Battery, Charging System and Starting System Chevrolet Chevy Express H1500

Fastener Tightening Specifications

Fastener Tightening Specifications

Battery Usage

Battery Usage

Generator Usage

Generator Usage

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Generator Connector & Terminal Parts Information

Generator Terminal Identification

Scheme 12

Generator - Auxiliary (KD9/YF2) Connector & Terminal Parts Information

Generator - Auxiliary (KD9/YF2) Terminal Identification

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Diagnostic Starting Point - Engine Electrical

Begin the system diagnosis with the Diagnostic System Check - Vehicle . The Diagnostic System Check will provide the following information

1. The identification of the control modules which command the system
2. The ability of the control modules to communicate through the serial data circuit
3. The identification of any stored diagnostic trouble codes (DTCs) and their status

The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located.

Scan Tool Data List

Engine Control Module (ECM)/Powertrain Control Module (PCM)

Circuit Description

The module has an internal voltage sensor with a dedicated circuit that checks the battery positive voltage and battery negative circuit voltage to determine if it is between 9-15.9 volts.

DTC Descriptor

This diagnostic procedure supports the following DTC

DTC B1327 Device Power 1 Circuit Low

Conditions for Running the DTC

This DTC shall run only if the module has power, ground and the ignition is not in START mode. This DTC shall execute regardless of the battery voltage.

Conditions for Setting the DTC

1. This DTC shall be set as current when the voltage falls below 9 volts for 2 seconds.
2. When the vehicle exits START the module shall delay checking the voltage for 2 seconds.

Action Taken When the DTC Sets

A message shall be sent out via class 2 and may illuminate the charge indicator.

Conditions for Clearing the MIL/DTC

1. In order to clear the DTC from a current status the voltage shall be greater than 9.54 volts for 2 seconds.
2. DTC may be cleared with a scan tool.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 3: Tests for the proper operation of the complete circuit.
2. 4: Tests for the proper operation of the battery positive voltage circuit.

DTC B1327

The engine control module (ECM)/powertrain control module (PCM) monitors the system voltage to make sure that the voltage stays within the proper range. If the ECM/PCM detects an excessively low system voltage, DTC P0562 will set.

When the charging system detects a fault, the instrument panel cluster (IPC) displays a message or the charge indicator will light.

This diagnostic procedure supports the following DTC

DTC P0562 System Voltage Low

1. The engine run time is more than 20 seconds and above 1,200 RPM.
2. The vehicle speed is above 8 km/h (5 mph).

The ECM/PCM detects an improper voltage below 11 volts for 5 seconds.

1. The ECM/PCM stores the DTC information into memory when the diagnostic runs and fails.
2. The ECM/PCM will store conditions which were present when the DTC set as Failure Records data only.
3. The ECM/PCM disables most outputs.
4. The transmission defaults to a predetermined gear.
5. The torque converter clutch (TCC) operation is inhibited.
6. The IPC displays a message.
7. The malfunction indicator lamp (MIL) will not illuminate.

Conditions for Clearing the DTC

1. The Conditions for Setting the DTC are no longer present.
2. A history DTC will clear after 40 malfunction-free ignition cycles.

DTC P0562

The engine control module (ECM)/powertrain control module (PCM) continuously monitors that the system voltage stays within the proper range. If the ECM/PCM detects an excessively high system voltage, DTC P0563 will set. A high voltage condition may cause a stalling condition or other driveability concerns.

This diagnostic procedure supports the following DTC

DTC P0563 System Voltage High

1. The engine run time is more than 20 seconds.
2. The engine is running above 1,200 RPM.
3. The vehicle speed is above 8 km/h (5 mph).

1. The ECM/PCM senses the system voltage is above 19 volts.
2. All of the conditions are present for 5 seconds.

1. The ECM/PCM stores DTC P0563 in the PCM memory when the diagnostic runs and fails.
2. The ECM/PCM will record the operating conditions at the time the diagnostic fails. The ECM/PCM stores this information in Failure Records.
3. The ECM/PCM disables most outputs.
4. The transmission defaults to a predetermined gear.
5. The torque converter clutch (TCC) operation is inhibited.
6. The instrument panel cluster (IPC) displays a message.
7. The malfunction indicator lamp (MIL) will not illuminate.

1. The Conditions for Setting the DTC are no longer present.
2. A history DTC will clear after 40 malfunction-free ignition cycles.

DTC P0563

The engine control module (ECM) supplies a ground path for the crank relay when start enable has been requested. The ECM monitors this circuit for conditions that are incorrect for the commanded state. If the ECM detects an improper circuit condition, crank relay DTC P0615 will set.

This diagnostic procedure supports the following DTC

DTC P0615 Starter Relay Control Circuit

System voltage is between 9-16 volts.

1. The ECM detects an improper voltage level on the control circuit that controls the crank relay.
2. The condition exists for at least 2 seconds.

1. The ECM will not illuminate the malfunction indicator lamp (MIL).
2. The ECM will store the conditions present when the DTC set as Failure Records data only.

1. The history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
2. The DTC can be cleared by using the scan tool Clear DTC Information function.

Diagnostic Aids

Ignition system DTCs set with the ignition switch in the START position if the crank relay or the starter is inoperative. When the ECM enables starter operation, the ECM also initiates the diagnostic test routines for DTCs P0335, P0340, and P0385. If a condition exists which prevents the engine from cranking, the ECM will not receive signal input from the crankshaft position (CKP) and camshaft position (CMP) sensors, and the DTCs will set.

Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may assist in diagnosing the condition. The information may help determine how often the condition that set the DTC occurs.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: Listen for an audible click when the crank relay operates. Press the ignition switch back and forth from the ON to START positions. Repeat this as necessary.
2. 3: This step tests for voltage at the coil side of the crank relay.
3. 4: This step verifies that the ECM is providing ground to the crank relay.
4. 5: This step tests if ground is constantly being applied to the crank relay.

DTC P0615

The engine control module (ECM) uses the generator turn on signal circuit to control the load of the generator on the engine. A high side driver in the ECM applies a voltage to the voltage regulator. This signals the voltage regulator to turn the field circuit ON and OFF. When the ECM turns ON the high side driver, the voltage regulator turns ON the field circuit. When the ECM turns OFF the high side driver, the voltage regulator turns OFF the field circuit.

The ECM monitors the state of the generator turn on signal circuit. The ECM should detect a low generator turn on signal circuit voltage when the key is ON and the engine is OFF, or when the charging system malfunctions. With the engine running, the ECM should detect a high generator turn on signal circuit. The ECM performs key ON and RUN tests to determine the status of the generator turn on signal circuit. During the key ON test, if the ECM detects a high generator turn on signal circuit voltage, DTC P0621 will set. DTC P0621 will also set if, during the RUN test, the ECM detects a low generator turn on signal circuit. When the DTC sets, the ECM will send a class 2 serial data message to the instrument panel cluster (IPC) to illuminate the charge indicator.

