Chevrolet Cobalt Service & Repair Manual: Battery Cable, Replace

Chevrolet Cobalt Service & Repair Manual / Maintenance / Battery Cable, Replace

Ground Cable

Battery To Battery Tray

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the battery ground to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® with Back-Up Battery: The Back-Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar® module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is ON, or with retained accessory power activated, may cause activation of the OnStar® Back-Up Battery system and will discharge and permanently damage the Back-Up Battery. Once the Back-Up Battery is activated, it will stay on until it has completely discharged. The Back-Up Battery is not rechargeable and once activated, the Back-Up Battery must be replaced.
Always use replacement cables that are of the same type, diameter and length of the cables that are being replaced.
Always route the replacement cable the same way as the original cable.
1. Disconnect battery ground cable from battery.
2. Disconnect body harness electrical connector (7) from battery current sensor (6), Fig. 1.
3. Remove battery ground cable ground bolt (4), Fig. 1.
4. Separate battery ground cable terminal (5) from battery support, Fig. 1.
5. Remove battery ground cable (3), Fig. 1.
6. Reverse procedure to install, noting following:
  a. Ensure anti-rotation tab on terminal (5) is correctly located, Fig. 1.
  b. Torque battery ground cable ground bolt (4) to 13 ft. lbs., Fig. 1.

Engine To Chassis

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the battery ground to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® with Back-Up Battery: The Back-Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar® module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is ON, or with retained accessory power activated, may cause activation of the OnStar® Back-Up Battery system and will discharge and permanently damage the Back-Up Battery. Once the Back-Up Battery is activated, it will stay on until it has completely discharged. The Back-Up Battery is not rechargeable and once activated, the Back-Up Battery must be replaced.
Always use replacement cables that are of the same type, diameter and length of the cables that are being replaced.
Always route the replacement cable the same way as the original cable.
1. Disconnect battery ground cable from battery.
2. On models with automatic transaxle, proceed as follows:
  a. Remove engine harness ground nut (4), Fig. 2.
  b. Remove engine harness ground terminal (3) from stud (1), Fig. 2.
  c. Remove battery ground cable ground terminal (2) from stud (1), Fig. 2.
3. On models with manual transaxle, proceed as follows:
  a. Raise and support vehicle using suitable lift.
  b. Remove engine harness ground nut (1), Fig. 3.
  c. Remove engine harness ground terminal (2) from stud (3), Fig. 3.
  d. Remove ground cable stud (3), Fig. 3.
  e. Separate battery ground cable ground terminal (4) from engine block, Fig. 3.
4. On all models, remove lefthand headlamp.
5. Remove battery ground cable ground nut from stud on side rail, through lefthand headlamp opening, Fig. 4.
6. Remove battery ground cable ground terminal from stud, Fig. 4.
7. Cut open tape on positive/ground battery cable conduit (1), and remove old tape from conduit, Fig. 5.
8. Separate battery ground cable (2) from positive cable (1) and remove ground cable from vehicle, Fig. 6.
9. Reverse procedure to install, noting following:
  a. Torque battery ground cable ground nut to stud on side rail to 15 ft. lbs.
  b. On models with manual transaxle,torque ground cable stud to 18 ft. lbs.
  c. On all models,torque engine harness ground nut to 13 ft. lbs.

