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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) Battery 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.
IMPORTANT: The NEW replacement battery will be delivered at approximately 80 percent state of charge (SOC) and must be charged alone to 100 percent SOC prior to installation.
  1. Charge the NEW replacement battery. Refer to Battery Charging (Non-HP2) or Battery Charging (HP2) .
  2. Install J 43679  , to the lifting points on the NEW battery.
    3. Fig 1: View Of J43679 (5.3L Engine w/RPO HP2)
    GM1338829Courtesy of GENERAL MOTORS CORP.
  3. Install the appropriate battery.
    4. Fig 2: View Of Battery (5.3L Engine w/RPO HP2)
    GM1403640Courtesy of GENERAL MOTORS CORP.
  4. Remove J 43679  , from the battery.
    5. Fig 3: View Of J43679 (5.3L Engine w/RPO HP2)
    GM1338829Courtesy of GENERAL MOTORS CORP.
  5. Ensure that the batteries (1, 2 and 3) have the positive and negative terminals properly oriented.
    6. Fig 4: Battery Proper Installation Positions (5.3L Engine w/RPO HP2)
    GM1456047Courtesy of GENERAL MOTORS CORP.
  6. Install the appropriate battery hold down bracket.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the appropriate battery hold down bracket nut.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    8. Fig 5: View Of Battery Hold Down Bracket & Nut (5.3L Engine w/RPO HP2)
    GM1403638Courtesy of GENERAL MOTORS CORP.
  8. Install the battery vent cap (2) to the appropriate battery.
    9. Fig 6: View Of Battery Vent Cap (5.3L Engine w/RPO HP2)
    GM1470609Courtesy of GENERAL MOTORS CORP.
  9. Connect the battery vent hose(s) to the appropriate battery.
  10. If necessary, engage the retainers securing the battery vent hose.
    11. Fig 7: View Of Battery Vent Hose (5.3L Engine w/RPO HP2)
    GM1403623Courtesy of GENERAL MOTORS CORP.
  11. If necessary, install the battery resistor to the battery 3 positive terminal.
  12. Install the power cable (3) to battery 3.
  13. Install the power cable nut (1) to battery 3.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    14. Fig 8: View Of High Current Connector Power Cable & Nuts (5.3L Engine w/RPO HP2)
    GM1338109Courtesy of GENERAL MOTORS CORP.
  14. If necessary, install the battery resistor to the battery 3 negative terminal.
  15. Install the power cable (2) to battery 2 and battery 3.
  16. Install the power cable nuts (3) to battery 2 and battery 3.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

  17. Install NEW tie straps (1) securing the power cable to the ESB.
    18. Fig 9: View Of ESB Power Cable, Tie Straps & Nuts (Battery 2 To Battery 3) (5.3L Engine w/RPO HP2)
    GM1338110Courtesy of GENERAL MOTORS CORP.
  18. If necessary, install the battery resistor to the battery 1 positive terminal.
  19. Install the power cable (3) to battery 1 and battery 2.
  20. Install the power cable nuts (1) to battery 1 and battery 2.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    21. Fig 10: View Of Battery Resistor, Power Cable & Nuts (5.3L Engine w/RPO HP2)
    GM1403626Courtesy of GENERAL MOTORS CORP.
  21. Connect the battery thermistor electrical connectors to the appropriate battery.
  22. Connect the battery resistor electrical connectors (1) to the appropriate battery.
    23. Fig 11: View Of Battery Resistor Connectors, Power Cable & Nut (5.3L Engine w/RPO HP2)
    GM1335904Courtesy of GENERAL MOTORS CORP.
  23. If necessary, install the battery cut-off switch. Refer to Energy Storage Box (ESB) Cut Off Switch Replacement (5.3L Engine w/RPO HP2) .
  24. Install the ESB intermediate cover. Refer to Energy Storage Box (ESB) Intermediate Cover Replacement (5.3L Engine w/RPO HP2) .
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