This diagnostic procedure supports the following DTC

DTC P0621 Generator L-Terminal Circuit

1. The ignition is ON.
2. The engine speed is more than 1,000 RPM.

1. The ECM detects the GEN L-Terminal active with the ignition ON.
2. The ECM detects the GEN L-Terminal inactive with the engine operating.
3. The above conditions are present for 6 seconds.

1. The ECM will record the operating conditions presents when the DTC set as Failure Records data only.
2. The IPC displays a message.
3. The malfunction indicator lamp (MIL) will not illuminate.

1. The Conditions for Setting the DTC are no longer present.
2. A history DTC will clear after 40 malfunction free ignition cycles.
3. The ECM receives the clear code command from the scan tool.

DTC P0621

Diagnostic Instructions

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-system-check-vehicle) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

Circuit/System Description

The engine control module (ECM)/powertrain control module (PCM) uses the generator field duty cycle signal circuit to monitor the duty cycle of the generator. The generator field duty cycle signal circuit connects to high side of the field windings in the generator. A pulse width modulated (PWM) high side driver in the voltage regulator turns the field windings ON and OFF. The ECM/PCM uses the PWM signal input to determine the generator load on the engine. This allows the ECM/PCM to adjust the idle speed to compensate for high electrical loads. The ECM/PCM monitors the status of the generator field duty cycle signal circuit. When the key is in the RUN position and the engine is OFF, the ECM/PCM should detect a duty cycle near 0 percent. However, when the engine is running, the duty cycle should be between 5-95 percent.

1. The vehicle speed is above 8 km/h (5 mph).
2. The system voltage is between 9.5-18 volts.

The ECM/PCM detects an out of range PWM signal during the KEY ON test the ECM/PCM detects, a PWM signal greater than 65 percent for at least 5 seconds or during the RUN test a PWM signal less than 5 percent for at least 15 seconds.

1. The ECM/PCM will command the charge indicator and or warning message to be illuminated on the instrument panel cluster (IPC) and the driver information center (DIC), if equipped.
2. The ECM/PCM will not illuminate the malfunction indicator lamp (MIL).
3. The ECM/PCM will store conditions, which were present when the DTC set as Fail Records data only.

1. The ECM/PCM will command the message OFF after one trip in which the diagnostic test has been run and passed.
2. The history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.

Reference Information

Schematic Reference

Starting and Charging Schematics

Connector End View Reference

Engine Electrical Connector End Views

Description and Operation

Charging System Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__wiring-repairs)

Scan Tool Reference

1. «Scan Tool Data List»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__scan-tool-data-list)
2. «Scan Tool Data Definitions»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)

Circuit/System Verification

With the scan tool installed, ignition ON and the engine running, observe the GEN-F Terminal Signal parameter in the ECM/PCM data list. The GEN-F Terminal Signal parameter should read between 5-95 percent.

Circuit/System Testing

1. Ignition OFF, disconnect the generator harness connector.
2. The ignition ON, engine OFF, connect a test lamp to battery positive voltage and repeatedly probe the generator field duty cycle circuit, harness side while monitoring the GEN-F Terminal Signal Parameter in the data list. It should change from 0 percent to above 95 percent. If the GEN-F Terminal Signal parameter was not affected by the test lamp, test the GEN-F Terminal Signal circuit for a short to ground, a high resistance, an open circuit. If the circuit tests normal replace the ECM/PCM.
3. If the circuit test normal during the Ignition ON/Run tests, and the ECM/PCM parameter changed from 0 percent to above 95 percent replace the generator.

Repair Procedures

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Control Module References»(/chevrolet/chevy-express-h1500/2003-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for ECM/PCM replacement, setup, and programming
2. «Generator Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) for generator replacement

Symptoms - Engine Electrical

1. Perform «Diagnostic System Check - Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-system-check-vehicle) before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. The control modules can communicate via the serial data link.
2. Review the system descriptions and operations in order to familiarize yourself with the system functions. Refer to one of the following system operations: «Battery Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) «Starting System Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__starting-system-description-and-operation) «Charging System Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the starting and charging systems. Refer to «Checking Aftermarket Accessories»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__checking-aftermarket-accessories) .
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Starter Solenoid Does Not Click»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__starter-solenoid-does-not-click)
2. «Starter Solenoid Clicks, Engine Does Not Crank»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__starter-solenoid-clicks-engine-does-not)
3. «Engine Cranks Slowly»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__engine-cranks-slowly)
4. «Charge Indicator Always On»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)
5. «Charge Indicator Inoperative»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__charge-indicator-inoperative)
6. «Battery Inspection/Test (Non-HP2)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)
7. «Battery Electrical Drain/Parasitic Load Test»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)
8. «Battery Common Causes of Malfunction»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__battery-common-causes-of-malfunction)
9. «Starter Motor Noise Diagnosis»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)
10. «Charging System Test»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__charging-system-test)
11. «Generator Noise Diagnosis»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system)

Follow these instructions in order to avoid an incorrect diagnosis because of connections

1. If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . This may cut through any coating or through any oxidation that may be present on the bolt. Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit.
2. If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following steps: Disconnect the negative battery cable. Disconnect the positive battery cable. Install the test adapters on the terminals. Follow the instructions for testing a removed battery.
3. If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the vehicle with the battery cables connected, perform the following steps: Disconnect the negative battery cable. Disconnect the positive battery cable. Install the tester adapters. IMPORTANT: Always write the test code displayed by the tester on the repair order for any warranty purposes. The number is a unique code that describes the test data for a particular battery at a particular time. The test code may occasionally repeat when you retest the same battery. More often, each test will result in a different code. Use the test code from the second, or Out of Vehicle test. Follow the instructions for testing a removed battery. Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result. Use the test code from the second test for any warranty purposes.
4. Use the correct terminal adapters. Do not use any common bolts or a combination of bolts, of nuts, and of washers as adapters when testing the battery. Use the test adapters that are provided with the J 42000 or GM P/N 12303040 terminal adapters. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . If the adapters that are provided with the J 42000 require replacement, use GM P/N 12303040. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . Any other adapter may not contact the correct areas of the battery terminal, causing a resistance that may result in an invalid battery test result.

Battery Inspection/Test (Non-HP2)

Tools Required

J 42000 Battery Tester. See Special Tools .

1. For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts.
2. The charging area should be well ventilated.
3. Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test it using the J 42000 before charging. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .

Charging Time Required

The time required to charge a battery will vary depending upon the following factors

1. The battery charger capacity-The higher the charger's amperage, the less time it will take to charge the battery.
2. The state-of-charge of the battery-A completely discharged battery requires more than twice as much charging time as a half charged battery. In a discharged battery with a voltage below 11 volts, the battery has a very high internal resistance and may only accept a very low current at first. Later, as the charging current causes the acid content to increase in the electrolyte, the charging current will increase. Extremely discharged batteries may not activate the reversed voltage protection in some chargers. Refer to the manufacturers instructions for operating this circuitry.
3. The temperature of the battery-The colder the battery is, the more time it takes to recharge the battery. The charging current accepted by a cold battery is very low at first. As the battery warms, the charging current will increase.

