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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1009 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSAUXILIARY BATTERY POSITIVE CABLE REPLACEMENT (6.2L)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Auxiliary Battery Positive Cable
    GM1857381Courtesy of GENERAL MOTORS CORP.
  1. Install the auxiliary battery positive cable to the vehicle.
    2. Fig 2: View Of Battery Cable Nuts, Retainers & Bolts
    GM1857177Courtesy of GENERAL MOTORS CORP.
  2. Install the auxiliary battery positive cable push nuts (6).
  3. Install the auxiliary battery positive cable retainer (2) to the stud on the front of dash.
    4. NOTE: Refer to Fastener Notice .
  4. Install the auxiliary battery positive cable and nut (4) to the battery relay.

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

  5. Position the auxiliary battery positive cable boot (5).
  6. Connect auxiliary battery positive cable electrical connector (1) to the auxiliary battery relay.
    7. Fig 3: View Of Positive Cable Nut, Jumper Cable Terminal & Fuse Nut
    GM1857184Courtesy of GENERAL MOTORS CORP.
  7. Install the auxiliary battery positive cable to the mega fuse holder.
  8. Install the generator battery jumper cable terminal (2) to the mega fuse stud.
  9. Install the generator battery jumper cable nut (3) to the mega fuse holder.

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

  10. Install the auxiliary battery positive cable nut (1) to the mega fuse holder.

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

    11. Fig 4: View Of Fuse Cover & Connectors
    GM1857176Courtesy of GENERAL MOTORS CORP.
  11. Connect the auxiliary battery positive cable electrical connector (2) to the engine wiring harness connector.
  12. Install the relay (1) clip to the stud on the front of dash.
  13. Install the mega fuse cover (3).
    14. Fig 5: View Of Positive Battery Cable Connector & (UBEC)
    GM1702797Courtesy of GENERAL MOTORS CORP.
  14. Install the auxiliary battery positive cable connector (1) to the UBEC.
    15. Fig 6: View Of Junction Block & Retainers
    GM1702795Courtesy of GENERAL MOTORS CORP.
  15. Ensure that the junction block retainers are in the open position (1).
  16. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3).
    17. Fig 7: View Of Under Hood Junction Block Cover
    GM1702793Courtesy of GENERAL MOTORS CORP.
  17. Install the underhood junction block cover.
  18. Connect the auxiliary battery negative 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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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.