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I replaced my battery but as I was tightening the bolt to fasten the clamp to the battery terminal, the bolt snapped in half. What is the name of the bolt/clamp that is used to tighten to the terminal
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This should do the trick, torque to specs then additional 90 degrees turn on all bolts
Notice: Use
the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking
compound or sealant are identified in the service procedure. Do not use
paints, lubricants, or corrosion inhibitors on fasteners or fastener
joint surfaces unless specified. These coatings affect fastener torque
and joint clamping force and may damage the fastener. Use the correct
tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
Use the following sequence in order to tighten the cylinder head bolts: Tighten
Important: Do not tip the battery more than 40 degrees during removal.
Install the battery (3) to the battery tray.
Install the battery hold down retainer (2).
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the battery hold down retainer bolt (1).
Tighten Tighten the battery hold down bolt to 18 N·m (13 lb ft).
Connect the battery positive cable to the battery.
Tighten Tighten the battery positive terminal bolt to 15 N·m (11 lb ft).
Install the RH fender diagonal brace. Refer to Front Fender Upper Diagonal Brace Replacement in Body Front End.
Connect the battery negative cable to the battery.
Tighten Tighten the battery negative terminal bolt to 15 N·m (11 lb ft).
Crankshaft Position Sensor Replacement - Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical. 4. Disconnect the crankshaft position (CKP) sensor electrical connector. 5. Remove the CKP sensor bolt (1). 6. Remove the CKP sensor (2) from the engine block: • Remove the sensor by pulling on the sensor connector. DO NOT pry on the bracket. • DO NOT rotate or twist the sensor or damage the mounting bracket if the sensor is being reused.
Installation Procedure
Important: When replacing the CKP sensor with a new sensor or reinstalling the original sensor, use the following recommended procedures: • Ensure that the CKP sensor bore is completely free of any foreign material, such as old O-ring, dirt, burrs, etc. • Ensure that the flange on the CKP sensor bore is not damaged. • Clean all the mounting surfaces before re-installing any components. • Inspect the CKP sensor and replace the sensor if any of the following conditions are present: - The bracket is damaged. - The bottom of the brass housing exhibits any damage. - Never install a sensor that has been dropped. • Lubricate the O-ring on the sensor with clean engine oil prior to installing the sensor . • Inspect all the connectors for any damaged terminals.
1. Install and fully seat the CKP sensor (2) into the engine block. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the CKP sensor bolt (1). Tighten Tighten the bolt to 9 N·m (80 lb in) 3. Ensure that the CKP sensor mounting flange is contacting the engine block. 4. Connect the CKP sensor electrical connector. 5. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical. 7. Lower the vehicle. 8. The CKP System Variation Learn Procedure must be performed after replacing the CKP sensor. Even if the original sensor is reinstalled, the Learn Procedure must be performed. 9. Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 2. Remove the exhaust gas recirculation (EGR) inlet pipe. Refer to Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement . 3. Disconnect the ECT sensor (1) . 4. Remove the ECT sensor.
Installation Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
1. Coat the sensor threads with sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N·m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Install the EGR inlet pipe. Refer to Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement . 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. 6. Engine Coolant Thermostat Replacement Tools Required J 38185 Hose Clamp Pliers
Removal Procedure 1. Partially drain the cooling system. Refer to Cooling
System Draining and Filling . 2. Use the J 38185 to remove the radiator hose clamp from the water inlet housing. 3. Remove the radiator hose from the water inlet housing. 4. Use the J 38185 to remove the heater hose clamp from the water inlet housing. 5. Remove the heater hose from the water inlet housing. 6. Use the J 38185 to remove the surge tank inlet hose clamp from the water inlet housing. 7. Remove the surge tank inlet hose from the water inlet housing. 8. Remove the water inlet housing bolts. Important: The water inlet housing (2) and the thermostat are replaced as an assembly. 9. Remove the water inlet housing and the thermostat. 10. Inspect and clean the water inlet mating surfaces.
Installation Procedure
1. Install the thermostat and the water inlet housing (2). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the water inlet housing bolts. Tighten Tighten the bolts to 9 N·m (80 lb in). 3. Install the surge tank inlet hose to the water inlet housing. 4. Use theJ 38185 to install the surge tank hose clamp to the water inlet housing. 5. Install the heater hose to the water inlet housing. 6. Use theJ 38185 to install the heater hose clamp to the water inlet housing. 7. Install the radiator hose to the water inlet housing. 8. Use theJ 38185 to install the radiator hose clamp to the water inlet housing. 9. Fill the cooling system. Refer to Cooling System Draining and Filling
Aztek, Rendezvous 2001-2005
Window Systems
- Power Windows
Removal & Installation
Position the window in the full down position.
Remove the trim panel.
Remove the water deflector.
Remove the outer belt sealing strip.
Remove the window weatherstrip.
Loosen the bolts to the clevice clamps.
Remove the window from the outside of the door.
To install:
Position the window between the inner and the outer door panels.
For front window, point the lower front corner of the window down
and pass through the belt opening. For rear window, point the lower rear
corner of the window down and pass through the belt opening.
Align the edges with the window weatherstrip channel.
NOTE
Use the correct fastener in the correct location. Replacement
fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of thread
locking compound or sealant are identified in the service procedure. Do
not use paints, lubricants, or corrosion inhibitors on fasteners or
fastener joint surfaces unless specified. These coatings affect fastener
torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Turn the window to a horizontal position and align the window with
the clevice clamps.
Tighten the clevice clamps bolts to 97 inch lbs. (11 Nm).
Install the window weatherstrip.
