engine DODGE RAM 2002 Service Repair Manual

of the vehicle. Inputs to the module include a resistor
multiplexed heated seat switch request circuit for
each of the two heated seat switches and the heated
seat sensor inputs from the seat cushions of each
front seat. In response to those inputs the heated
seat module controls battery current feeds to the
heated seat elements and sensors, and controls the
ground for the heated seat switch indicator lamps.
NOTE: The vehicle's engine must be running in
order for the heated seat system to function. This
eliminates the possibility of draining the vehicles
battery voltage while operating the heated seat sys-
tem.
When a heated seat switch (Driver or Passenger) is
depressed a signal is received by the heated seat
module, the module energizes the proper indicator
LED (Low or High) in the switch by grounding the
indicator lamp circuit to indicate that the heated seat
system is operating. At the same time, the heated
seat module energizes the selected heated seat sensor
circuit and the sensor provides the module with an
input indicating the surface temperature of the
selected seat cushion.
The Low heat set point is about 36É C (96.8É F),
and the High heat set point is about 42É C (107.6É F).
If the seat cushion surface temperature input is
below the temperature set point for the selected tem-
perature setting, the heated seat module energizes
an N-channel Field Effect Transistor (N-FET) within
the module which energizes the heated seat elements
in the selected seat cushion and back. When the sen-
sor input to the module indicates the correct temper-
ature set point has been achieved, the module
de-energizes the N-FET which de-energizes the
heated seat elements. The heated seat module will
continue to cycle the N-FET as needed to maintain
the selected temperature set point.
If the heated seat module detects a heated seat
sensor value input that is out of range or a shorted
or open heated seat element circuit, it will notify the
vehicle operator or the repair technician of this con-
dition by flashing the High and/or Low indicator
lamps in the affected heated seat switch. Refer to
Diagnosis and Testing Heated Seat Systemin
Heated Systems for flashing LED diagnosis and test-
ing procedures. Refer toDiagnosis and Testing
Heated Seat Modulein this section for heated seat
module diagnosis and testing procedures. Also refer
to the Body Diagnostic Manual for additional diagno-
sis and testing procedures.DIAGNOSIS AND TESTING - HEATED SEAT
MODULE
If a heated seat fails to heat and one or both of the
indicator lamps on a heated seat switch flash, refer
toHeated Seat System Diagnosis and Testingin
Heated Systems for flashing LED failure identifica-
tion. Refer toWiring Diagramsin for complete
heated seat system wiring diagrams.
(1) Remove the heated seat module from its
mounting location (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/MEMORY HEATED
SEAT/MIRROR MODULE - REMOVAL).
NOTE: IN ORDER TO PERFORM THE FOLLOWING
TESTS IT WILL BE NECESSARY TO REMOVE THE
HEATED SEAT RELAY AND INSTALL A JUMPER
WIRE IN TERMINALS 87 AND 30, BYPASSING THE
HEATED SEAT RELAY.
NOTE: ANY RESISTANCE VALUES (OHMSV) GIVEN
IN THE FOLLOWING TEXT ARE SUPPLIED USING
THE AUTOMATIC RANGE GENERATED BY A
FLUKETAUTOMOTIVE METER. IF ANOTHER TYPE
OF MEASURING DEVICE IS USED THE VALUES
GENERATED MAY NOT BE THE SAME AS THE
RESULTS SHOWN HERE, OR MAY HAVE TO BE
CONVERTED TO THE RANGE USED HERE.
Fig. 20 Heated Seat Module Electrical Connector
BR/BEELECTRONIC CONTROL MODULES 8E - 21
HEATED SEAT MODULE (Continued)

