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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 >> Starter Motor Solenoid Replacement (6.6L (LB7) Engine) >> 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. If necessary, install the solenoid plunger and spring.
    2. Fig 1: View Of Solenoid Plunger & Spring (6.6L (LB7) Engine)
    GM1201142Courtesy of GENERAL MOTORS CORP.
  2. Using Three Bond silicone 1207B, GM P/N 97720043, seal the starter solenoid attachment area.
    3. Fig 2: Sealing Starter Solenoid Attachment Area (6.6L (LB7) Engine)
    GM1201144Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure 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.
  3. 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. Tip the solenoid and insert the lever into the loop, push the solenoid against the housing.
    4. Fig 3: View Of Solenoid Plunger & Drive Gear Lever (6.6L (LB7) Engine)
    GM1201131Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the solenoid bolts.

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

    5. Fig 4: View Of Solenoid Bolts (6.6L (LB7) Engine)
    GM1201129Courtesy of GENERAL MOTORS CORP.
  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.
  7. Tighten the M-terminal stud nut.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

    8. Fig 5: View Of M-Terminal Stud, Nut & Cable (6.6L (LB7) Engine)
    GM1201128Courtesy of GENERAL MOTORS CORP.
  8. Using Three Bond silicone 1207B, GM P/N 97720043, seal the M-terminal stud connection (2).
  9. Reposition the M-terminal stud weather cover (1).
    10. Fig 6: View Of M-Terminal Stud Weather Cover & Epoxy Coating (6.6L (LB7) Engine)
    GM1201127Courtesy of GENERAL MOTORS CORP.
  10. Bench test the starter in a free-run condition prior to installation.
  11. Install the starter motor. Refer to Starter Motor Replacement (4.3L Engine)  or Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines)  or Starter Motor Replacement (6.6L (LB7) Engine)  or Starter Motor Replacement (6.6L (LLY) Engine)  or Starter Motor Replacement (8.1L Engine) .
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