Charging Procedure

Note. Turn OFF the ignition when connecting or disconnecting the battery cables, the battery charger or the jumper cables. Failure to do so may damage the ECM/PCM or other electronic components.

Note. Refer to FASTENER NOTICE .

When charging side-terminal batteries with the battery cables connected, connect the charger to the positive cable bolt and to a ground located away from the battery. When charging side-terminal batteries with the battery cables disconnected, install the battery side terminal adapters and connect the charger to the adapters.

Tighten: Tighten the battery side terminal adapters to 15 N.m (11 lb ft).

Use the following procedure to charge the battery

1. Turn OFF the charger.
2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal on the Battery or Fuse Block - Underhood.
4. Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment that is connected directly to the battery negative terminal, but away from the battery. If the negative battery cable is disconnected and a terminal adapter is being used, connect directly to the adapter.
5. Turn ON the charger and set to the highest setting for normal charging.
6. Inspect the battery every half hour after starting the battery charger. Charge the battery until the taper-rate charger indicates that the battery is fully charged. Estimate the battery temperature by feeling the side of the battery. If it feels hot to the touch or its temperature is over 45°C (125°F), discontinue charging and allow the battery to cool before resuming charging.
7. After charging, test the battery. Refer to «Battery Inspection/Test (Non-HP2)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

J 38758 Parasitic Draw Test Switch. See Special Tools .

1. Be sure to rule out any possible obvious influences, such as customer error or aftermarket equipment.
2. Customer driving habits, such as regular short trips. This does not allow enough time to properly charge the battery. Refer to «Battery Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Verify that the battery and charging system are in proper working order. Refer to «Battery Charging (Non-HP2)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) and «Charging System Test»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__charging-system-test) .
4. A battery discharging for no apparent reason while the vehicle is parked can be caused by an intermittent draw, such as a module waking up, or a continuous draw, such as a dome light or stuck relay.
5. Some systems and modules such as OnStar®, and regulated voltage control (RVC), if equipped, are designed to wake-up, perform a task, and go back asleep at regular intervals. Refer to «Body Control System Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/communication-devices/#data-communication-system) for the system or modules description and operation.
6. Remote keyless entry (RKE) will wake up due to an outside input. Refer to «Keyless Entry System Description and Operation»(/chevrolet/chevy-express-h1500/2003-2012/remont/door-locks-anti-theft-systems/#keyless-entry-system-and-remote-functions__keyless-entry-system-description-and-operation) .
7. The battery run down time will vary depending on cold cranking amperage (CCA) and reserve capacity (RC). If the CCA and RC are higher, then the battery run down time would be longer. If the CCA and RC are lower, then the battery run down time would be shorter. The graph below indicates roughly how many days a 690 CCA battery with at 110 min. RC (60.5 AH) starting at 80 percent state of charge will last with a constant current draw until it reaches 50 percent state of charge. Differences in battery rating and temperature will affect the results.

Battery Electrical Drain/Parasitic Load Test

Note. Do not turn the parasitic draw test switch to the OFF position with the engine running. Damage will occur to the vehicle's electrical system.

Note. The test switch must be in the ON position when removing the fuses in order to maintain continuity in the electrical system. This avoids damaging the digital multimeter due to accidental overloading, such as a door being opened to change a fuse.

1. Disconnect the battery negative cable from the battery negative terminal.
2. Install the male end of the J 38758 to the battery ground terminal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
3. Turn the J 38758 knob to the OFF position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
4. Install the battery negative cable to the female end of the J 38758 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
5. Turn the J 38758 knob to the ON position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
6. Road test the vehicle and activate ALL of the accessories, including the radio and air conditioning. This may take up to 30 minutes.
7. Park the vehicle. Turn the ignition switch to the OFF position and remove the ignition switch key.
8. Connect a 10A fused jumper wire to the test switch tool terminals.
9. Turn the J 38758 knob to the OFF position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . The current now flows through the jumper wire.
10. Wait 1 minute. If the fuse blows, install an inductive ammeter and go to step 19.
11. Remove the fused jumper wire.
12. Set a digital multimeter to the 10A scale.
13. Connect the digital multimeter to the test switch tool terminals.
14. Turn the J 38758 knob to the OFF position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . The current flows now through the digital multimeter.
15. Wait 1 minute. Check and record the current reading. When there is a current reading on 2A or less, turn the J 38758 knob to the ON position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . The electrical current will now pass through the switch. Then switch the digital multimeter down to the 2A scale for a more accurate reading when the J 38758 knob is turned OFF. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
16. Turn the J 38758 knob to the OFF position. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) . Wait 15 minutes for most vehicles.
17. Check and record the current reading.
18. Note the battery reserve capacity, amp hour rating. Refer to «Battery Usage»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__battery-usage) . Divide the reserve capacity by 4, amp hour rating by 2.4. Compare this to the multimeter milliampere reading taken in the previous step. The parasitic current drain should not exceed this number. Example: If a battery has a reserve capacity of 100 minutes, (60 A/H) the current drain should not exceed 25 mA.
19. If excessive current drain is not found at this time and there are no other apparent causes, complete the following
20. Using the MIN/MAX function of the digital multimeter, monitor the parasitic drain overnight or during the day. This will determine if something has been activated during that time frame.
21. When the vehicle has an unacceptable amount of parasitic current drain, remove each fuse one at a time until the current drain falls to an acceptable level. This will indicate which circuit is causing the drain. Refer to «Power Distribution Schematics»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-introduction) to diagnose exactly which part of the suspect circuit is causing the parasitic drain. In some cases a non-fused circuit or component, such as a relay, is the cause of excessive parasitic current drain.
22. Repeat the parasitic current drain test procedure after any repair has been completed to make sure that the parasitic current drain is at an acceptable level.
23. When the cause of the excessive current drain has been located and repaired, remove the J 38758 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
24. Connect the battery negative cable to the battery negative terminal.

Battery Common Causes of Malfunction

A battery is not designed to last forever. With proper care, however, the battery will provide years of good service. If the battery tests good but still fails to perform well, the following are some of the more common causes

1. A vehicle accessory was left on overnight.
2. The driving speeds have been slow with frequent stops with many electrical accessories in use, particularly air conditioning, headlights, wipers, heated rear window, cellular telephone, etc.
3. The electrical load has exceeded the generator output, particularly with the addition of aftermarket equipment.
4. Existing conditions in the charging system, including the following possibilities: A slipping belt A bad generator
5. The battery has not been properly maintained, including a loose battery hold down or missing battery insulator if used.
6. There are mechanical conditions in the electrical system, such as a short or a pinched wire, attributing to power failure. Refer to «General Electrical Diagnosis»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis) .

Electrolyte Freezing

The freezing point of electrolyte depends on its specific gravity. A fully charged battery will not freeze until the ambient temperature gets below -54°C (-65°F). However, a battery with a low state of charge may freeze at temperatures as high as -7°C (+20°F). Since freezing may ruin a battery, the battery should be protected against freezing by keeping it properly charged. As long as the green eye is visible in the hydrometer, the freezing point of the battery will be somewhere below -32°C (-25°F).

