Battery Positive Cable Replacement 4.8L /5.3L /6.0L

1. On all models, remove the bolt retaining the coolant recovery reservoir or surge tank.
2. Position the coolant recovery reservoir or the surge tank aside.
3. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection .



4. Disconnect the battery positive cable from the battery.
5. On models equipped with the 4.8L, or 6.0L engine, disconnect the positive lead to the junction block.



6. On models equipped with 4.8L, 5.3L or 6.0L engine, unclip the battery positive cable from the engine harness clip (1).
7. Unclip the battery positive cable from the engine harness retainer (2).



8. On all models, raise the vehicle. Refer to Lifting and Jacking the Vehicle .
9. Disconnect the positive lead at the starter solenoid.



10. On models with 4.8L and 6.0L engine, remove the battery positive cable retainer clips (1).
11. Remove the positive cable to the chassis harness clips (2).



12. Remove the positive cable retainer clips (1) from the frame.
13. Remove battery positive cable retainer clips (2) from crossmember.



14. On all models, lower the vehicle.
15. On models equipped with the 4.8L, 5.3L or 6.0L engine, unclip the battery positive cable from the fan shroud.



16. On all models, disconnect the positive lead to the generator.
17. Remove the positive cable from the vehicle. Note the location of the retaining clips.

1. On all models, install the positive cable to the vehicle.

Ensure the cable is routed correctly and installed in the retainer clips.

Notice: Refer to Fastener Notice in the Preface section.

2. Connect the positive lead to the generator.

Tighten
Tighten the generator output (BAT) nut to 10 N·m (89 lb in).




3. On models equipped with the 4.8L, 5.3L or 6.0L engine, clip the positive cable to the fan shroud.
4. On all models, raise the vehicle. Refer to Lifting and Jacking the Vehicle .



5. On models with 4.8L and 6.0L engine, install the positive cable retainer clips (2) to the crossmember.
6. Install the positive cable retainer clips (1) to the frame.



7. Install the positive cable to the chassis harness clips (2).
8. Install the positive cable retainer clips (1).



9. Install the positive lead to the starter solenoid.

Tighten
Tighten the positive lead to starter solenoid to 10 N·m (89 lb in).

10. On all models, lower the vehicle.



11. On models equipped with 4.8L, 5.3L or 6.0L engine, clip battery positive cable to the engine harness retainer (2).
12. Clip the positive cable to the engine harness clip (1).



13. On models equipped with the 4.8L, or 6.0L engine, install the positive lead to the junction block.

Tighten
Tighten the junction block nut to 10 N·m (89 lb in).

14. On all models, connect the battery positive cable to the battery.

Tighten
Tighten the battery terminals to 14 N·m (123 lb in).

15. Connect the battery negative cable to the battery. Refer to Battery Negative Cable Disconnection and Connection .



16. Install the coolant recovery reservoir or surge tank and the bolt.

Tighten
Tighten the coolant recovery reservoir or surge tank bolt to 11 N·m (97 lb in).

Battery Positive Cable Replacement 6.6L - Primary

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Disconnect the positive battery cable from the battery.



3. Remove the positive cable nut from the junction block and disconnect the cable.



4. Remove the positive cable nut from the generator and disconnect the cable .
5. Remove the engine cover. Refer to Engine Cover Replacement .



6. Disconnect the wiring harness clips and the positive cable from the glow plug module.
7. Remove the battery positive cable from the engine harness clip.



8. Remove the battery positive cable from the engine harness clips (1).
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .



10. Remove the battery positive cable bolt (1) and clip (2) from the frame.
11. Remove the battery positive cable retaining clip from the transmission line bracket.



12. Remove the positive battery cable nut (7) from the starter and disconnect the cable (8).
13. Remove the positive battery cable.

1. Position the positive cable to the vehicle using the same cable routing as in removal.

Notice: Refer to Fastener Notice in the Preface section.




2. Position the positive cable (8) to the starter and install the nut (7).

Tighten
Tighten the positive cable to starter nut to 10 N·m (89 lb in).

