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Starting System: Removal & Installation Chevrolet Silverado 2500

Starter 27 illustrations ~1422 words

REMOVAL & INSTALLATION

WARNINGVehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering column, instrument panel or related components, see the following applicable procedures: For pickups, see AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM . For utility vehicles, see AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM .
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES before disconnecting battery.
CAUTIONUse the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Removal (4.3L Engine)

  1. Turn off all lamps and accessories. Turn ignition off. Disconnect negative battery cable. (Scheme 2)
  2. Raise and suitably support vehicle.
  3. Remove starter motor bolts. (Scheme 3)
  4. Remove starter lead nut.
  5. Remove positive cable from starter.
  6. Remove starter solenoid nut. (Scheme 4)
  7. Remove harness from starter.
  8. Remove starter from vehicle.

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Removal (4.8L, 5.3L & 6.0L Engine)

  1. Turn off all lamps and accessories. Turn ignition off. Disconnect negative battery cable. (Scheme 2)
  2. Raise and suitably support vehicle.
  3. Remove transmission cover bolt. (Scheme 5)
  4. Remove front axle mounting bracket nut. (Scheme 6)
  5. Reposition front axle mounting bracket bolt until bolt tip is flush with support bushing.
  6. Remove starter bolts. (Scheme 7)
  7. Disconnect oil level sensor electrical connector.
  8. Slide starter forward until starter clears transmission.
  9. Remove starter lead nut. see scheme 12
  10. Remove starter lead from starter.
  11. Remove positive cable nut. (Scheme 8)
  12. Remove positive cable from starter.
  13. Place starter on a workbench.
  14. If necessary, unsnap transmission cover from starter. (Scheme 9)
  15. If necessary, remove starter heat shield. (Scheme 10)

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Removal (6.6L Engine)

  1. Turn off all lamps and accessories. Turn ignition off. Disconnect negative battery cable. (Scheme 2)
  2. Raise the vehicle.
  3. If equipped with 4WD, remove the right front tire and wheel.
  4. If equipped with 4WD, remove the right front fender wheelhouse inner panel. (Scheme 11)
  5. Remove the battery positive cable from the starter motor. (Scheme 12)
  6. Remove the solenoid wires.
  7. Remove the starter motor bolts. (Scheme 13)
  8. Remove the starter motor assembly.

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Removal (8.1L Engine)

  1. Turn off all lamps and accessories. Turn ignition off. Disconnect negative battery cable. (Scheme 2)
  2. Raise and suitably support the vehicle with safety stands.
  3. If necessary, remove the engine shield bolts and shield. (Scheme 14)
  4. If necessary, remove the oil pan skid plate bolts and plate. (Scheme 15)
  5. Remove the front axle mounting bracket nut. (Scheme 6)
  6. Reposition the front axle mounting bracket bolt until the bolt tip is flush with the support bushing.
  7. Remove the starter bolts. (Scheme 16)
  8. Slide the starter forward until the starter clears the transmission.
  9. Remove the starter lead nut. (Scheme 17)
  10. Remove the starter lead from the starter.
  11. Remove the positive cable nut. (Scheme 18)
  12. Remove the positive cable from the starter.
  13. If necessary, remove the starter heat shield bolts, nut, and shield. (Scheme 19)

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Installation (4.3L Engine)

  1. Install starter to vehicle. (Scheme 4)
  2. Install harness to starter.
  3. Install starter solenoid nut. Tighten starter solenoid nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  4. Install positive cable to starter.
  5. Install starter lead nut. Tighten starter lead nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  6. Install starter motor bolts. (Scheme 3) Tighten starter motor bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  7. Lower the vehicle.
  8. Connect negative battery cable. (Scheme 2) Tighten battery terminal bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).

Installation (4.8L, 5.3L & 6.0L Engine)

  1. If necessary, install starter heat shield. (Scheme 10)
  2. If necessary, snap transmission cover to starter. (Scheme 9)
  3. Install positive cable to starter. (Scheme 8)
  4. Install positive cable nut. Tighten positive cable nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  5. Install starter lead to starter. see scheme 12
  6. Install starter lead nut. Tighten starter lead nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  7. Position starter into place. (Scheme 7)
  8. Install starter bolts. Tighten starter bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  9. Connect oil level sensor electrical connector.
  10. Position front axle mounting bracket bolt until bolt is fully seated. (Scheme 6)
  11. Install front axle mounting bracket nut. Tighten front axle mounting bracket nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  12. Install transmission cover bolt. (Scheme 5) Tighten transmission cover bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  13. If necessary, install oil pan skid plate and bolts. (Scheme 15) Tighten oil pan skid plate bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  14. If necessary, install engine shield and bolts. (Scheme 14) Tighten engine shield bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  15. Lower vehicle.
  16. Connect negative battery cable. (Scheme 2) Tighten battery terminal bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).