Battery Protection During Vehicle Storage

Certain devices on the vehicle maintain a small continuous current drain on the battery. A battery that is not used for an extended period of time will discharge. Eventually permanent damage will result. Discharged batteries will also freeze in cold weather. Refer to Battery Inspection/Test (Non-HP2) .

In order to maintain a battery state of charge while storing the vehicle for more than 30 days

1. Ensure that the green dot is visible in the built-in hydrometer.
2. Disconnect the battery ground to protect the battery from discharge by parasitic current drains.

When the battery cannot be disconnected

1. Maintain a high state of charge.
2. Establish a regular schedule for recharging the battery every 20-45 days.

A battery that has remained in a discharged state for a long period of time is difficult to recharge or may be permanently damaged.

Jump Starting in Case of Emergency (Non HP2)

Note. This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components.

This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables.

1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. Do not let the 2 vehicles touch. Make sure that the jumper cables do not have loose clamps or missing insulation.
2. Perform the following steps on both vehicles: Place the automatic transmission in PARK. Block the wheels. Set the parking brake. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. Turn OFF the ignition switch.
3. Attach the end of one jumper cable to the positive terminal of the discharged battery.
4. Attach the other end of the first cable to the positive terminal of the booster battery.
5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery.
6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery.
7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM.
8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: Turn the ignition OFF. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Attempt to start the engine of the vehicle with the discharged battery.
9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started.

Charging System Test

Charging System Test

Diagnostic Aids (Diesel Engine Only)

When starting a cold engine, glow plug cycle time can last 18 seconds with an after glow time of 30 seconds depending on engine temperature. Average glow plug amperage draw is 130 amps. The intake air heater may draw as high as 45 amps. Due to these high current draws the battery indicator may remain on until the amperage draw is reduced.

Charge Indicator Always On

Charge Indicator Inoperative

Charge Indicator Inoperative

Noise from a generator may be due to electrical or mechanical noise. Electrical noise magnetic whine usually varies with the electrical load placed on the generator and is a normal operating characteristic of all generators. When diagnosing a noisy generator, it is important to remember that loose or misaligned components around the generator may transmit the noise into the passenger compartment and that replacing the generator may not solve the problem.

Generator Noise Diagnosis

Starter Solenoid Does Not Click

Starter Solenoid Does Not Click

Starter Solenoid Clicks, Engine Does Not Crank

Starter Solenoid Clicks, Engine Does Not Crank

Engine Cranks Slowly

Perform the following checks

1. Battery-Battery Inspection/Test. Refer to «Battery Inspection/Test (Non-HP2)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Wiring-Inspect the wiring for damage. Inspect all connections to the starter motor, solenoid, battery, and all ground connections. Refer to «Circuit Testing»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__circuit-testing) , «Wiring Repairs»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__wiring-repairs) , «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor) and «Connector Repairs»(/chevrolet/chevy-express-h1500/2003-2012/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-troubleshooting-diagnosis__connector-repairs) .
3. Engine-Make sure the engine is not seized. Refer to «Symptoms - Engine Mechanical»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-1-of-4) .

If the battery, the wiring and the engine are functioning properly and the engine continues to crank slowly, replace the starter motor. Refer to Starter Motor Replacement (4.3L) or Starter Motor Replacement (4.8L, 5.3L, and 6.0L) or Starter Motor Replacement (6.6L) .

1. Inspect the flywheel ring gear for damage or unusual wear.
2. Shim the starter if applicable.
3. In order to add pinion to ring gear clearance a full size shim must be used. Do not shim only 1 starter mounting bolt. There are 3 shims available in different shapes for clearance. All are 1 mm (0.039 in) thick.

Starter Motor Noise Diagnosis

Removal Procedure

1. Turn OFF all the lamps and accessories.
2. Turn the ignition OFF.
3. Remove the battery ground (negative) cable and bolt from the battery.
4. Remove the battery ground (negative) cable and bolt from the battery for auxiliary battery.

Installation Procedure

1. Install the battery ground (negative) cable and bolt to the battery. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
2. Install the battery ground (negative) cable and bolt to the battery for the auxiliary battery. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).

1. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the battery negative cable lead from the inner fender panel.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
4. Disconnect the battery negative cable lead from the frame.
5. Disconnect the battery negative cable lead from the engine block.
6. Lower the vehicle.
7. Remove the battery negative cable from the vehicle.

1. Install the battery negative cable to the vehicle.
2. Connect the battery negative cable lead to the engine block. Tighten: Tighten the bolt that retains the battery negative cable lead to the engine block to 25 N.m (18 lb ft).
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
4. Connect the battery negative cable lead to the frame.
5. Lower the vehicle.
6. Connect the battery negative cable lead to the inner fender panel. Tighten: Tighten the nut that retains the battery negative cable to the inner fender well to 10 N.m (89 lb in).
7. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) . Tighten: Tighten the battery negative terminal bolt to 17 N.m (13 lb ft).

1. On all models, disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the battery negative cable lead from the inner fender panel.
3. On models with 5.3L engine, disconnect the battery negative cable lead from the frame.
4. On all models, disconnect the battery negative cable lead from the engine block.
5. On models with 4.8L and 6.0L engine, disconnect the battery negative cable lead from the frame.
6. On all models, remove the battery negative cable from the vehicle.

1. On all models, install the battery negative cable to the vehicle.
2. On models with 4.8L and 6.0L engine, connect the battery negative cable lead to the frame.
3. On all models, connect the battery negative cable lead to the engine block. Tighten: Tighten the bolt that retains the battery negative cable lead to the engine block to 25 N.m (18 lb ft).
4. On models with 5.3L engine, connect the battery negative cable lead to the frame.
5. On all models, connect the battery negative cable lead to the inner fender panel. Tighten: Tighten the nut that retains the battery negative cable to the inner fender well to 10 N.m (89 lb in).
6. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) . Tighten: Tighten the battery negative terminal bolt to 17 N.m (13 lb ft).

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
2. Disconnect the battery negative cable from the auxiliary battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect the negative ground leads from the frame.
4. Remove the battery negative cable from the vehicle.

1. Install the battery negative cable to the vehicle.
2. Connect the negative ground leads to the frame. Tighten: Tighten the negative ground leads to 10 N.m (89 lb in).
3. Connect the battery negative cable to the auxiliary battery. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
4. Lower the vehicle.

1. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the battery negative cable lead from the inner fender panel.
3. Disconnect the battery negative cable lead from the engine block.
4. Remove the battery negative cable from the vehicle.

1. Install the battery negative cable to the vehicle.
2. Connect the battery negative cable lead to the engine block. Tighten: Tighten the bolt that retains the battery negative cable lead to the engine block to 25 N.m (18 lb ft).
3. Connect the battery negative cable lead to the inner fender panel. Tighten: Tighten the nut that retains the battery negative cable to the inner fender well to 10 N.m (89 lb in).
4. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) . Tighten: Tighten the battery negative terminal bolt to 17 N.m (13 lb ft).

