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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1615 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSSTARTER SOLENOID CABLE REPLACEMENT (WITH LU3)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 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 Solenoid Cable
    GM1877399Courtesy of GENERAL MOTORS CORP.
  1. Install the starter solenoid cable to the vehicle.
    2. Fig 2: View Of Battery Cable Components
    GM1702504Courtesy of GENERAL MOTORS CORP.
  2. Install the starter solenoid cable to the positive battery terminal.
    3. CAUTION: Refer to Fastener Caution .
  3. Tighten the starter solenoid cable nut (5) to 5 N.m (44 lb in).
  4. Close the starter solenoid cable cover at the positive battery terminal.
  5. Install the starter solenoid cable terminal (2) to the mega fuse stud.
  6. Install the starter solenoid cable nut (1) to the mega fuse stud and tighten to 9 N.m (80 lb in).
  7. Install the starter solenoid cable clip (4) to the A/C evaporator tube.
    8. Fig 3: View Of Mega Fuse Cover
    GM1702800Courtesy of GENERAL MOTORS CORP.
  8. Install the mega fuse cover.
  9. Raise the vehicle.
    10. Fig 4: View Of Starter Solenoid Cable & Nut
    GM1699544Courtesy of GENERAL MOTORS CORP.
  10. Install the starter solenoid cable (2) to the starter.
  11. Install the starter solenoid cable nut (1) to the starter and tighten to 9 N.m (80 lb in).
    12. Fig 5: View Of Starter Solenoid Cable Clip & Bolt
    GM1702990Courtesy of GENERAL MOTORS CORP.
  12. Position the starter solenoid cable clip to the frame and install the starter solenoid cable clip bolt (2).
  13. Install the starter solenoid cable clip (1) to the wheelhouse panel.
    14. Fig 6: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  14. Position the oil pan skid plate and install the bolts and tighten to 28 N.m (21 lb ft).
  15. Lower the vehicle.
  16. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  17. 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.