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 25STARTING............................... 31
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM.............................2
CLEANING.............................5
INSPECTION...........................6
SPECIFICATIONS
BATTERY............................6
SPECIAL TOOLS........................7
BATTERY
DESCRIPTION..........................7
DIAGNOSIS AND TESTING - BATTERY.......7
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING...........................8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST.....................10
STANDARD PROCEDURE - HYDROMETER
TEST...............................11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST.......................12
STANDARD PROCEDURE - LOAD TEST....12
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST.........................13
STANDARD PROCEDURE - USING
MIDTRONICS ELECTRICAL TESTER.......15REMOVAL.............................16
INSTALLATION.........................16
BATTERY HOLDDOWN
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18
BATTERY CABLE
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - BATTERY
CABLES............................19
REMOVAL
POSITIVE CABLE REMOVAL - GASOLINE
ENGINE.............................21
NEGATIVE CABLE REMOVAL - GASOLINE
ENGINE.............................22
INSTALLATION
POSITIVE CABLE INSTALLATION -
GASOLINE ENGINE....................22
NEGATIVE CABLE INSTALLATION -
GASOLINE ENGINE....................22
BATTERY TRAY
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................24
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on gasoline engine equipped
models. Models equipped with a diesel engine utilize
two 12-volt batteries connected in parallel. All of thecomponents of the battery system are located within
the engine compartment of the vehicle. The service
information for the battery system in this vehicle
covers the following related components, which are
covered in further detail elsewhere in this service
manual:
BR/BEENGINE SYSTEMS 8F - 1

²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintenance for the recommended battery main-
tenance schedules and for the proper battery jump
starting procedures. While battery charging can be
considered a maintenance procedure, the battery
charging procedures and related information are
located in the standard procedures section of this ser-
vice manual. This was done because the battery must
be fully-charged before any battery system diagnosis
or testing procedures can be performed. Refer to
Standard procedures for the proper battery charging
procedures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MIDTRONICS ELECTRICAL SYSTEM TESTER
The Midtronicstautomotive battery and charging
system tester is designed to help the dealership tech-
nicians diagnose the cause of a defective battery or
charging system. Follow the instruction manual sup-
plied with the tester to properly diagnose a vehicle. If
the instruction manual is not available refer to the
standard procedure in this section, which includes
the directions for using the midtronics electrical sys-
tem tester.
8F - 2 BATTERY SYSTEMBR/BE
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.1. The electrical system
ignition-off draw is excessive.1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.2. Determine if the charging system is performing
to specifications using the Midtronics battery and
charging system tester. Refer to Charging System
for additional charging system diagnosis and
testing procedures. Repair the faulty charging
system, as required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Midtronics battery and charging system tester.
Refer to the Standard Procedures in this section
for additional test procedures. Charge the faulty
battery, as required.
4. The battery terminal
connections are loose or
corroded.4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Midtronics battery and charging system tester.
Refer to the Standard Procedures in this section
for additional test procedures. Replace the faulty
battery, as required.
7. The starting system is
faulty.7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
BR/BEBATTERY SYSTEM 8F - 3
BATTERY SYSTEM (Continued)

CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
NOTE: Models equipped with the diesel engine
option are equipped with two 12-volt batteries, con-
nected in parallel (positive-to-positive and negative-
to-negative). In order to ensure proper charging of
each battery, these batteries MUST be disconnected
from each other, as well as from the vehicle electri-
cal system, while being charged.
Some battery chargers are equipped with polarity-
sensing circuitry. This circuitry protects the battery
charger and the battery from being damaged if they
are improperly connected. If the battery state-of-
charge is too low for the polarity-sensing circuitry to
detect, the battery charger will not operate. This
makes it appear that the battery will not accept
charging current. See the instructions provided by
the manufacturer of the battery charger for details
on how to bypass the polarity-sensing circuitry.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine the battery
cranking capacity. Refer to Standard Procedures for
the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
and must be replaced.
Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat-
tery System Inspection for the proper battery system
inspection procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce-
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure the voltage at the battery posts with a
voltmeter, accurate to 1/10 (0.10) volt (Fig. 5). If the
reading is below ten volts, the battery charging cur-rent will be low. It could take some time before the
battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
(2) Disconnect and isolate the battery negative
cable. Connect the battery charger leads. Some bat-
tery chargers are equipped with polarity-sensing cir-
cuitry. This circuitry protects the battery charger and
the battery from being damaged if they are improp-
erly connected. If the battery state-of-charge is too
low for the polarity-sensing circuitry to detect, the
battery charger will not operate. This makes it
appear that the battery will not accept charging cur-
rent. See the instructions provided by the manufac-
turer of the battery charger for details on how to
bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltage
and current they provide. The amount of time
required for a battery to accept measurable charging
current at various voltages is shown in the Charge
Rate Table. If the charging current is still not mea-
surable at the end of the charging time, the battery
is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the bat-
tery may be good and the charging should be
completed in the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The time required to charge a battery will vary,
depending upon the following factors:
²Battery Capacity- A completely discharged
heavy-duty battery requires twice the charging time
of a small capacity battery.
Fig. 5 Voltmeter - Typical
BR/BEBATTERY SYSTEM 8F - 9
BATTERY (Continued)

