Electrical - Vehicle No-Start Condition

Bulletin No.: 04-06-03-012

Date: October 29, 2004

TECHNICAL

Subject:
No Start (Replace Battery Cable Assembly)

Models:
2002-2004 Chevrolet Astro
2002-2004 GMC Safari

Two-Wheel Drive Vans Only

Condition

Some customers may comment on a vehicle no start condition.

Cause

The battery cable assembly may be missing a retaining clip and allowing the cable assembly to make contact with the inner tie rod and center drag link on right turns, causing a direct battery to ground condition.

Correction

Replace the battery cable assembly.

1. Disconnect the negative and positive battery cables.

2. Remove the negative battery distribution wire from the ground stud to the left of the radiator.

3. Remove the fuse/relay center cover and remove the positive battery distribution wire.

4. Remove the battery cable harness retainer clips from the body.

5. Raise the vehicle.

6. Remove the remaining harness clips.

7. Remove the negative cable from the engine block stud.

8. Remove the positive cable from the starter motor solenoid.

9. Remove the cable assembly.





10. Install the cable assembly and push the retaining clips into the frame. The new cable will have an added retainer clip that will hold the cable back from making contact with the steering linkage as seen in illustration above.

11. Install the negative cable and stud to the engine block.

Tighten

Tighten the negative cable stud to engine block to 40 N.m (29 lb ft).

12. Install the positive cable to the start motor solenoid.

Tighten

Tighten the positive cable to starter motor solenoid to 9 N.m (80 lb in).

13. Lower the vehicle.

14. Install the positive cable to the stud at the fuse / relay center.

Tighten

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

15. Install the cover.

16. Install the negative cable ground lead to the radiator support.

Tighten

Tighten the nut to 45 N.m (33 lb ft).

17. Install the positive cable to the battery.

Tighten

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

18. Install the negative cable to the battery

Tighten

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

19. Reset the clock and radio stations.





Parts Information

Parts are currently available from GMSPO.

Warranty Information





For vehicles repaired under warranty, use the table.





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