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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1533 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSSTARTER 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 2009 GMC Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Starter & Heat Shield
    GM663472Courtesy of GENERAL MOTORS CORP.
  1. If the starter was replaced, install the starter heat shield to the starter.
    2. Fig 2: View Of Starter
    GM1877493Courtesy of GENERAL MOTORS CORP.
  2. Position the starter to the vehicle.
    3. Fig 3: View Of Engine Wiring Harness & Components
    GM1877018Courtesy of GENERAL MOTORS CORP.
  3. Install the engine wiring harness lead (5) to the starter.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the engine wiring harness lead nut (2).

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

    5. Fig 4: View Of Starter Solenoid Cable & Nut
    GM1699544Courtesy of GENERAL MOTORS CORP.
  5. Install the starter solenoid cable lead (2) to the starter.
  6. Install the starter solenoid cable (1) nut.

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

    7. Fig 5: View of Starter Motor Bolts
    GM1877492Courtesy of GENERAL MOTORS CORP.
  7. Install the starter motor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    8. Fig 6: View Of Starter Solenoid Cable Clip & Bolt
    GM1702990Courtesy of GENERAL MOTORS CORP.
  8. Position the starter solenoid cable clip to the frame and install the starter solenoid cable clip bolt (2).

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    9. Fig 7: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  9. Position the oil pan skid plate and install the bolts, if equipped.

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

  10. Lower the vehicle.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) , Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)  or Battery Negative Cable Disconnection and Connection (With 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.