WARNING
Do NOT allow the sealing lips on the outer belt sealing strip to
roll over and point downwards. If this condition is present the window
will not raise properly.
Install the outer belt sealing strip.
Install the water deflector.
Install the inner trim panel.
Window Motor & Regulator
Remove the door trim panel.
Remove the water deflector.
For rear window, remove the rear speaker.
Disconnect the window from the regulator carrier plate.
Position the window in the full up position and tape it to the
window frame.
Disconnect the electrical connector from the window regulator
motor.
Loosen the bolts on the window regulator motor.
Loosen the bolts on the window regulator rail.
Remove the window regulator, lifting up and out from the key slots
on the door inner panel and through the access hole.
To install:
Install the window regulator bolts half way into the window
regulator motor and the rail.
Position the window regulator rail through the access hole first.
Position the window regulator motor through the access hole.
NOTE
Use the correct fastener in the correct location. Replacement
fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of thread
locking compound or sealant are identified in the service procedure. Do
not use paints, lubricants, or corrosion inhibitors on fasteners or
fastener joint surfaces unless specified. These coatings affect fastener
torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the window regulator into the key slots. Attach the
regulator to the motor and the rail. Secure the regulator with bolts and
tighten the bolts to 97 inch lbs. (11Nm).
Remove the tape and position the window to the regulator carrier
plate.
Connect the window to the regulator carrier plate.
Connect the electrical connector to the window regulator motor.
Alternator: Service and Repair Generator Replacement GENERATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to Battery Disconnect Caution in Service Precautions. - Failure to observe step 1 may result in a serious personal injury. If a tool is shorted at the generator lead, the tool will become hot enough to cause a serious burn. 1. Disconnect the negative (-) battery cable. 2. Loosen the belt tension by turning the drive belt tensioner clockwise. 3. Remove the drive belt. 4. Disconnect the wire clamp (3) from the wire clip. 5. Remove the terminal cap and nut (1). 6. Disconnect the engine wire. 7. Disconnect the generator connector (2). 8. Remove the two mounting bolts. 9. Remove the generator (4). INSTALLATION PROCEDURE 1. Install the generator (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Secure the generator with the two generator mounting bolts. Tighten - Tighten the upper bolt to 25 N.m (18 lb ft). - Tighten the lower bolt to 54 N.m (40 lb ft). 3. Connect the generator connector (2). 4. Connect engine wire to the generator. 5. Secure the engine wire with the nut. Tighten Tighten the nut to 9.8 N.m (86 lb in). 6. Install the terminal cap (1) to the nut. 7. Install the wire clamp (3) to the wire clip. 8. Install the drive belt. - Visually inspect the drive belt for wear and damage. - Minor cracks on the ribbed side of the belt are considered acceptable. Replace the belt if pieces are missing from the ribs. - Ensure that the belt tensioner moves downward when the belt is pressed down in the center with a force of approximately 98 N (22 lb). 9. Connect the negative (-) battery cable. Tighten Tighten the bolt to 15 N.m (11 lb ft).
Install the starter and the inboard starter mounting bolt. Do not tighten.
Install the starter shims, if equipped.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the outboard starter mounting bolt.
Tighten Tighten the starter mounting bolts to 50 N·m (37 lb ft).
Connect the wires to the solenoid.
Tighten
•
Tighten the battery positive cable nut to 9 N·mN·m (80 lb in).
•
Tighten the engine wiring harness to starter nut to 1.9 N·m (16 lb in).
Install the differential carrier shield, if equipped.
Install the differential carrier shield mounting bolts, if equipped.
Tighten Tighten the differential carrier bolts to 25 N·m (18 lb ft).
Install the tire and wheel assembly. Refer to Wheel Installation in Tires and Wheels.
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery.
(2) Remove generator drive belt. Refer to 7, Cooling System for procedure.
(3) Remove generator pivot and mounting bolts/nut (Fig. 2) , or (Fig. 3). Position generator for access to wire connectors.
(4) If equipped, unsnap plastic cover from B+ terminal.
(5) Remove B+ cable output terminal mounting
nut at rear of generator (Fig. 4), (Fig. 5), or (Fig. 6). Disconnect terminal from generator.
(6) Disconnect field wire connector at rear of generator by pushing on connector tab.
(7) Remove generator from vehicle.
INSTALLATION
(1) Position generator to engine and snap field
wire connector into rear of generator.
(2) Install B+ terminal to generator mounting
stud. Tighten mounting nut. Refer to Torque Specifications.
(3) If equipped, snap plastic cover to B+ terminal.
(4) Install generator mounting fasteners and
tighten. Refer to Torque Specifications.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
There are two types of batteries in use today. Top terminal type is found on top of the battery normaly found in older cars. These are metal posts that on the battery and the cable terminals has basically a metal clamp that fits over the battery posts and is tightened to create a good contact. To remove the terminal end from the post loosen the nut on the bolt and insert a good size screw driver into the clamp so as to wedge it open and free it from the battery. Trying to pry the clamp up off the post could easily damage the battery. The least amount of force applied to the battery post the better. There is actualy a puller made for this very purpose and can be found at most auto parts stores.
The side terminals are, as the name indicates, are located on the side of the battery. Unlike the post on a top terminal battery there are two threaded bolt holes on the upper side where the cable eye terminals are attached. This only requires the removal of the bolt with the proper size wench.
In both cases the other end of the negative cable is normaly attached to the engine block for a ground. You just have to loosen the attaching fastener and replace the cable end. The positive end in most cases is attached to the starter but just follow the cable to it's attaching point and remove the fastener and replace the cable. It always advisable to coat the terminal ends with and electrical sealer made just for this purpose that can be purchased at any auto parts store.
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