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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 500 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONS (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)AUXILIARY BATTERY AND TRAY REPLACEMENT (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)INSTALLATION PROCEDURE (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure (Battery, Charging System And Starting System)

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure (Battery, Charging System And Starting System)
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Battery Retainer Bolt And Retainer
    GM2014377Courtesy of GENERAL MOTORS CORP.
  1. Install the battery (1) into the battery tray (2).
    2. WARNING: Refer to Fastener Caution .
  2. Install the battery bolt and retainer (3) and tighten to 18 N.m (12 lb ft).
    3. Fig 2: Identifying Lower Auxiliary Battery Tray To Frame Bolts
    GM2014374Courtesy of GENERAL MOTORS CORP.
  3. Lift the battery and tray assembly (2) onto the upper auxiliary battery tray bolts (1). Do not tighten the upper bolts at this time.
  4. Install the lower battery tray bolts (3) and tighten to 25 N.m (18 lb ft).
  5. Connect the positive battery cable to the auxiliary battery and tighten the bolt to 14 N.m (123 lb in).
  6. Connect the negative battery cable to the auxiliary battery and to the primary battery. Refer to Battery Negative Cable Disconnection and Connection .
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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.