Express, Savana, G1500, G2500, G3500, 1998-2005

Starter

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Removal & Installation



4.3L & 5.0L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Bracket and shield
     
    Wires
     
    Mounting bolts and shims
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter
     
    Mounting bolts and shim. Torque the bolts to 33 ft lbs. (45 Nm).
     
    Wires. Torque battery wire nut to 89 inch lbs. (10 Nm) and ignition nut to 18 inch lbs. (2 Nm).
     
    Bracket and shield. Torque the nuts to 53 inch lbs. (6 Nm).
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the starter motor-4.3L and 5.0L engines.

     

  2.  

4.3L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Bracket and shield
     
    Wires
     
    Mounting bolts and shims
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter
     
    Mounting bolts and shim. Torque the bolts to 33 ft lbs. (45 Nm).
     
    Wires. Torque battery wire nut to 89 inch lbs. (10 Nm) and ignition nut to 18 inch lbs. (2 Nm).
     
    Bracket and shield. Torque the nuts to 53 inch lbs. (6 Nm).
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the starter motor-4.3L engines.

     

  2.  

4.8L, 5.3L & 6.0L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Protective shields (as necessary)
     
    Starter solenoid shield
     
    Starter-to-transmission close out cover bolt
     
    Engine oil level sensor connection
     

  6.  
  7. Slide the starter forward until the starter clears the transmission.

    Starter transmission close out cover
     
    Positive battery cable and wiring harness from the starter
     
    Starter

    Click image to see an enlarged view

    Fig. Starter removal-4.8L, 5.3L and 6.0L engines

     

  8.  

To install:

  1. Install or connect the following:

    Starter
     
    Positive battery cable.
     
    Starter transmission close out cover
     
    Mounting bolts to the engine block and tighten to 37 ft. lbs. (50 Nm)
     
    Oil level sensor connection
     
    Starter-to-transmission close out cover bolt
     
    Starter solenoid shield
     
    Protective shields (as necessary)
     

  2.  
  3. Remove the safety stands.
  4.  
  5. Lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Protective shields (as necessary)
     
    Starter solenoid shield
     
    Starter-to-transmission close out cover bolt
     
    Engine oil level sensor connection
     

  6.  
  7. Slide the starter forward until the starter clears the transmission.
    NOTE
    If additional clearance is necessary, remove the right front wheel and tire, then remove the starter from the wheel well.



    Starter transmission close out cover
     
    Positive battery cable and wiring harness from the starter
     
    Starter
     



    Click image to see an enlarged view

    Fig. Starter removal-4.8L, 5.3L and 6.0L engines

  8.  

To install:

  1. Install or connect the following:

    Starter
     
    Positive battery cable.
     
    Starter transmission close out cover
     
    Mounting bolts to the engine block and tighten to 37 ft. lbs. (50 Nm)
     
    Oil level sensor connection
     
    Starter-to-transmission close out cover bolt
     
    Starter solenoid shield
     
    Protective shields (as necessary)
     

  2.  
  3. Remove the safety stands.
  4.  
  5. Lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  

5.7L & 7.4L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Mounting bolts and shims
     
    Wires
     
    Heat shield
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter
     
    Wires. Torque battery wire nut to 89 inch lbs. (10 Nm), and ignition nut to 18 inch lbs. (2 Nm).
     
    Heat shield. Torque the bolts to 53 inch lbs. (6 Nm) and the nuts to 35 inch lbs. (3 Nm).
     
    Mounting bolts and shim. Torque the bolts to 33 ft lbs. (45 Nm).
     
    Negative battery cable
     

  2.  

6.5L Engine
  1. Remove or disconnect the following:

    Negative battery cables
     
    Mounting bolts/nuts and shim, if used
     
    Starter
     
    Wires
     
    Heat shield and bracket

    Click image to see an enlarged view

    Fig. Exploded view of the starter motor-6.5L engine shown

     

  2.  

To install:

  1. Install or connect the following:

    Heat shield and bracket. Torque the bolts to 13 ft lbs. (17 Nm).
     
    Wires. Torque battery wire nut to 89 inch lbs. (10 Nm), and ignition nut to 18 inch lbs. (2 Nm) on 6.5L engines.
     
    Starter
     
    Mounting bolts/nuts and shim, if used. Torque the bolts to 33 ft lbs. (45 Nm) and the nut to 75 inch lbs. (8.5 Nm) for 6.5L engines.
     
    Negative battery cables
     

  2.  

6.6L Engine
  1. Remove or disconnect the following:

    Negative battery cables
     
    Right front wheel and fender splash shield
     
    Turbocharger exhaust pipe
     
    Mounting bolts/nuts and shim, if used
     
    Starter
     
    Wires
     
    Heat shield and bracket

    Click image to see an enlarged view

    Fig. Starter mounting-6.6L engines

     

  2.  

To install:

  1. Install or connect the following:

    Heat shield and bracket.
     
    Wires. Tighten the solenoid nut to 30 inch lbs. (3.4 Nm) and the positive battery cable nut to 80 inch lbs. (9 Nm).
     