BATTERY HOLDDOWN
DESCRIPTION
The battery hold down hardware (Fig. 17) includes
two bolts, two U-nuts and a hold down strap. The
battery hold down bracket consists of a formed steel
rod with a stamped steel angle bracket welded to
each end. The hold down bracket assembly is then
plastic-coated for corrosion protection. Models
equipped with the optional diesel engine have a sec-
ond battery installed in a second battery tray on the
right side of the engine compartment. The hold down
hardware for the right side battery is mirror image of
the hold down hardware used for the left side bat-
tery.
When installing a battery into the battery tray, be
certain that the hold down hardware is properly
installed and that the fasteners are tightened to the
proper specifications. Improper hold down fastener
tightness, whether too loose or too tight, can result in
damage to the battery, the vehicle or both.
OPERATION
The battery holddown secures the battery in the
battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removal and lubrica-tion of the battery holddown hardware is recom-
mended to prevent hardware seizure at a later date.
CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
All of the battery hold down hardware except for
the outboard U-nut can be serviced without removal
of the battery or the battery tray. The battery tray
must be removed from the vehicle to service the out-
board U-nut. If the outboard U-nut requires service
replacement, refer toBattery Trayin the index of
this service manual for the location of the proper bat-
tery tray removal and installation procedures.
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.
(4) Remove the two battery hold down bolts from
the battery hold down strap (Fig. 18).
Fig. 17 Battery Hold Downs - Typical
1 - BATTERY TRAY
2 - U-NUT (2)
3 - BATTERY
4 - BOLT (2)
5 - HOLD DOWN STRAP
Fig. 18 Left Battery Hold Downs Remove/Install -
Typical for Right Battery
1 - BATTERY TRAY
2 - U-NUT (2)
3 - BATTERY
4 - BOLT (2)
5 - HOLD DOWN STRAP
BR/BEBATTERY SYSTEM 8F - 17