1. Remove the bolt retaining the coolant recovery reservoir or surge tank.
2. Move the coolant recovery reservoir or the surge tank aside.
3. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Disconnect the battery positive cable from the battery.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
6. Disconnect the positive lead to the starter solenoid.
7. Lower the vehicle.
8. Unclip the battery positive cable from the fan schroud.
9. Disconnect the positive lead to the generator.
10. Remove the cable from the vehicle. Note the location of the retaining clips.

1. Install the cable to the vehicle. Ensure the cable is routed correctly and installed in the retainer clips.
2. Connect the positive lead to the generator. Tighten: Tighten the generator output (BAT) nut to 18 N.m (13 lb ft).
3. Clip the battery positive cable to the fan schroud.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
5. Install the positive lead to the starter solenoid. Tighten: Tighten the positive lead to starter solenoid to 10 N.m (89 lb in).
6. Lower the vehicle.
7. Connect the battery positive cable to the battery. Tighten: Tighten the battery terminals to 17 N.m (13 lb ft).
8. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
9. Install the coolant recovery reservoir or surge tank and the bolt. Tighten: Tighten the coolant recovery reservoir or surge tank bolt to 11 N.m (97 lb in).

1. On all models, remove the bolt retaining the coolant recovery reservoir or surge tank.
2. Move the coolant recovery reservoir or the surge tank aside.
3. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Disconnect the battery positive cable from the battery.
5. On models equipped with the 4.8L, or 6.0L engine, disconnect the positive lead to the junction block.
6. On models equipped with 4.8L, 5.3L or 6.0L engine, unclip battery positive cable from engine harness clip (1).
7. Unclip battery positive cable from engine harness retainer (2).
8. On all models, raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
9. Disconnect the positive lead to the starter solenoid.
10. On models with 4.8L and 6.0L engine, remove battery positive cable retainer clips (1).
11. Remove battery positive cable to chassis harness clips (2).
12. Remove battery positive cable retainer clips (1)from frame.
13. Remove battery positive cable retainer clips (2) from crossmember.
14. On all models, lower the vehicle.
15. On models equipped with the 4.8L, 5.3L or 6.0L engine, unclip the battery positive cable from the fan shroud.
16. On all models, disconnect the positive lead to the generator.
17. Remove the cable from the vehicle. Note the location of the retaining clips.

1. On all models, install the cable to the vehicle. Ensure the cable is routed correctly and installed in the retainer clips.
2. Connect the positive lead to the generator. Tighten: Tighten the generator output (BAT) nut to 18 N.m (13 lb ft).
3. On models equipped with the 4.8L, 5.3L or 6.0L engine, clip the battery positive cable to the fan shroud.
4. On all models, raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
5. On models with 4.8L and 6.0L engine, install battery positive cable retainer clips (2) to the crossmember.
6. Install battery positive cable retainer clips (1)to the frame.
7. Install battery positive cable to chassis harness clips (2).
8. Install battery positive cable retainer clips (1).
9. Install the positive lead to the starter solenoid. Tighten: Tighten the positive lead to starter solenoid to 10 N.m (89 lb in).
10. On all models, lower the vehicle.
11. On models equipped with 4.8L, 5.3L or 6.0L engine, clip battery positive cable to the engine harness retainer (2).
12. Clip battery positive cable to the engine harness clip (1).
13. On models equipped with the 4.8L, or 6.0L engine, install the positive lead to the junction block. Tighten: Tighten the junction block nut to 10 N.m (89 lb in).
14. On all models, connect the battery positive cable to the battery. Tighten: Tighten the battery terminals to 17 N.m (13 lb ft).
15. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
16. Install the coolant recovery reservoir or surge tank and the bolt. Tighten: Tighten the coolant recovery reservoir or surge tank bolt to 11 N.m (97 lb in).

1. Disconnect the auxiliary battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the auxiliary positive battery cable.
3. Remove the auxiliary positive battery cable to the frame clips (1).
4. Remove the auxiliary positive battery cable to chassis harness clips (2).
5. Remove the auxiliary positive battery cable to frame clips (1).
6. Remove the auxiliary positive battery cable to crossmember clips (2).
7. Remove the auxiliary positive battery cable to engine harness clips (3).
8. Remove the auxiliary positive battery cable nut from the junction block.
9. Disconnect the auxiliary positive battery cable wiring harness clips.
10. Remove the auxiliary positive battery cable.

1. Position the auxiliary positive battery cable and connect the wiring harness clips.
2. Position the auxiliary positive battery cable to the junction block and install the cable nut. Tighten: Tighten the auxiliary positive cable nut to 8 N.m (71 lb in).
3. Install the auxiliary positive battery cable to engine harness clips (3).
4. Install the auxiliary positive battery cable to crossmember clips (2).
5. Install the auxiliary positive battery cable to frame clips (1).
6. Install the auxiliary positive battery cable to the chassis harness clips (2).
7. Install the auxiliary positive battery cable to the frame clips (1).
8. Connect the auxiliary positive battery cable to the auxiliary battery. Tighten: Tighten the auxiliary positive cable bolt to 17 N.m (13 lb ft).
9. Connect the auxiliary negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the positive battery cable.
3. Remove the positive cable nut from the junction block and disconnect the cable.
4. Remove the positive cable nut from the generator and disconnect the cable.
5. Disconnect the wiring harness clips and the positive cable from the glow plug module.
6. Remove battery positive cable from engine harness clip.
7. Remove battery positive cable from engine harness clips (1).
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
9. Remove the battery positive cable nut (1) and clip (2) from frame.
10. Remove the battery positive cable retaining clip from the transmission line bracket.
11. Remove the positive battery cable nut (7) from the starter and disconnect the cable (8) and the wiring harness clips.
12. Remove the positive battery cable.

1. Position the positive battery cable.
2. Position the positive battery cable (8) to the starter and install the nut (7). Connect the wiring harness clips. Tighten: Tighten the positive battery cable to starter nut to 9 N.m (80 lb in).
3. Install the battery positive cable retaining clip to the transmission line bracket.
4. Install the battery positive cable nut (1) and clip (2) to the frame.
5. Lower the vehicle.
6. Install battery positive cable to engine harness clips (1).
7. Install battery positive cable to engine harness clip.
8. Connect the positive battery cable to the glow plug module and connect the wiring harness clips.
9. Install the positive battery cable to the generator and install the nut. Tighten: Tighten the positive battery cable to generator nut to 9 N.m (80 lb in).
10. Position the positive battery cable to the junction block and install the cable nut. Tighten: Tighten the positive battery cable to junction block nut to 8 N.m (71 lb in).
11. Connect the positive battery cable to the battery. Tighten: Tighten the positive battery cable bolt to 17 N.m (13 lb ft).
12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the auxiliary battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the positive extension cable nut from the junction block and disconnect the cable.
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
4. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
5. Remove the positive extension cable nut from the intake air heater and disconnect the cable.
6. Disconnect the wiring harness clips.
7. Remove the battery positive cover from the underhood bused electrical center (UBEC).
8. Remove the positive extension cable nut from the UBEC terminal stud.
9. Remove the positive extension cable.

