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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) Carrier 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. With the aid of an assistant, install the ESB carrier.
  2. Position the ESB in order to connect the HVAC duct to the ESB.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the ESB carrier nuts.

    Tighten:  Tighten the nuts to 47 N.m (35 lb ft).

    4. Fig 1: View Of ESB Carrier To Floor Nuts (5.3L Engine w/RPO HP2)
    GM869219Courtesy of GENERAL MOTORS CORP.
  4. Connect the low voltage cable electrical connector (1) on the driver side of the ESB.
  5. Install the retaining clip (2) to ESB carrier.
    6. Fig 2: View Of Low Voltage Cable Electrical Connector & Retaining Clip (5.3L Engine w/RPO HP2)
    GM1462971Courtesy of GENERAL MOTORS CORP.
  6. Connect the 12-volt harness electrical connector on the passenger side.
  7. Install the ground straps to the stud (2).
  8. Install the ground strap nut (1).

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

  9. Connect the 120-volt AC electrical connector (3).
  10. Connect the 42-volt positive/negative cable electrical connector (4).
    11. Fig 3: View Of 42-Volt Positive/Negative Cable Electrical Connector, AC Electrical Connector, Ground Strap & Stud
    GM1237048Courtesy of GENERAL MOTORS CORP.
  11. Install the red CPA retainer to the 42-volt connector.
  12. Install the 42-volt positive/negative cable retainer and nuts.
    13. Fig 4: View Of 42-Volt Positive/Negative Cable Retainer & Nuts (5.3L Engine w/RPO HP2)
    GM1237047Courtesy of GENERAL MOTORS CORP.
  13. Connect the ESB. Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2) .
  14. Install the ESB trim cover. Refer to Energy Storage Box (ESB) Trim Cover Replacement (5.3L Engine w/RPO HP2) .
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