3. Install the positive cable retaining clip to the transmission line bracket.



4. Install the battery positive cable nut (1) and clip  (2) to the frame.
5. Lower the vehicle.



6. Install the positive cable to engine harness clips (1).
7. Install the positive cable to the engine harness clip.



8. Connect the positive cable to the glow plug module and connect the wiring harness clips.
9. Install the engine cover. Refer to Engine Cover Replacement .



10. Install the positive battery cable to the generator and install the nut.

Tighten
Tighten the positive cable to generator nut to 10 N·m (89 lb in).




11. Install the positive cable to the junction block and install the nut.

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

12. Connect the positive cable to the battery.

Tighten
Tighten the bolt to 14 N·m (123 lb in).

13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Battery Positive Cable Replacement 6.6L - Auxiliary

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .



2. Disconnect the auxiliary battery positive cable.



3. Remove the auxiliary positive battery cable to the frame clips (1).
4. Remove the auxiliary positive battery cable to chassis harness clips (2).



5. Remove the auxiliary positive battery cable to frame clips (1).
6. Remove the auxiliary positive battery cable to crossmember clips (2).
7. Remove the auxiliary positive battery cable to frame clip (3).



8. Remove the auxiliary positive battery cable nut from the junction block.
9. Disconnect the auxiliary positive battery cable wiring harness clips.
10. Remove the auxiliary positive battery cable from the vehicle.

1. Position the auxiliary positive battery cable and connect the wiring harness clips.

Notice: Refer to Fastener Notice in the Preface section.




2. Position the auxiliary positive battery cable to the junction block and install the cable nut.

Tighten
Tighten the auxiliary positive cable nut to 8 N·m (71 lb in).




3. Install the auxiliary positive battery cable to frame clip  (3).
4. Install the auxiliary positive battery cable to crossmember clips (2).
5. Install the auxiliary positive battery cable to frame clips (1).



6. Install the auxiliary positive battery cable to the chassis harness clips (2).

Install the auxiliary positive battery cable to the frame clips (1).




8. Connect the auxiliary positive battery cable to the auxiliary battery.

Tighten
Tighten the auxiliary positive cable bolt to 14 N·m (123 lb in).

9. Connect the auxiliary negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Battery Positive Cable Replacement With 4.3L

1. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement



4. Remove the bolt retaining the coolant recovery reservoir or surge tank.
5. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement
6. Remove the accelerator and cruse control cables with accelerator bracket ONLY from the throttle body. Refer to Throttle Body Assembly Replacement



7. Remove the bolt retaining the coolant recovery reservoir or surge tank.
8. Move the coolant recovery reservoir or the surge tank aside.



9. Disconnect the battery positive cable from the battery.
10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.



11. Disconnect the positive lead to the starter solenoid.
12. Lower the vehicle.



13. Disconnect the positive lead to the generator.
14. Remove the cable from the vehicle. Note the location of the retaining clips.

1. Install the cable to the vehicle.

Ensure the cable is routed correctly and installed in the retainer clips.

Notice: Refer to Fastener Notice in the Preface section.




2. Connect the positive lead to the generator.

Tighten
Tighten the generator output (BAT) nut to 18 N·m (13 lb ft).

3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.



4. Install the positive lead to the starter solenoid.

Tighten
Tighten the positive lead to starter solenoid to 10 N·m (89 lb in).

5. Lower the vehicle.
6. Connect the battery positive cable to the battery.

Tighten
Tighten the battery terminals to 17 N·m (13 lb ft).

7. Install the accelerator and cruse control cables with accelerator bracket ONLY to the throttle body. Refer to Throttle Body Assembly Replacement
8. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement



9. Install the coolant recovery reservoir or surge tank and the bolt.

Tighten
Tighten the coolant recovery reservoir or surge tank bolt to 11 N·m (97 lb in).

10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
11. Install the engine cover. Refer to Engine Cover Replacement.
12. Connect the battery negative cable to the battery. Refer to Battery Negative Cable Disconnection and Connection .