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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 114 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSBATTERY TRAY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Battery Tray Support
    GM1459608Courtesy of GENERAL MOTORS CORP.
  1. If necessary, position the battery tray support (3).
  2. Loosely install the battery tray support stud (1) and bolts (2).
    3. Fig 2: View Of Battery Tray
    GM1783863Courtesy of GENERAL MOTORS CORP.
  3. Install the battery tray.
  4. Loosely install the battery tray bolts and nut.
    5. NOTE: Refer to Fastener Notice .
  5. Tighten the battery tray support bolts/stud and the battery tray bolts/nut.

    Tighten: 

    • Tighten the battery support bolts and stud to 25 N.m (18 lb ft).
    • Tighten the battery tray bolts to 15 N.m (11 lb ft).
    • Tighten the battery tray nut to 12 N.m (106 lb in).

    6. Fig 3: Identifying Junction Block Assembly
    GM1783957Courtesy of GENERAL MOTORS CORP.
  6. Install the engine wiring harness electrical connector (5) and the forward lamp wiring harness electrical connector (4) to the battery tray.
  7. Install the body wiring harness electrical connectors (3) to the battery tray.
  8. Install the junction block and tighten the junction block bolts (2).

    Tighten:  Tighten the bolts to 7 N.m (62 lb in).

  9. Install the junction block cover (1).
    10. Fig 4: View Of Battery Positive Cable, Cable Clips, Bolts & Nuts
    GM1783030Courtesy of GENERAL MOTORS CORP.
  10. Install the positive battery cable to the junction block and tighten the battery cable bolt (6).

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

  11. Install the battery. Refer to Battery Replacement .
  12. Install the ECM. Refer to one of the following:
RENDER: 1.0x

NO RELATED

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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.