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Battery Cable: Service and Repair

BATTERY CABLES

DESCRIPTION





The battery cables (2) and (4) are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires (2) have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires (4) have a black insulating jacket and a smaller female battery terminal clamp.

The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement. The replacement parts may include portions of the wiring circuits for the generator and other components on some models. Refer to the appropriate wiring information for the location of the proper battery cable wire harness diagrams. The wiring information also includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.

OPERATION
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system.

DIAGNOSIS AND TESTING

BATTERY CABLES
A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.

When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable.

TESTING

VOLTAGE DROP TEST

WARNING
If the battery shows signs of freezing, leaking, loose posts, or low electrolyte level, do not test, assist-boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result.

WARNING
Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result.

WARNING
Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result.

WARNING
If the battery is equipped with removable cell caps, be certain that each of the cell caps is in place and tight before the battery is returned to service. Personal injury and/or vehicle damage may result from loose or missing cell caps.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished:
^ The battery is fully-charged and tested.
^ Fully engage the parking brake.
^ If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position.
^ Verify that all lamps and accessories are turned off.
^ To prevent a gasoline engine from starting, remove the Automatic ShutDown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location.





1. Connect the positive lead of the voltmeter (1) to the battery negative terminal post. Connect the negative lead of the voltmeter (1) to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post.





2. Connect the positive lead of the voltmeter (1) to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post.





3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable.





4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground (3) on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.

REMOVAL

NEGATIVE





1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
2. Disconnect and isolate the battery negative cable terminal clamp (4).
3. Remove the bolt (2) securing the negative cable eyelet (3) to the left front fender.
4. One at a time, trace the battery cable retaining pushpins (5), fasteners and routing clips until the cable is free from the vehicle.





5. Raise the vehicle on a hoist.
6. Remove the bolt (3) securing the negative cable (1) to the engine (2).
7. Separate the cable from the engine harness conduit.
8. Remove the battery negative cable from the vehicle.

POSITIVE





1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
2. Disconnect and isolate the battery negative cable.
3. Loosen the band clamp (2) on the air inlet tube (1) and remove the bolts (3) from the air intake resonator (4). Remove the resonator from the vehicle.





4. Disconnect the battery positive cable terminal clamp (8).
5. Remove the nut (5) securing the cable to the Integrated Power Module (IPM) (7) stud (6).
6. Lift the terminal cap and remove the nut (3) securing the cable (4) to the alternator.





7. Disconnect the starter solenoid wire harness connector (1).
8. Disconnect the battery cable retaining pushpin (5) securing the cable to the left frame rail (4).





9. Raise the vehicle on a hoist.
10. Remove the nut (2) securing the cable (1) to the starter solenoid (3).
11. Disconnect the battery cable retaining pushpin (6) securing the cable to the engine block.
12. Lower the vehicle.
13. Remove the battery positive cable from the vehicle.

INSTALLATION

NEGATIVE





1. Position the battery negative cable (4) in the vehicle and into the engine harness conduit.
2. One at a time, install the battery cable retaining pushpins (5), fasteners and routing clips until the cable is secure in the vehicle.
3. Install the bolt (2) securing the negative cable eyelet (3) to the left front fender. Tighten the bolt to 20 Nm (15 ft. lbs.).





4. Raise the vehicle on a hoist.
5. Install the bolt (3) securing the negative cable (1) to the engine block (2). Tighten the bolt to 16.5 Nm (145 in. lbs.).





6. Lower the vehicle.
7. Connect the battery negative cable terminal clamp (4). Tighten the battery terminal clamp pinch-bolt hex nut to 5 Nm (45 in. Lbs.).
8. Check the vehicle for normal operation.

POSITIVE





1. Position the battery positive cable (4 and 8) in the vehicle.
2. Install the nut (5) securing the cable to the Integrated Power Module (IPM) (7) stud (6). Tighten the nut to 11.5 Nm (105 in. lbs.).
3. Install the nut (3) securing the cable (4) to the alternator. Tighten the nut to 14 Nm (125 in. lbs.).





4. Install the cable pushpin (5) into the left frame rail (4).
5. Connect the starter solenoid wire harness connector (1).





6. Raise the vehicle on a hoist.
7. Install the nut (2) securing the cable (1) to the starter solenoid (3). Tighten the nut to 13 Nm (115 in. lbs.).
8. Connect the battery cable retaining pushpin (6) securing the cable to the engine block.
9. Lower the vehicle.





10. Connect the battery positive cable terminal clamp (8). Tighten the battery terminal clamp pinch-bolt hex nut to 5 Nm (45 in. Lbs.).





11. Position the resonator (4) into the vehicle. Install the bolts (3) into the air intake resonator (4) and tighten the band clamp (2) on the air inlet tube (1).
12. Connect the battery negative cable terminal clamp. Tighten the battery terminal clamp pinch-bolt hex nut to 5 Nm (45 in. lbs.).
13. Check the vehicle for normal operation.
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