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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 385 (BATTERY, CHARGING SYSTEM & STARTING SYSTEM)REPAIR INSTRUCTIONSSTARTER MOTOR REPLACEMENT (6.6L (LLY) ENGINE)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 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the starter motor.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the starter motor bolts.

    Tighten:  Tighten the bolts to 78 N.m (58 lb ft).

    3. Fig 1: View Of Starter (6.6L (LLY) Engine)
    GM1334814Courtesy of GENERAL MOTORS CORP.
  3. Install the positive battery cable lead (8) to the starter.
  4. Install the positive battery cable nut (7).

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

    5. Fig 2: View Of Cables, Connector & Retainers - Lower Right Of Engine
    GM1369543Courtesy of GENERAL MOTORS CORP.
  5. Install the engine wiring harness lead (1) to the starter.
  6. Install the engine wiring harness nut (4).

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

    7. Fig 3: View Of Engine Wiring Harness, Nut & Lead
    GM1369542Courtesy of GENERAL MOTORS CORP.
  7. Install the right fender wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  8. If necessary, install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery)  or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
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.