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Home >> Chevrolet >> 2003 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Electrical >> Charging Systems >> Battery >> Repair Instructions >> Battery Positive Cable Replacement >> Installation Procedure

Installation Procedure

CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks:
  1. Place the transmission in park.
  2. Engage the parking brakes and block the wheels.
  3. Disconnect the battery feed at the-distributor.
  1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame.

    Place one probe of the J 39200  on the grounded battery post (not on the cable clamp) and the other on the frame.

    Operate the starter and note the voltage reading.

    Fig 1: Removing Battery Positive Cable
    G01646494Courtesy of GENERAL MOTORS CORP.
  2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating.
  3. Check the voltage drop between the starter housing and the frame with the starter operating.
  4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit.

    In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned.

    If the cables are frayed or the clamps are corroded, the cables should be replaced.

    When selecting the new cables, ensure that the new cables are the same length and the same new cables are the same length and the same diameter as the original cables being replaced.



  1. For FWD, install the battery positive cable in the same position as the original.
  2. For A4WD, install the battery positive cable in the same position as the original.
    Fig 1: Installing Battery Positive Cable
    G01646495Courtesy of GENERAL MOTORS CORP.
    NOTE: When installing the positive battery cable to the starter solenoid, the inner nut on the solenoid battery terminal must be tightened before the battery cable and the other leads are installed. Failure to do so will result in the solenoid or the solenoid terminal damage.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Connect the battery positive cable to the starter solenoid.

    Tighten 

    Tighten the nut to 9 N.m (80 lb in).

  4. Connect the additional battery positive cable lead to the underhood electrical center.

    Tighten 

    Tighten the nut to 9 N.m (80 lb in).

  5. Connect the battery positive terminal bolt to the battery.

    Tighten 

    Tighten the bolt to 15 N.m (11 lb ft).

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