Battery Chevrolet Chevy Express H2500

Fastener Tightening Specifications

Fastener Tightening Specifications

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Diagnostic Information and Procedures

Note. Begin the system diagnosis with the DIAGNOSTIC STARTING POINT - ENGINE ELECTRICAL .

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Scan Tool Data Definitions

Ignition 1 Signal: The scan tool displays the current voltage at the battery.

GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output.

GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads.

Diagnostic Trouble Code (DTC) List

Diagnostic Trouble Code (DTC) List

Symptoms - Engine Electrical

Important: The following steps must be completed before using the symptom tables.

1. Perform «DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. The control module(s) can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to «Battery Description and Operation»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .

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-h2500/2003-2003/remont/electrical-component-locations/#wiring-systems-general-information__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 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-h2500/2003-2003/remont/starter/#starting-system__starter-solenoid-does-not-click)
2. «STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-solenoid-clicks-engine-does-not)
3. «ENGINE CRANKS SLOWLY»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__engine-cranks-slowly)
4. «Battery Inspection/Test»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery)
5. «TEST B: CHARGE INDICATOR LIGHT ALWAYS ON»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__test-b-charge-indicator-light-always)
6. «TEST C: CHARGE INDICATOR LIGHT INOPERATIVE»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__test-c-charge-indicator-light-inoperative)
7. «TEST A: CHARGING SYSTEM TEST»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system)
8. «TEST D: GENERATOR NOISE DIAGNOSIS»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__test-d-generator-noise-diagnosis)

Diagnostic Aids

Important

1. The battery test using the J 42000 Battery Tester requires correct connections to the battery terminals. A failure to obtain the correct connections during the test may result in a failed test on a good battery.
2. Use the Out of Vehicle test for each battery when testing a vehicle with dual batteries. Follow these instructions in order to avoid an incorrect diagnosis because of connections
3. If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt. 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.
4. 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.
5. 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.
6. 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. If the adapters that are provided with the J 42000 require replacement, use GM P/N 12303040. 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.

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Tools Required

J 42000 Battery Tester

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.

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

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. CAUTION: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment.
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 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»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .

Tools Required

1. J 38758 Parasitic Draw Test Switch
2. J 39200 Digital Multimeter

If the vehicle exhibits a low or dead battery after an overnight period, or discharges over a period of 2 or 3 days, the electrical system should be checked for an excessive electrical drain. This is referred to as Parasitic Current Drain.

If a battery needs recharging and no cause is evident, check the vehicle for excessive parasitic current drain.

One or more on-board solid state control modules, such as the body control module (BCM) may at some time exhibit a failure mode that causes a high parasitic drain on the vehicle's battery. When the battery is disconnected to install an ammeter, etc., the excessive current drain may not occur once the circuit continuity is restored. Even though cycling the ignition key to the RUN and then to the OFF position may cause such a drain to recur, there may be drains that will not recur unless the vehicle systems are reactivated in a road test. Since the ignition switch must not be rotated to the ACCESSORY, RUN or START position with an ammeter installed between the battery terminal and the battery cable, a current drain test tool must be used as described in the following procedures.

Before starting this procedure, ensure that the ignition switch is in the LOCK position, all electrical accessories are turned OFF, the underhood lamp is disconnected, the door glass is open and the doors are closed.