    Starter
     
    Mounting bolts/nuts and shim, if used. Tighten the starter bolts to 63 ft. lbs. (85 Nm).
     
    Turbocharger exhaust pipe
     
    Right front fender splash shield and wheel
     
    Negative battery cables
     

  2.  

8.1L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Positive battery cable nut
     
    Positive cable from the solenoid
     
    Engine harness ground nut and ground from the solenoid
     
    Mounting bolts and starter
     
    Heat shield bolts, nut and shield, if necessary
     

  2.  

To install:

  1. Install or connect the following:

    Heat shield, bolts and nut if removed. Tighten the bolts to 35 inch lbs. (3 Nm) and the nut to 44 inch lbs. (5 Nm).
     
    Starter and bolts. Tighten to 37 ft. lbs. (50 Nm).
     
    Ground wire and nut. Tighten to 30 inch lbs. (3.4 Nm).
     
    Positive cable and nut. Tighten to 80 inch lbs. (9 Nm).
     
    Negative battery cable.
     

  2.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Positive battery cable nut
     
    Positive cable from the solenoid
     
    Engine harness ground nut and ground from the solenoid
     
    Mounting bolts and starter
     
    Heat shield bolts, nut and shield, if necessary
     

  2.  

To install:

  1. Install or connect the following:

    Heat shield, bolts and nut if removed. Tighten the bolts to 35 inch lbs. (3 Nm) and the nut to 44 inch lbs. (5 Nm).
     
    Starter and bolts. Tighten to 37 ft. lbs. (50 Nm).
     
    Ground wire and nut. Tighten to 30 inch lbs. (3.4 Nm).
     
    Positive cable and nut. Tighten to 80 inch lbs. (9 Nm).
     
    Negative battery cable.
     

  2.  

Solenoid or Relay



Removal & Installation
  1. Remove the starter motor.
  2.  
  3. Reposition the M-terminal stud weather cover.
  4.  
  5. Clean the epoxy coating from the M-terminal stud.
  6.  
  7. Loosen the M-terminal stud nut.
  8.  
  9. Remove the cable from the M-terminal stud.
  10.  
  11. Remove the solenoid bolts.
  12.  
  13. Separate the solenoid from the housing and unhook the solenoid plunger from the drive gear lever.
  14.  
  15. Note that the spring (3) is positioned against the drive gear lever (1) and the drive gear lever is placed inside the solenoid plunger loop (2).

    Click image to see an enlarged view

    Fig. Spring (3) is positioned against the drive gear lever (1) and the drive gear lever is placed inside the solenoid plunger loop (2)

  16.  
  17. Remove the solenoid housing.
  18.  
  19. If necessary, remove the solenoid plunger and spring.
  20.  

To install:

  1. If necessary, install the solenoid plunger and spring.
  2.  
  3. Using Three Bond silicone 1207B, GM P/N 97720043, seal the starter solenoid attachment area.
    WARNING
    Make sure that the drive gear lever (1) is properly installed into the solenoid plunger (2) loop. Improper installation of the drive gear lever will cause an abnormal or no operation condition of the starter.



    Click image to see an enlarged view

    Fig. Make sure that the drive gear lever (1) is properly installed into the solenoid plunger (2) loop

  4.  
  5. Install the solenoid, making sure to insert the drive gear lever (1) into the solenoid plunger (2) loop, perform the following:
    1. Pull the gear lever (1) out away from the starter housing and pull the plunger (2) out away from the solenoid.
    2.  
    3. Tip the solenoid and insert the lever into the loop, push the solenoid against the housing.
    4.  

  6.  
  7. Install the solenoid bolts and tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Wipe the excess silicone pressed out during the solenoid installation from around the base of the solenoid to make a weather proof seal.
  10.  
  11. Install the cable to the M-terminal stud between the washers and terminal nut.
  12.  
  13. Tighten the M-terminal stud nut and tighten the nut to 71 inch lbs. (8 Nm).
  14.  
  15. Using Three Bond silicone 1207B, GM P/N 97720043, seal the M-terminal stud connection.
  16.  
  17. Reposition the M-terminal stud weather cover.
  18.  
  19. Bench test the starter in a free-run condition prior to installation.
  20.  
  21. Install the starter motor.
  22.  

Testing & Troubleshooting



Voltage Drop Test

NOTE
The battery must be in good condition and fully charged prior to performing this test.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the ignition system by unplugging the ignition system fuse. Verify that the vehicle will not start.
  4.  
  5. Connect a voltmeter between the positive terminal of the battery and the main terminal on the starter solenoid from the battery.
  6.  
  7. Turn the ignition key to the START position and note the voltage on the meter.
  8.  
  9. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  10.  
  11. Connect a voltmeter between the positive terminal of the battery and the terminal on the solenoid leading to the starter.
  12.  
  13. Turn the ignition key to the START position and note the voltage on the meter.
  14.  
  15. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    NOTE
    Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

  16.  

 
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