Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 621 (BATTERY)REPAIR INSTRUCTIONSBATTERY RELAY REPLACEMENT - AUXILIARYINSTALLATION 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 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Install the auxiliary battery relay.
NOTE: Refer to FASTENER NOTICE .
Install the auxiliary battery relay nuts.
Tighten

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

Fig 1: Install Auxiliary Battery Relay & Nuts
Courtesy of GENERAL MOTORS CORP.
Connect the auxiliary battery relay electrical connector (1).

Fig 2: Connect Auxiliary Battery Relay Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the auxiliary battery positive cable to the auxiliary battery relay.
Install the auxiliary battery positive cable nut.
Tighten

Tighten the nut to 9 N.m (80 lb in).
Position the boot to cover the stud.

Fig 3: Install Auxiliary Battery Positive Cable Nut
Courtesy of GENERAL MOTORS CORP.
Install the auxiliary battery positive cable to the auxiliary battery relay.
Install the auxiliary battery positive cable nut (2).
Tighten

Tighten the nut to 9 N.m (80 lb in).
Position the boot (3) to cover the stud.
Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .

Fig 4: Install Auxiliary Battery Positive Cable Nut
Courtesy of GENERAL MOTORS CORP.

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.