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Ground Repair

Ground Repair

Electrical Grounds

Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements.

In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods:


• Welded M6 stud and nut

• Welded M6 nut and bolt

• Welded M8 nut and bolt


Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


Determine which attachment method is used, and carry out the appropriate repair.


M6 Weld Stud Replacement

1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange.

2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry.

3.
Note

Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.


Drill a 10 mm (0.40 in) diameter hole through the panel.

4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible.

5.
Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application.

6. Using a rivet stud installer, install the replacement conductive M6 rivet stud.

7. Ensure the new rivet stud is securely fastened, with no detectable movement.

8.
Note

The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding.


Completely wrap the threads of the rivet stud with painters tape or equivalent.

9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair .

10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads.

11. Remove the painters tape or equivalent from the rivet stud threads.

12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry.

13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections .

14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads.

15. Install the ground terminal to the new rivet stud.

16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. I

17. Refer to Fastener Caution .

Install the M6 nut and tighten to 8 Nm (71 lb in) .

18. Check for proper system operation.



M6 Weld Nut

1.
Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application.

2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry.

3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush.

4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt threads.

5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections .

6. Install the electrical ground terminal to the new, conductive M7 bolt.

7. Refer to Fastener Caution .

Install the M7 nut and tighten to 9 Nm (80 lb in) .

8. Check for proper system operation.



M6 Weld Nut (Alternative Repair)

1.
Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application.

2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site.

3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry.

4.
Note

Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.


Drill a 10 mm (0.40 in) diameter hole through the panel.

5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible.

6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads.

7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections .

8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location.

9. Refer to Fastener Caution .

Tighten the conductive M6 nut to 8 Nm (71 lb in) .

10.
Note

The repair area must be properly refinished to maintain positive electrical grounding.


Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair .

11. Check for proper system operation.



M8 Weld Nut

1.
Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application.

2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site.

3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry.

4.
Note

Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.


Drill a 10 mm (0.40 in) diameter hole through the panel.

5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible.

6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads.

7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections .

8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location.

9. Refer to Fastener Caution .

Tighten the conductive M8 nut to 22 Nm (16 lb ft) .

10.
Note

The repair area must be properly refinished to maintain positive electrical grounding.


Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair .

11. Check for proper system operation.



M8 Weld Nut (Alternative Repair)

1.
Warning

Use GM approved replacement fasteners with conductive finish for electrical ground repair.


If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application.

2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange.

3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry.

4.
Note

Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.


Drill a 10 mm (0.40 in) diameter hole through the panel.

5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible.

6. Using a rivet stud installer, install the replacement conductive M6 rivet stud.

7. Ensure the new rivet stud is securely fastened, with no detectable movement.

8.
Note

The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding.


Completely wrap the threads of the rivet stud with painters tape or equivalent.

9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair .

10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads.

11. Remove the painters tape or equivalent from the rivet stud threads.

12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry.

13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections .

14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads.

15. Install the ground terminal to the new, conductive M6 rivet stud.

16. Refer to Fastener Caution .

Tighten the conductive M6 nut to 8 Nm (71 lb in) .

17. Check for proper system operation.