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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 955 (Battery, Charging System & Starting System) >> Repair Instructions >> Energy Storage Box (ESB) 120V Cable Replacement (5.3L Engine w/RPO HP2) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Feed the 120-volt cable (1) through the receptacle opening (2) in the ESB.
    2. Fig 1: View Of 120-Volt Cable & Receptacle Opening (5.3L Engine w/RPO HP2)
    GM1343186Courtesy of GENERAL MOTORS CORP.
  2. Route the 120-volt cable as noted earlier.
    3. Fig 2: View Of 120-Volt Cable (5.3L Engine w/RPO HP2)
    GM1403631Courtesy of GENERAL MOTORS CORP.
  3. Connect the retainers securing the 120-volt cable within the ESB.
    4. Fig 3: View Of 120-Volt Cable Connector Screws (5.3L Engine w/RPO HP2)
    GM1403630Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the 120-volt cable connector screws.

    Tighten:  Tighten the screws to 6 N.m (53 lb in).

  5. Install the receptacle outlet cover screws (1).

    Tighten:  Tighten the screws to 0.5 N.m (4.4 lb in).

    6. Fig 4: View Of Receptacle Box & Outlet Screws (5.3L Engine w/RPO HP2)
    GM1343181Courtesy of GENERAL MOTORS CORP.
  6. Install the ESB intermediate cover. Refer to Energy Storage Box (ESB) Trim Cover Replacement (5.3L Engine w/RPO HP2) .
  7. Connect the 120-volt AC electrical connector (3).
    8. Fig 5: View Of 42-Volt Positive/Negative Cable Electrical Connector, AC Electrical Connector, Ground Strap & Stud
    GM1237048Courtesy of GENERAL MOTORS CORP.
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