Battery Replacement

REMOVAL
1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.

Disconnect Battery Negative Cable:

2. Loosen the battery cable terminal clamp nuts and disconnect both battery cables, negative cable first. If necessary, use a puller to remove the terminal clamps from the battery posts.

Clean Battery Cable Terminal Clamp - Typical:

3. Inspect the battery cable terminal clamps for corrosion and damage. Remove any corrosion using a wire brush or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution. Replace any battery cable that has damaged or deformed terminal clamps.

WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.

Battery Remove/Install:

4. Remove the battery hold down bracket screw and remove the bracket from the battery support.
5. Remove the battery and thermoguard unit from the battery support.
6. Inspect the battery support and the hold down bracket for damage. Clean the battery support and the hold down bracket with a sodium bicarbonate (baking soda) and warm water cleaning solution to remove any acid film. Replace any damaged parts.

Battery Thermogaurd Remove/Install:

7. Release the latch on each end of the battery thermoguard and remove the thermoguard from the battery.
8. Inspect the battery thermoguard for damage. Clean the thermoguard using a sodium bicarbonate (baking soda) and warm water cleaning solution to remove any acid film. Replace any damaged parts.
9. Inspect the battery case for cracks or other damage that could result in electrolyte leaks. Also, check the battery terminal posts for looseness. Batteries with damaged cases or loose posts must be replaced.

Removing Battery Cell Caps - Typical:

10. Check the electrolyte level in the battery. Use a putty knife or another suitable wide flat-bladed tool to pry the cell caps off liquid reaches the bottom of the vent well. DO NOT OVERFILL.
11. Inspect the battery built-in test indicator sight glass for an indication of the battery condition. If the battery is discharged, charge as required. Refer to Built-In Test Indicator Diagnosis for more information. Also refer to Battery Charging in the Service Procedures for more information.

Clean Battery - Typical:

12. If the battery is to be reinstalled, clean the outside of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution to remove any acid film. Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, refer to Battery Ratings and Classifications in the Specifications. Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle.

Clean Battery Terminal Post - Typical:

13. Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner, and a sodium bicarbonate (baking soda) and warm water cleaning solution.

INSTALLATION
1. Install the thermoguard over the battery case. Be certain that the latch on each end of the thermoguard is fully engaged.

Battery Cables:

2. Position the battery and thermoguard unit in the battery support. Ensure that the positive and negative terminal posts are correctly positioned. The cable terminal clamps must reach the correct battery terminal post without stretching the cables.
3. Be certain that the ledge on the outboard side of the battery case is engaged under the lip on the outboard side of the battery support, then loosely install the battery hold down bracket and screw. Be certain that the ledge on the bottom of the hold down bracket is oriented towards the inboard side of the battery case. Proper hold down bracket orientation can also be determined by noting the direction of the arrow-like formations of the molded reinforcing ribs on the top of the hold down bracket. These arrows should be pointed towards the battery.
4. Once it is certain that the battery and the hold down bracket are properly positioned, tighten the hold down bracket screw to 3.3 Nm (30 in. lbs.). Improper hold down fastener tightness, whether too loose or too tight, can result in damage to the battery, the hold down bracket, and/or the battery support.

CAUTION: Be certain that the battery cables are connected to the correct battery terminals. Reverse polarity may damage electrical components.

5. Connect and tighten the battery positive cable terminal clamp. Then connect and tighten the battery negative cable terminal clamp. Tighten both battery cable terminal clamp nuts to 8.5 Nm (75 in. lbs.).

6. Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the battery cable terminal clamps and battery terminal posts.