Courtesy of GENERAL MOTORS CORP.
  20. Install the engine wiring harness clip (1) to the starter solenoid cable.
  21. Install the engine wiring harness clips (2) to the starter solenoid cable channel.
    22. Fig 10: View Of Oil Pan Skid Plate & Bolts
    GM1698083Courtesy of GENERAL MOTORS CORP.
  22. Install the oil pan skid plate and tighten the rear 2 bolts and install and tighten the front 2 bolts.

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

  23. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (GMC) or Front Wheelhouse Liner Replacement - Right Side (Chevrolet) .
    24. Fig 11: View Of Mega Fuse Nut
    GM1874029Courtesy of GENERAL MOTORS CORP.
  24. Install the starter solenoid cable branch terminal to the mega fuse stud.
  25. Install the starter solenoid cable to mega fuse nut (1).

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

    26. Fig 12: View Of Mega Fuse Cover
    GM1873916Courtesy of GENERAL MOTORS CORP.
  26. Install the mega fuse cover.
    27. Fig 13: View Of Starter Solenoid Cable Clips
    GM1874027Courtesy of GENERAL MOTORS CORP.
  27. Install the starter solenoid cable clip (3) to the battery tray.
  28. Install the starter solenoid cable clips (4) to the A/C evaporator tube.
  29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  30. 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.