Attachment III - Technical Instructions

Starter Cable Assembly Replacement

Technical Instructions

Starter Cable Replacement

1. Disconnect both cables at the battery. Be sure to remove the negative battery cable first. Remove the negative cable pigtail screw and disconnect the pigtail at the connector. Retain the screw.

2. Raise the vehicle on a hoist.

3. CAUTION:
Read this step completely before proceeding further.

^ Remove the red protective cover from the starter solenoid terminals.

^ Remove the battery cable attaching nut on the solenoid and remove the cable.

^ Remove the solenoid wire.

NOTE:
The terminal is covered with a black plastic cover. This acts as a release feature for the terminal and, by pulling back on the plastic cover, the terminal lock will be detached, allowing the complete assembly to slide off. Pulling on the wire to remove it will damage the terminal and may cause problems during the new cable installation.

4. Follow the cable to the first bracket mounting stud on the engine. This stud is located in the front of the engine on the lower right hand side. This stud will have a few other brackets attached. Remove the nut, brackets, and battery cable bracket.

5. Cut the plastic band that is retaining the cable to the sway bar.

6. Remove the next cable bracket which is attached to the engine sub frame on the lower left hand side of the fender (approximately 12 inches below the battery tray).

7. Lower the vehicle.

8. Remove both of the Christmas tree clips holding the cable to the battery tray.

9. Remove the two cable attaching nuts from the starter relay located on the upper part of the left hand fender apron. Notice which terminal the extra wires are attached to for installation of the new cable.

10. Raise the vehicle.

11. Install the new battery cable on the starter solenoid and secure with the attaching nut. Torque to 9-13.5 N-m (7-10 lb-ft). Push on the solenoid wire; it uses a new self locking feature. Snap on the red protective cover.

12. Route the cable to the engine stud located on the front lower right hand side of the engine. Install the battery cable bracket and then all other brackets. Install and tighten the locking nut to 23-36 N-m (17-27 lb-ft).

13. Route the cable under the front of the engine and under the oil filter and then, UP TO A SECOND ENGINE ATTACHING STUD located on the front lower left hand side of the engine block. This stud also has the ground cable attached to it. Remove the attaching nut. Place the battery cable bracket over the ground cable on the stud and reinstall the attaching nut. Torque to 23-36 N-m (17-27 lb-ft). Please note that this is the vehicle ground and the nut must secure both the ground cable and the cable bracket. This cable bracket will keep the proper cable alignment under the engine pulley and oil filter.

14. Attach the battery cable bracket to the fender sheet metal (under the battery tray). Torque to 8-13 N-m (6-10 lb-ft).

15. Lower the vehicle.

16. From the left side of the engine compartment, attach the two Christmas tree connectors into the battery tray.

17. Route the remaining cable up to the starter relay. Attach the battery molded connector and all other wires to their terminals. Install and tighten the two attaching nuts to 5.1-6.1 N-m (45-54 lb-in).

NOTE:
Review the complete cable routing (above and below the engine) it should not contact any sharp edges and must be positioned to prevent contact with any moving parts. Routing is important since the starter cable is wired directly to the battery and the cable carries battery current and voltage all the time.

18. Attach the battery cables to the battery, the negative battery pigtail lead to the body with the screw removed in step 1 and torque to 8-12 N-m (6-10 lb-ft). Connect the pigtail to the connector. Be sure to install the negative battery cable last.