Positive Cable

Battery To Junction Block

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the battery ground to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® with Back-Up Battery: The Back-Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar® module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is ON, or with retained accessory power activated, may cause activation of the OnStar® Back-Up Battery system and will discharge and permanently damage the Back-Up Battery. Once the Back-Up Battery is activated, it will stay on until it has completely discharged. The Back-Up Battery is not rechargeable and once activated, the Back-Up Battery must be replaced.
Always use replacement cables that are of the same type, diameter and length of the cables that are being replaced.
Always route the replacement cable the same way as the original cable.
1. Disconnect battery ground cable from battery.
2. Reposition carpet, but do not remove console.
3. Open positive battery cable (1) cover, Fig. 1.
4. Loosen positive battery cable nut.
5. Remove positive battery cable (1) from battery, Fig. 1.
6. Disconnect positive battery cable electrical connector (9) from body harness electrical connector (8), Fig. 1.
7. Remove positive battery cable clips (1) from weld studs, from inside vehicle, Fig. 7.
8. Remove positive battery cable clip (2) from floor pan, Fig. 7.
9. Remove positive battery cable clip (2) from latch bar, Fig. 8.
10. Unfold body clip tabs and remove positive battery cable from body clip (3), Fig. 8.
11. Remove positive battery cable clips (3) from weld studs, Fig. 8.
12. Remove positive battery cable clip (4) from floor pan, Fig. 8.
13. Remove positive battery cable from body wiring harness clips (1), Fig. 9.
14. Remove positive battery cable clip (2) from weld stud, Fig. 10.
15. Remove positive battery cable from body wiring harness clips (3), Fig. 10.
16. Unseat grommet (1) from front of dash, Fig. 10.
17. Remove junction block cover.
18. Remove junction block nut (1), Fig. 11.
19. Remove positive battery cable terminal (2) from junction block stud, Fig. 11.
20. Remove positive battery cable (3) from body wiring harness clip (2), Fig. 12.
21. Remove positive battery cable clip (1) from junction block, Fig. 12.
22. Remove positive battery cable from under junction block.
23. Route positive battery cable through hole in front of dash.
24. Remove positive battery cable from inside vehicle.
25. Reverse procedure to install, noting following:
  a. Torque junction block nut to 13 ft. lbs.
  b. Torque positive battery cable nut to 13 ft. lbs.

Junction Block To Starter

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the battery ground to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® with Back-Up Battery: The Back-Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar® module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is ON, or with retained accessory power activated, may cause activation of the OnStar® Back-Up Battery system and will discharge and permanently damage the Back-Up Battery. Once the Back-Up Battery is activated, it will stay on until it has completely discharged. The Back-Up Battery is not rechargeable and once activated, the Back-Up Battery must be replaced.
Always use replacement cables that are of the same type, diameter and length of the cables that are being replaced.
Always route the replacement cable the same way as the original cable.
1. Disconnect battery ground cable from battery.
2. Remove junction block cover.
3. Remove junction block nut (1), Fig. 11.
4. Remove positive battery cable terminal (2) from junction block stud, Fig. 11.
5. Remove positive battery cable clip (3) from engine control module (ECM) bracket, Fig. 11.
6. Raise and support vehicle using suitable lift.
7. Remove starter solenoid terminal nut (5), Fig. 13.
8. Remove positive battery cable terminal (4) from starter solenoid, Fig. 13.
9. Cut open tape on positive/ground battery cable conduit (1), and remove old tape from conduit, Fig. 5.
10. Separate positive battery cable (1) from ground cable (2) and remove positive battery cable from vehicle, Fig. 6.
11. Reverse procedure to install, noting following:
  a. Torque starter solenoid terminal nut to 13 ft. lbs.
  b. Torque junction block nut to 13 ft. lbs.

Fig. 1 Battery ground cable removal from battery & tray

Fig. 2 Engine harness & ground cable removal from stud. Automatic transaxle

Fig. 3 Engine harness & ground cable removal from stud. Manual transaxle

Fig. 4 Battery ground cable removal from side rail

Fig. 5 Positive/ground battery cable conduit tape location

Fig. 6 Exploded view of battery positive & ground cables

Fig. 7 Positive battery cable removal from floor pan weld studs

Fig. 8 Positive battery cable removal from body clip & floor pan

Fig. 9 Positive battery cable removal from body harness clips

Fig. 10 Positive battery cable removal from front of dash

Fig. 11 Positive battery cable terminal removal from junction block

Fig. 12 Positive battery cable removal from junction block

Fig. 13 Positive battery cable removal from starter

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