Installation (6.6L Engine)

  1. Install the starter motor to the engine rear cover. (Scheme 13)
  2. Install the starter motor bolts. Tighten the starter bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  3. Install the solenoid wires. (Scheme 12)
  4. Install the starter solenoid nut. Tighten the starter solenoid nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  5. Install the battery positive cable to the solenoid stud.
  6. Install the battery positive cable nut. Tighten the starter battery positive cable nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  7. Install the right front fender wheelhouse inner panel, if equipped with 4WD. (Scheme 11)
  8. Install the right front tire and wheel, if equipped with 4WD.
  9. Lower the vehicle.
  10. Connect negative battery cable. (Scheme 2) Tighten battery terminal bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).

Installation (8.1L Engine)

  1. If necessary, install the starter heat shield, nut and bolts. (Scheme 19) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000). Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  2. Install the positive cable to the starter. (Scheme 18)
  3. Install the positive cable nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  4. Install the starter lead to the starter. (Scheme 17)
  5. Install the starter lead nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  6. Position the starter into place. (Scheme 16)
  7. Install the starter bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  8. Position the front axle mounting bracket bolt until the bolt is fully seated. (Scheme 6)
  9. Install the front axle mounting bracket nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  10. If necessary, install the oil pan skid plate and bolts. (Scheme 15) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  11. If necessary, install the engine shield and bolts. (Scheme 14) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  12. Lower the vehicle.
  13. Connect negative battery cable. (Scheme 2) Tighten battery terminal bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  1. Remove the Underhood Bussed Electrical Center (UBEC) cover. (Scheme 20)
  2. Remove the starter motor relay.
  3. To install, insert the starter motor relay.
  4. Install the UBEC cover. (Scheme 20)

Scheme 20

Scheme 20
Scheme 20

Removal

  1. Remove the starter motor. See «STARTER»(ref-138814-S16413176512002042300000).
  2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter heat shield. (Scheme 10)
  3. If equipped with a 8.1L engine, remove the starter heat shield bolts and nut. (Scheme 19)
  4. Remove the starter heat shield.

Installation

  1. If equipped with a 8.1L engine, install the starter heat shield. (Scheme 19)
  2. Install the starter heat shield bolts, and nut. Tighten the starter heat shield bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000). Tighten the starter heat shield nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  3. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the starter heat shield. (Scheme 10)
  4. Install the starter motor. See «STARTER»(ref-138814-S16413176512002042300000).
  1. Remove the starter motor. See «STARTER»(ref-138814-S16413176512002042300000).
  2. Reposition the M-terminal stud weather cover. (Scheme 21)
  3. Clean the epoxy coating from the M-terminal stud.
  4. Loosen the M-terminal stud nut. (Scheme 22)
  5. Remove the cable from the M-terminal stud.
  6. Remove the solenoid bolts. (Scheme 23)
  7. Separate the solenoid from the housing and unhook the solenoid plunger from the drive gear lever. (Scheme 24)
  8. Note that the spring is positioned against the drive gear lever and the drive gear lever is placed inside the solenoid plunger loop. (Scheme 25)
  9. Remove the solenoid housing. (Scheme 26)
  10. If necessary, remove the solenoid plunger and spring. (Scheme 27)

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. If necessary, install the solenoid plunger and spring. (Scheme 27)
  2. Using Three Bond Silicone 1207B (GM P/N 97720043), seal the starter solenoid attachment area. (Scheme 28)
  3. Install the solenoid, making sure to insert the drive gear lever into the solenoid plunger loop, perform the following: Pull the gear lever out away from the starter housing and pull the plunger out away from the solenoid. Tip the solenoid and insert the lever into the loop, push the solenoid against the housing.
  4. Install the solenoid bolts. (Scheme 23) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  5. Wipe the excess silicone pressed out during the solenoid installation from around the base of the solenoid to make a weather proof seal.
  6. Install the cable to the M-terminal stud between the washers and terminal nut. (Scheme 22)
  7. Tighten the M-terminal stud nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138814-S15350063572002042300000).
  8. Using Three Bond silicone 1207B, seal the M-terminal stud connection. (Scheme 21)
  9. Reposition the M-terminal stud weather cover.
  10. Bench test the starter in a free-run condition prior to installation.
  11. Install the starter motor. See «STARTER»(ref-138814-S16413176512002042300000).

Scheme 28

Scheme 28
Scheme 28

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