1. Position the positive extension cable and connect the wiring harness clips.
2. Position the positive extension cable to the UBEC terminal stud and install the nut. Tighten: Tighten the positive extension cable to UBEC terminal stud to 9 N.m (80 lb in).
3. Install the battery positive cover to the UBEC.
4. Position the positive extension cable to the intake air heater and install the nut. Tighten: Tighten the positive extension cable to intake air heater nut to 4 N.m (34 lb in).
5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Position the positive extension cable to the junction block and install the cable nut. Tighten: Tighten the positive extension cable to junction block nut to 8 N.m (71 lb in).
8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the coolant recovery reservoir and bolt.
2. Disconnect the battery negative cable from the negative battery terminal. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect the battery positive cable from the positive battery terminal. Refer to «Battery Positive Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the battery hold-down retainer bolt and retainer.
5. Remove the battery from the vehicle.
6. Inspect the battery for: Damage Worn or corroded cables and connectors Damage or foreign objects in the battery carrier
7. If damage is noted, find and correct the cause.
8. Clean any corrosion form the battery cables and connectors.
9. Clean the battery tray and remove any foreign objects from the tray.

1. Install the battery into the battery carrier.
2. Install the battery hold-down retainer and bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the battery positive cable and the positive battery cable terminal to the battery. Refer to «Battery Positive Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Connect the battery negative cable and the negative battery cable terminal to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Install the coolant recovery reservoir. Tighten: Tighten the reservoir bolt to 11 N.m (97 lb in).

1. Disconnect the battery negative cable from the negative battery terminal. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
3. Disconnect the auxiliary negative cable from the battery terminal.
4. Disconnect the auxiliary battery positive cable from the battery terminal.
5. Remove the battery hold down retaining bolt.
6. Remove the battery from the tray.

1. Install the battery into the battery tray.
2. Install the battery hold-down retainer and bolt. Tighten: Tighten the battery hold-down retainer bolt to 25 N.m (18 lb ft).
3. Connect the auxiliary battery positive and negative cables to the battery. Tighten: Tighten the auxiliary battery cables to 15 N.m (11 lb ft).
4. Lower the vehicle.
5. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the coolant recovery reservoir bolt and reposition the reservoir.
2. Disconnect the battery negative cable from the battery negative terminal. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect the battery positive cable from the battery positive terminal. Refer to «Battery Positive Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the battery limiter from the vehicle if equipped.
5. Remove the battery hold-down bolt and retainer.
6. Remove the battery.
7. Remove the battery tray bolts.
8. Disconnect the vacuum hoses.
9. Disconnect the vacuum pump electrical connector.
10. Remove the battery tray from the vehicle.

1. Install the battery tray to the vehicle.
2. Connect the vacuum pump hoses and electrical connector.
3. Install the battery tray bolts. Tighten: Tighten the battery tray bolts to 25 N.m (18 lb ft).
4. Install the battery.
5. Install the battery hold-down retainer and bolt. Tighten: Tighten the battery hold-down retainer bolt to 25 N.m (18 lb ft).
6. Install the positive battery cable to the battery with the battery terminal bolt. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
7. Install the battery negative cable to the battery with the battery terminal bolts. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) . Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
8. Install the coolant recovery reservoir. Tighten: Tighten the bolt to 11 N.m (97 lb in).

1. Disconnect the battery negative cable from the battery negative terminal. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
3. Disconnect the auxiliary battery positive and negative cables. Refer to «Battery Positive Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) and «Battery Negative Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the auxiliary battery hold-down retainer bolt.
5. Remove the auxiliary battery from the auxiliary battery tray.
6. Remove the auxiliary battery hold-down tray bolts.
7. Remove the auxiliary battery tray from the vehicle.

1. Install the auxiliary battery tray to the vehicle.
2. Install the auxiliary battery tray bolts to the battery tray. Tighten: Tighten the auxiliary battery tray bolts to 25 N.m (18 lb ft).
3. Install the auxiliary battery to the auxiliary battery tray.
4. Install the auxiliary battery hold-down retainer bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Connect the auxiliary battery positive and negative cables. Refer to «Battery Positive Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Positive Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) and «Battery Negative Cable Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (4.8L, 5.3L and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (Auxiliary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Replacement (Primary 6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
6. Lower the vehicle.
7. Install the front battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the engine wiring harness ground bolt.
2. Reposition the engine wiring harness ground and ground strap.
3. Remove the ground strap nut from the stud at the front of dash.
4. Remove the ground strap from the stud.

1. Install the ground strap to the stud.
2. Install the ground strap nut to the stud at the front of dash. Tighten: Tighten the nut to 9 N.m (80 lb in).
3. Position the ground strap and engine wiring harness ground.
4. Install the engine wiring harness ground bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
3. Remove the starter motor brackets and shields, if equipped.
4. Disconnect the wires from the starter solenoid.
5. Remove the bolts and the shims, if present, from the starter motor.
6. Remove the starter motor from the engine.

1. Install the starter motor to the engine.
2. Install the bolts and the shims, if present, to the starter motor. Tighten: Tighten the bolts to 45 N.m (33 lb ft).
3. Connect the wires to the starter solenoid. Tighten: Tighten the starter lead nut to the solenoid to 10 N.m (89 lb in). Tighten the starter solenoid wires to the solenoid to 2 N.m (18 lb in).
4. Install the starter motor brackets and shields.
5. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
3. Remove the right transmission cover bolt.
4. Remove the starter bolts.
5. Disconnect the oil level sensor electrical connector.
6. Slide the starter forward until the starter clears the transmission.
7. Remove the starter solenoid nut.
8. Remove the starter lead from the solenoid stud.
9. Remove the starter lead nut.
10. Remove the positive cable from the starter stud.
11. Place the starter on a workbench.
12. Unsnap the transmission cover from the starter.
13. If necessary, remove the starter shield.

1. If necessary, install the starter shield.
2. Snap the transmission cover to the starter.
3. Install the positive cable to the starter stud.
4. Install the starter lead nut. Tighten: Tighten the starter lead nut to 10 N.m (89 lb in).
5. Install the starter solenoid lead to the solenoid stud.
6. Install the starter solenoid nut. Tighten: Tighten the starter solenoid nut to 3.4 N.m (30 lb in).
7. Slide the starter rearward.
8. Install the starter bolts. Tighten: Tighten the starter bolts to 50 N.m (37 lb ft).
9. Connect the oil level sensor electrical connector.
10. Install the right transmission cover bolt. Tighten: Tighten the transmission cover bolt to 9 N.m (80 lb in).
11. Lower the vehicle.
12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
3. Remove the engine wiring harness nut (4).
4. Remove the engine wiring harness lead (1) from the starter.
5. Remove the positive battery cable nut (7).
6. Remove the positive battery cable lead (8) from the starter.
7. Remove the starter motor bolts.
8. Remove the starter motor.