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1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) . .
2. Install the male end of the J 38758 Parasitic Draw Test Switch to the battery negative terminal.
3. Turn OFF the test switch.
4. Install the battery negative cable to the female end of the test switch.
5. Turn ON the test switch.
6. Road test the vehicle while activating all accessories, including the radio and the air conditioning.
7. Turn OFF the ignition switch. Remove the key. Important: From this point on, electrical continuity must be maintained in the ground circuit of the battery through the J 38758 in the ON position or through the J 39200 . The BCM can draw several amps of current after the ignition is turned off. Refer to «BODY CONTROL SYSTEM DESCRIPTION AND OPERATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-cab-control-systems/#body-control-system) .
8. Install the scan tool and perform the power down now feature from the BCM output menu. After performing this function the scan tool can be powered off or disconnected, then wait an additional 5 minutes before continue testing.
9. Set the J 39200 Digital Multimeter to the 10 A scale. Important: If an ammeter other than the J 39200 is used, ensure that the vehicle does not have a high current drain that would damage the ammeter when connected to the circuit. This can be done using the following procedure: Connect a jumper wire with an in-line 10 A fuse J 36169-A to the terminals of the test switch. Turn the test switch to the OFF position. Wait 10 seconds. If the fuse does not blow, the current is less than 10 A and the ammeter can be used safely. Turn the test switch to the ON position before the fused jumper wire is removed and the multimeter is installed.
10. Connect the ammeter to the test switch terminals.
11. Turn OFF the test switch. This allows the current to flow through the ammeter.
12. Wait at least 60 seconds, then check the current reading. When there is a current reading of 2 A or less, turn ON the test switch, this maintains continuity in the electrical system. Then, switch the meter down to the 2 A scale, for a more accurate reading, when the test switch is reopened.
13. Take the reading in milli-amps.
14. Note the battery reserve capacity. Refer to «Battery Usage»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) . Divide this number by 4. Compare this to the multimeter reading. The current drain should not exceed this number. Example: If a battery has a reserve capacity of 100 minutes, the current drain should not exceed 25 milli-amps. If the vehicle has 2 batteries, add the reserve capacities together and divide this total by 4. CAUTION: Always turn the test switch knob to the ON position before removing each fuse to maintain continuity in the electrical system and to avoid damaging the meter due to accidental overloading, such as opening a door to change a fuse.
15. When the current draw is too high, remove the electrical system fuses one at a time until the draw returns to a value less than or equal to specifications.
16. Repeat the parasitic current drain test procedure after any repair has been completed.
17. When the cause of the excessive current draw has been located and repaired, remove the meter and the parasitic draw test switch and terminal adapters.
18. Connect the negative cable to the battery negative terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .

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 PROCEDURES»(/chevrolet/chevy-express-h2500/2003-2003/remont/electrical-component-locations/#wiring-systems-general-information) .

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).

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 .

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

Important: If a green dot is not visible in the hydrometer, charge the battery. Refer to Battery Charging .

1. Ensure that the green dot is visible in the built-in hydrometer. WARNING: Refer to «BATTERY DISCONNECT CAUTION»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__battery-disconnect-caution) .
2. Disconnect the battery ground to protect the battery from discharge by parasitic current drains. When the battery cannot be disconnected
3. Maintain a high state of charge.
4. 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

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.

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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. Important: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start.
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. CAUTION: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment.
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.

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1. Turn off all the lamps and accessories.
2. Turn the ignition OFF. WARNING: Refer to «BATTERY DISCONNECT CAUTION»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__battery-disconnect-caution) .
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

Important: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end.

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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). Important: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end.
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).

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1. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
2. Disconnect the battery negative cable lead from the inner fender panel.
3. Raise the vehicle.
4. Disconnect the battery negative cable lead from the engine block.
5. Remove the battery negative cable from the vehicle.

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1. Install the battery negative cable to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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. Lower the vehicle.
4. 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).
5. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) . Tighten Tighten the battery negative terminal bolt to 17 N.m (13 lb ft).

Scheme 36

1. Raise the vehicle.
2. Disconnect the battery negative cable from the auxiliary battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
3. Disconnect the negative ground leads from the frame.
4. Remove the battery negative cable from the vehicle.

Scheme 37

1. Install the battery negative cable to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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.

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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 Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
4. Disconnect the battery positive cable from the battery.
5. If equipped with the 4.8L, 5.3L or 6.0L engine, disconnect the positive lead to the junction block.
6. Raise the vehicle.
7. Disconnect the positive lead to the starter solenoid.
8. Lower the vehicle.
9. Disconnect the positive lead to the generator.
10. Remove the cable from the vehicle. Note the location of the retaining clips.

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1. Install the cable to the vehicle. Ensure the cable is routed correctly and installed in the retainer clips. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Connect the positive lead to the generator. Tighten Tighten the generator output (BAT) nut to 18 N.m (13 lb ft).
3. Raise the vehicle.
4. Install the positive lead to the starter solenoid. Tighten Tighten the positive lead to starter solenoid to 10 N.m (89 lb in).
5. Lower the vehicle.
6. If equipped with the 4.8L, 5.3L 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).
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 Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
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).

Removal Procedure

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1. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
2. Disconnect the battery negative cable from the auxiliary battery.
3. Disconnect the battery positive cable from the junction block.
4. Raise the vehicle.
5. Remove the battery positive cable retainers from the frame.
6. Disconnect the battery positive cable from the auxiliary battery.
7. Remove the battery positive cable from the vehicle.

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1. Install the battery positive cable to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Connect the battery positive cable to the auxiliary battery. Tighten Tighten the auxiliary battery positive cable to 15 N.m (11 lb ft).
3. Install the battery positive cable retainers to the frame.
4. Lower the vehicle.
5. Connect the battery positive cable to the junction block. Tighten Tighten the nut to 10 N.m (89 lb in).
6. Connect the battery negative cable to the auxiliary battery. Tighten Tighten the bolt to 15 N.m (11 lb ft).
7. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) . Tighten Tighten the bolt to 17 N.m (13 lb ft).

