Battery Cable

The battery cables 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 clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and 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 soldered. The battery positive cable wires feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a smaller female battery terminal clamp.

Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some vehicles.

The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery 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 opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system.

One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block.

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. 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.

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 load 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 the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can be found in the Fuse Block located in the left front bumper fascia. See the fuse and relay layout label affixed to the underside of the Fuse Block cover for ASD relay identification and location.

1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) 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 (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) 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.

Starter Solenoid B(+) Terminal Stud

3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid B(+) terminal stud (3). 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.

Good Clean Ground On Engine Block

4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). 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.

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current.

NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and diesel similar.

1. Loosen the pinch clamp bolt and disconnect and isolate the battery negative cable (2). 2. Loosen the pinch clamp bolt and disconnect the battery positive cable (1). 3. Remove the negative cable retaining stud (7) from the mounting surface on the inner fender. Remove the cable (6) from the stud. 4. Disconnect the cable assembly routing clips from the inner fender.

Module (TIPM) Cover

5. Remove the positive cable retaining nut (1) from the mounting stud on the Totally Integrated Power Module (3). Remove the cable (2) from the stud.

Cable From/To Generator

6. Remove the positive battery cable nut (1) from the B+ terminal of the generator (5). Remove the cable (2) from the generator.

Battery Cable Retaining Pushpins & Cables

7. Remove the positive battery cable nut (4) from the B+ terminal of the starter motor (3). Remove the cable (7) from the starter. 8. Remove the negative battery cable nut (1) from the mounting stud (2) on the engine block. Remove the

cable (8) from the stud. 9. One at a time, trace any remaining battery cable retaining pushpins (6), fasteners and routing clips until the cables are free from the vehicle. 10. Remove the battery cables from the engine compartment.

Cable Retaining Pushpins & Cables

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current.

NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and diesel similar.

1. Position the battery cables in the engine compartment. 2. One at a time, install the battery cable retaining pushpins (6), fasteners and routing clips until the cables are installed exactly where they were in the vehicle. 3. Install the negative battery cable (8) to the mounting stud (2) on the engine block. Install the negative battery cable retaining nut (1). 4. Connect the positive battery cable (7) to the B+ terminal of the starter motor (3). Install the retaining nut (4) and tighten it to 13 N.m (115 in. lbs.).

Cable From/To Generator

5. Connect the positive battery cable (2) to the B+ terminal of the generator (5). Install the retaining nut (1) and tighten it to 14 N.m (125 in. lbs.).

Module (TIPM) Cover

6. Position the Totally Integrated Power Module (TIPM) positive cable (2) onto the mounting stud (3) and install the retaining nut (1). Tighten the nut to 9 - 11 N.m (80 - 100 in. lbs.). Close the TIPM cover (4).

7. Connect the battery cable assembly routing clips to the inner fender. 8. Position the negative battery cable (6) onto the mounting stud (7). Install the mounting stud onto the inner fender and tighten to 12 N.m (9 ft. lbs.) 9. Connect the battery positive cable (1). Tighten the cable clamp nut to 5 N.m (45 in. lbs.) 10. Connect the battery negative cable (2). Tighten the cable clamp nut to 5 N.m (45 in. lbs.)

BATTERY TRAY