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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2416 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSSTARTER REPLACEMENTINSTALLATION 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 does not describe the selected car, but rather 8 other vehicles, including the 2011 GMC Yukon XL, 2011 GMC Yukon, 2011 Chevrolet Tahoe, 2011 Chevrolet Suburban, and 2011 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Starter And Heat Shield
    GM663472Courtesy of GENERAL MOTORS CORP.
  1. If the starter was replaced, install the starter heat shield.
    2. Fig 2: Transmission Cover And Starter
    GM663489Courtesy of GENERAL MOTORS CORP.
  2. If the starter was replaced, snap the transmission cover onto the starter.
    3. Fig 3: Starter Solenoid Cable And Nut
    GM1699544Courtesy of GENERAL MOTORS CORP.
  3. Install the starter through the wheel well opening.
  4. Install the starter solenoid cable to the starter.
    5. CAUTION:

    Refer to Fastener Caution .

  5. Install the starter solenoid cable nut (1).

    Tighten 

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

    6. Fig 4: Starter Solenoid Cable Clip And Bolt
    GM1702990Courtesy of GENERAL MOTORS CORP.
  6. Position the starter solenoid cable clip to the frame and install the starter solenoid cable clip bolt (2).

    Tighten 

    Tighten the clip bolt to 10 N.m (89 lb in).

    7. Fig 5: Engine Wiring Harness Lead Terminal
    GM1699540Courtesy of GENERAL MOTORS CORP.
  7. Install the engine wiring harness lead terminal (2) to the starter.
  8. Install the engine wiring harness lead nut (3).

    Tighten 

    Tighten the lead nut to 5 N.m (44 lb in).

    9. Fig 6: Starter (4.8L, 5.3L & 6.0L)
    GM663527Courtesy of GENERAL MOTORS CORP.
  9. Position the starter into place.
  10. Install the starter bolts.

    Tighten 

    Tighten the starter bolts to 50 N.m (37 lb ft).

  11. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation .
  12. Raise the vehicle.
    13. Fig 7: Engine Wiring Harness Electrical Connector And Components
    GM1698087Courtesy of GENERAL MOTORS CORP.
  13. Connect the engine wiring harness electrical connector (4) to the oil level sensor.
    14. Fig 8: Transmission Cover Bolt
    GM663487Courtesy of GENERAL MOTORS CORP.
  14. Install the transmission cover bolt.

    Tighten 

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

  15. Install the oil pan skid plate if equipped, Refer to Oil Pan Skid Plate Replacement (1500 with RPO NZZ) , Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) .
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
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.