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1. Remove the coolant recovery reservoir bolt and position the reservoir to the side.
2. Disconnect the battery negative cable from the negative battery terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
3. Disconnect the battery positive cable from the positive battery terminal. Refer to «Battery Positive Cable Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
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.

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1. Install the battery into the battery carrier. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
4. Connect the battery negative cable and the negative battery cable terminal to the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
5. Install the coolant recovery reservoir. Tighten Tighten the reservoir bolt to 11 N.m (97 lb in).

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1. Disconnect the battery negative cable from the negative battery terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
2. Raise the vehicle.
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.

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1. Install the battery into the battery tray. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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 Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .

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1. Remove the coolant recovery reservoir bolt and reposition the reservoir. WARNING: Refer to «BATTERY DISCONNECT CAUTION»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__battery-disconnect-caution) .
2. Disconnect the battery negative cable from the battery negative terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
3. Disconnect the battery positive cable from the battery positive terminal. Refer to «Battery Positive Cable Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
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. Remove the battery tray from the vehicle.

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1. Install the battery tray to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the battery tray bolts. Tighten Tighten the battery tray bolts to 25 N.m (18 lb ft).
3. Install the battery.
4. Install the battery hold-down retainer and bolt. Tighten Tighten the battery hold-down retainer bolt to 25 N.m (18 lb ft).
5. 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).
6. Install the battery negative cable to the battery with the battery terminal bolts. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) . Tighten Tighten the battery terminal bolt to 17 N.m (13 lb ft).
7. Install the coolant recovery reservoir. Tighten Tighten the bolt to 11 N.m (97 lb in).

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1. Disconnect the battery negative cable from the battery negative terminal. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
2. Raise the vehicle.
3. Disconnect the auxiliary battery positive and negative cables. Refer to «Battery Positive Cable Replacement - Auxiliary»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) and «Battery Negative Cable Replacement - Auxiliary»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
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.

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1. Install the auxiliary battery tray to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
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 - Auxiliary»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) and «Battery Negative Cable Replacement - Auxiliary»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .
6. Lower the vehicle.
7. Install the front battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-h2500/2003-2003/remont/body-electrical/#battery) .

Scheme 68

Scheme 69

1. In order to remove the engine ground strap the battery negative cable is removed from the engine. Some of the vehicle information may get discarded when the battery negative cable is removed. Refer to «RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/entertainment-systems/#entertainment-system__radioaudio-system-description-and-operation) for the information that may have to be reset. The battery negative cable does not require disconnection at the battery.
2. Raise the vehicle.
3. Remove the bolt retaining the battery negative cable and the ground strap to the engine.
4. Remove the bolt retaining the ground strap to the frame.
5. Remove the ground strap.

Scheme 70

Scheme 71

1. Install the bolt and the ground strap to the frame. Align the tab on the ground strap with the hole in the frame. Tighten Tighten the ground strap to frame bolt to 25 N.m (18 lb ft).
2. Install the bolt with the battery negative cable and the ground strap to the front of the engine. Align the ground strap in order to avoid contact with the transmission cooler pipes. Tighten Tighten the ground strap to engine bolt to 25 N.m (18 lb ft).
3. Lower the vehicle.
4. Reset the vehicle information. Refer to «RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/entertainment-systems/#entertainment-system__radioaudio-system-description-and-operation) .

Scheme 72

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

Scheme 73

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

A battery has 2 ratings

1. Reserve capacity
2. 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 .

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.

Scheme 74

Scheme 75

See also:
• DIAGNOSTIC STARTING POINT - ENGINE ELECTRICAL
• DTC P0562
• DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL
• CHECKING AFTERMARKET ACCESSORIES
• TESTING FOR INTERMITTENT AND POOR CONNECTIONS
• STARTER SOLENOID DOES NOT CLICK
• STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK
• ENGINE CRANKS SLOWLY
• TEST B: CHARGE INDICATOR LIGHT ALWAYS ON
• TEST C: CHARGE INDICATOR LIGHT INOPERATIVE
• TEST D: GENERATOR NOISE DIAGNOSIS
• BATTERY DISCONNECT CAUTION
• FASTENER NOTICE
• BODY CONTROL SYSTEM DESCRIPTION AND OPERATION
• GENERAL ELECTRICAL DIAGNOSIS PROCEDURES
• RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION
• Battery Description and Operation