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 MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1009 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSSTARTER MOTOR REPLACEMENT (6.6L)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 Starter Motor & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the starter motor.

NOTE: Refer to Fastener Notice .

Install the starter motor bolts (1).
Tighten: Tighten the bolts to 85 N.m (63 lb ft).
Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) .

Fig 2: View Of Starter Solenoid Cable Terminal, Bracket & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the engine wiring harness lead (2) to the starter motor.
Install the engine wiring harness lead nut (3).
Tighten: Tighten the nut to 3.4 N.m (30 lb in).

Fig 3: View Of Starter Solenoid Cable & Components

Courtesy of GENERAL MOTORS CORP.

Install the starter solenoid cable (7) to the starter.
Install the starter solenoid cable nut (6) to the starter.
Tighten: Tighten the nut to 9 N.m (80 lb in).
Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) or Front Wheelhouse Liner Replacement - Right Side (GMC) .
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.