1. Install the starter motor.
2. Install the starter motor bolts. Tighten: Tighten the bolts to 78 N.m (58 lb ft).
3. Install the positive battery cable lead (8) to the starter.
4. Install the positive battery cable nut (7). Tighten: Tighten the nut to 9 N.m (80 lb in).
5. Install the engine wiring harness lead (1) to the starter.
6. Install the engine wiring harness nut (4). Tighten: Tighten the nut to 3.4 N.m (30 lb in).
7. Lower the vehicle.
8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Loosen the air cleaner outlet duct clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Remove the positive crankcase ventilation (PCV) hose.
3. Remove the air cleaner adapter nut.
4. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
5. Remove the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) .
7. Remove the wiring harness bracket bolt.
8. Remove the heater hose bracket bolt.
9. Remove the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
10. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) .
11. Remove the generator bracket bolts and nut.
12. Remove the generator bracket.

1. Install the generator bracket.
2. Install the generator bracket bolts and nut. Tighten: Tighten the bolts/nut to 41 N.m (30 lb ft).
3. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) .
4. Install the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Install the heater hose bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Install the wiring harness bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
7. Install the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) .
9. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
10. Install the air cleaner adapter nut.
11. Install the PCV hose.
12. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamps to 4 N.m (35 lb in).

1. Remove the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (6.6L Diesel)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
3. Remove the generator bracket bolts.
4. Remove the generator bracket.

1. Install the generator bracket.
2. Install the generator bracket bolts. Tighten: Tighten the generator bracket bolts to 50 N.m (37 lb ft).
3. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (6.6L Diesel)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
4. Install the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Disconnect the generator electrical connector.
4. Remove the positive battery cable from the generator, perform the following: Slide the boot down to access the terminal stud. Remove the positive cable nut. Remove the positive cable.
5. Remove the generator bolts (1).
6. Remove the generator (2).
7. Disconnect the RH engine wiring main harness connector.
8. Remove the 2 RH engine wiring harness bracket bolts and position aside.
9. Remove the 2 wiring harness routing bolts.
10. Remove the oil indicator tube bracket bolt.
11. Remove the drive belt tensioner bolt and tensioner.
12. Remove the bolts and the generator mounting bracket.
13. If necessary, remove the 3 bolts and the generator extension bracket.

1. If necessary, position the generator extension bracket and install 3 bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. Position the generator mounting bracket and install the bolts. Tighten: Tighten the generator mounting bracket bolts to 50 N.m (37 lb ft).
3. Position the drive belt tensioner and install the bolt, Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
4. Install the oil indicator tube bracket bolt. Tighten: Tighten the oil indicator tube bracket bolt to 21 N.m (15 lb ft).
5. Install the 2 wiring harness routing bolts. Tighten: Tighten the wiring harness routing bolts to 10 N.m (89 lb in).
6. Position the RH engine wiring harness bracket and install the 2 bolts. Tighten: Tighten the RH engine wiring harness bracket bolts to 10 N.m (89 lb in).
7. Connect the RH engine wiring harness connector.
8. Position the generator.
9. Install the generator bolts (1). Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
10. Install the positive cable to the auxiliary generator, perform the following: Install the positive cable. Install the positive cable nut. Tighten: Tighten the positive cable nut to 9 N.m (80 lb in). Slide the boot to cover the terminal stud.
11. Connect the generator electrical connector.
12. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
13. Install the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the auxiliary generator electrical connector.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
4. Remove the positive battery cable from the auxiliary generator, perform the following: Slide the boot (4) down to access the terminal stud. Remove the positive cable nut (1). Remove the positive cable.
5. Remove the auxiliary generator bolts (3).
6. Remove the auxiliary generator (4).
7. Remove the auxiliary generator bracket bolts.
8. Remove the auxiliary generator bracket.

1. Install the auxiliary generator bracket.
2. Install the auxiliary generator bracket bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the auxiliary generator (4).
4. Install the auxiliary generator bolts (3). Tighten: Tighten the bolt to 50 N.m (37 lb ft).
5. Install the positive cable to the auxiliary generator, perform the following: Install the positive cable. Install the positive cable nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in). Slide the boot (4) up to cover the terminal stud.
6. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
7. Connect the auxiliary generator electrical connector (3).
8. Install the radiator fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-43l-introduction-2-of-2) in Engine Controls - 4.3L.
4. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Remove the drive belt from the generator. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) in Engine Mechanical - 4.3L.
6. Remove the heater hose pipe from the generator.
7. Remove the oil fill tubes from the support bracket.
8. Remove the support bracket from the generator bracket.
9. Remove the generator mounting bolts.
10. Remove the generator from the engine.
11. Disconnect the electrical connectors.

1. Connect the electrical connectors to the generator. Tighten: Tighten the generator output (BAT) terminal nut to 18 N.m (13 lb ft).
2. Install the generator to the engine.
3. Install the generator mounting bolts. Tighten: Tighten the generator front mounting bolts to 50 N.m (37 lb ft). Tighten the generator rear mounting bolt to 25 N.m (18 lb ft).
4. Install the oil fill tube support bracket to the generator bracket.
5. Install the oil fill tube support bracket bolt and stud. Tighten: Tighten the oil fill tube support bracket bolt and stud to 25 N.m (18 lb ft).
6. Install the oil fill tube to the support bracket.
7. Install the oil fill tube screw to the support bracket. Tighten: Tighten the oil fill tube screw to 5 N.m (44 lb in).
8. Install the heater hose pipe to the generator.
9. Install the drive belt to the generator. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) in Engine Mechanical - 4.3L.
10. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
11. Install the air cleaner. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) in Engine Controls - 4.3L.
12. Install the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
13. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) .
3. Disconnect the generator electrical connector (3).
4. Remove the generator cable from the generator, perform the following: Slide the boot down revealing the terminal stud. Remove the generator cable nut from the terminal stud. Remove the generator cable.
5. Remove the generator bolts.
6. Remove the generator.

1. Install the generator.
2. Install the generator bolts. Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
3. Install the generator cable to the generator, perform the following: Install the generator cable. Install the generator cable nut to the terminal stud. Tighten: Tighten the generator cable nut to 9 N.m (80 lb in). Slide the boot over the terminal stud.
4. Connect the generator electrical connector (3).
5. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) .
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the generator bolts (1).
4. Remove the generator front support bracket attached to generator bracket and generator.
5. Position the generator to access wiring.
6. Remove the positive battery cable from the generator, perform the following: Slide the boot down to access the terminal stud. Remove the positive cable nut. Remove the positive cable.
7. Disconnect the generator electrical connector.
8. Remove the generator (2).

1. Install generator to engine.
2. Connect the generator electrical connector.
3. Install the positive battery cable to the generator, perform the following: Position the positive cable. Install the positive cable nut. Tighten: Tighten the positive cable nut to 9 N.m (80 lb in). Slide the boot down to cover the terminal stud.
4. Position the generator (2) to the mounting bracket.
5. Install the generator bolts (1). Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
6. Install the generator front support bracket and attach to generator and generator bracket.
7. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
8. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Disconnect the auxiliary generator electrical connector.
4. Remove the positive cable from the auxiliary generator, perform the following: Slide the boot down to access the terminal stud. Remove the positive cable nut. Remove the positive cable.
5. Remove the auxiliary generator bolts (3).
6. Remove the auxiliary generator (4).

1. Position the auxiliary generator (4).
2. Install the auxiliary generator bolts (3). Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
3. Install the positive cable to the auxiliary generator, perform the following: Position the positive cable. Install the positive cable nut. Tighten: Tighten the nut to 9 N.m (80 lb in). Slide the boot to cover the terminal stud.
4. Connect the generator electrical connector.
5. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
6. Install the upper shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 13

Batteries that are no longer wanted must be disposed of by an approved battery recycler and must never be thrown in the trash or sent to a landfill.

Batteries that are not part of the vehicle itself, not the battery under the hood, must only be transported on public streets for business purposes via approved hazardous material transportation procedures.

Battery storage, charging, and testing facilities in repair shops must meet various requirements for ventilation, safety equipment, material segregation, etc.

The maintenance-free battery is standard. There are no vent plugs in the cover. The battery is completely sealed except for 2 small vent holes in the side. These vent holes allow the small amount of gas that is produced in the battery to escape.

The battery has 3 functions as a major source of energy

1. Engine cranking
2. Voltage stabilizer
3. Alternate source of energy with generator overload

The battery specification label, example below, contains information about the following

1. The test ratings
2. The original equipment catalog number
3. The recommended replacement model number

Scheme 14

Battery Ratings

A battery may have 3 ratings

1. Amp hour
2. Reserve capacity
3. Cold cranking amperage

When a battery is replaced, use a battery with similar ratings. Refer to the battery specification label on the original battery or refer to Battery Usage .

Amp Hour

The amp hour rating of a battery is the amount of time it takes a fully charged battery, being discharged at a constant rate of 1 amperes and a constant temperature of 27°C (80°F), to reach a terminal voltage of 10.5 volts. Refer to Battery Usage for the amp hour rating of the original equipment battery.

Reserve Capacity

Reserve capacity is the amount of time in minutes it takes a fully charged battery, being discharged at a constant rate of 25 amperes and a constant temperature of 27°C (80°F), to reach a terminal voltage of 10.5 volts. Refer to Battery Usage for the reserve capacity rating of the original equipment battery.

Cold Cranking Amperage

The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold temperatures. The cold cranking amperage rating is the minimum amperage the battery must maintain for 30 seconds at -18°C (0°F) while maintaining at least 7.2 volts. Refer to Battery Usage for the cold cranking amperage rating for this vehicle.

Generator

The CS130 generator is non-repairable. It is electrically similar to earlier models. The generator feature the following major components

1. The delta stator
2. The rectifier bridge
3. The rotor with slip rings and brushes
4. A conventional pulley
5. Dual internal fans
6. A voltage regulator

The pulley and the fan cool the slip ring and the frame.

The CS stands for charging system and 130 is the measurement in millimeters, of the outside diameter of the stator laminations. The generator is rated at 100 amperes.

The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit.

Regulator

The voltage regulator controls the field current of the rotor in order to limit system voltage. The regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions

1. Radio noise control
2. Obtain the correct average current needed for proper system voltage control

At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent.

Charging System Indicator

The IPC illuminates the battery indicator when the following occurs

1. The generator output is less than 11 volts or greater than 16 volts (switched low).
2. The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds.
3. The ignition is on, with the engine off.

Starting System Description and Operation

The PG-260 is a non-repairable starter motor. It has pole pieces that are arranged around the armature within the starter housing. When the solenoid windings are energized, the pull-in winding circuit is completed to ground through the starter motor. The hold-in winding circuit is completed to ground through the solenoid. The windings work together magnetically to pull in and hold in the plunger. The plunger moves the shift lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the flywheel ring gear on the engine. At the same time, the plunger closes the solenoid switch contacts in the starter solenoid. Full battery voltage is then applied directly to the starter motor and it cranks the engine.

As soon as the solenoid switch contacts close, current stops flowing thorough the pull-in winding as battery voltage is now applied to both ends of the windings. The hold-in winding remains energized; its magnetic field is strong enough to hold the plunger, shift lever, starter drive assembly, and solenoid switch contacts in place to continue cranking the engine. When the engine starts, the pinion gear overrun sprag protects the armature from excessive speed until the switch is opened.

When the ignition switch is released from the CRANK position, voltage is removed from the starter solenoid S terminal. Current flows from the motor contacts through both windings to ground at the end of the hold-in winding. However, the direction of the current flow through the pull-in winding is now in the opposite direction of the current flow when the winding was first energized.

The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the windings, along with the help of the return spring, cause the starter drive assembly to disengage and the solenoid switch contacts to open simultaneously. As soon as the contacts open, the starter motor is turned off.

Special Tools

Special Tools Illustration Tool Number/Description J-38758 Parasitic Draw Test Switch J-41450-B Universal CS Generator Test Harness J-42000 Battery Tester J-45681 Jumper Harness

Scheme 15

Scheme 16

Scheme 17

Scheme 18

See also:
• Diagnostic System Check - Vehicle
• Body Control System Schematics
• Power and Grounding Connector End Views
• Circuit Testing
• Wiring Repairs
• Testing for Intermittent Conditions and Poor Connections
• Connector Repairs
• Control Module References
• Strategy Based Diagnosis
• Diagnostic Procedure Instructions
• Diagnostic Repair Verification
• Checking Aftermarket Accessories
• Battery Disconnect Caution
• FASTENER NOTICE
• Keyless Entry System Description and Operation
• Power Distribution Schematics
• General Electrical Diagnosis
• Instrument Cluster Replacement
• Drive Belt Replacement - Accessory
• Drive Belt Tensioner Diagnosis
• Park/Neutral Position Switch Replacement
• Park/Neutral Position Switch Replacement
• Park/Neutral Position Switch Adjustment
• Park/Neutral Position Switch Adjustment
• Lifting and Jacking the Vehicle
• Air Cleaner Assembly Replacement
• Fan Replacement
• Drive Belt Replacement
• Power Steering Pump Replacement (4.3L)
• Drive Belt Replacement
• Air Cleaner Assembly Replacement
• DTC B1327
• Starter Solenoid Does Not Click
• Charging System Test
• Scan Tool Data List
• Starting System Description and Operation
• Starter Solenoid Clicks, Engine Does Not Crank
• Engine Cranks Slowly
• Charge Indicator Inoperative
• Battery Common Causes of Malfunction
• Special Tools
• Battery Usage
• Symptoms - Engine Electrical