(5) Remove the battery hold down strap from the
top of the battery case.
INSTALLATION
(1) Clean and inspect the battery hold down hard-
ware (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- CLEANING).
(2) Position the battery hold down strap across the
top of the battery case.
(3) Install and tighten the two battery hold down
bolts through the holes on each end of the hold down
strap and into the U-nuts on each side of the battery
tray. Tighten the bolts to 4 N´m (35 in. lbs.).
(4) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 4 N´m (35
in. lbs.).
BATTERY CABLE
DESCRIPTION
The battery cables (Fig. 19) are large gauge,
stranded copper wires sheathed within a heavy plas-
tic or synthetic rubber insulating jacket. The wire
used in the battery cables combines excellent flexibil-
ity and reliability with high electrical current carry-
ing capacity. Refer toWiring Diagramsfor the
location of the proper battery cable wire gauge infor-
mation.The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
positive cable wire harness or the battery negative
cable wire harness, which may include portions of
the wiring circuits for the generator and other com-
ponents on some models.
GASOLINE ENGINE BATTERY CABLES
Gasoline engine models 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 termi-
nal clamp. The battery positive cable also includes a
red molded rubber protective cover for 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 posi-
tive cable wires have a red insulating jacket to pro-
vide 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 have a black insulating jacket
and a smaller female battery terminal clamp.
DIESEL ENGINE BATTERY CABLES
Diesel engine models feature a clamping type
female battery terminal made of soft lead die cast
onto one end of the battery cable wire. A square
headed pinch-bolt and hex nut are installed at the
open end of the female battery terminal clamp. The
pinch-bolt on the left side battery positive cable
female terminal clamp also has a stud extending
from the head of the bolt. Large eyelet type terminals
are crimped onto the opposite end of the battery
cable wire and then solder-dipped. The battery posi-
tive cable wires have a red insulating jacket to pro-
vide 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 have a black insulating jacket
and a smaller female battery terminal clamp.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a return path for electrical current gen-
erated by the charging system for restoring the volt-
age 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 ter-
minal pinch bolts allow the female terminal clamps
to be tightened around the male terminal posts on
Fig. 19 Battery Cables - Typical
1 - EYELET
2 - NUT
3 - POWER DISTRIBUTION CENTER
4 - POSITIVE CABLE
5 - SCREW
6 - NEGATIVE CABLE
7 - EYELET
8 - CLIP
8F - 18 BATTERY SYSTEMBR/BE
BATTERY HOLDDOWN (Continued)

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 elec-
trical system.
GASOLINE ENGINE
The battery positive cable terminal clamp is
crimped onto the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Power Distri-
bution Center (PDC), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp
is also crimped onto the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the front of the left engine cylinder head. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
just ahead of the battery. An additional ground wire
with two eyelet terminals is used to provide ground
to the vehicle frame. One eyelet terminal of this
ground wire is installed under the head of the bat-
tery negative cable terminal clamp pinch-bolt, and
the other eyelet terminal is secured with a ground
screw to the outer surface of the left frame rail,
below the battery.
DIESEL ENGINE
The left battery positive cable terminal clamp is
die cast onto the ends of two wires. One wire has an
eyelet terminal that connects the left battery positive
cable to the B(+) terminal stud of the Power Distri-
bution Center (PDC), and the other wire has an eye-
let terminal that connects the left battery positive
cable to the B(+) terminal stud of the engine starter
motor solenoid. The right battery positive cable ter-
minal clamp is die cast onto the end of a single wire.
The eyelet terminal on the other end of the right bat-
tery positive cable is connected to the stud on the
pinch-bolt of the left battery positive cable terminal
clamp. This stud also provides a connection point for
the eyelet terminals from the fuel heater relay and
intake air heater relay jumper harness take outs. All
of these eyelet terminals are secured to the left bat-
tery positive cable terminal clamp pinch-bolt stud
with a single hex nut.The left battery negative cable terminal clamp is
die cast onto the ends of two wires. One wire has an
eyelet terminal that connects the left battery nega-
tive cable to the vehicle powertrain through a ground
screw on the left side of the engine block, below the
power steering and vacuum pumps. The other wire
has an eyelet terminal that connects the left battery
negative cable to the vehicle body through a ground
screw on the left front fender inner shield, just ahead
of the left battery. An additional ground wire with
two eyelet terminals is used to provide ground to the
vehicle frame. One eyelet terminal of this ground
wire is installed under the nut of the left battery
negative cable terminal clamp pinch-bolt, and the
other eyelet terminal is secured with a ground screw
to the outer surface of the left frame rail, below the
left battery. The right battery negative cable terminal
is also die cast onto the ends of two wires. One wire
has an eyelet terminal that connects the right bat-
tery negative cable to the vehicle powertrain through
a ground screw on the right side of the engine block,
just forward of the right engine mount. The other
wire has an eyelet terminal that connects the right
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
just behind the right battery.
DIAGNOSIS AND TESTING - BATTERY CABLES
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cables. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion 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 impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive 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.
BR/BEBATTERY SYSTEM 8F - 19
BATTERY CABLE (Continued)

VOLTAGE DROP TEST
WARNING: MODELS EQUIPPED WITH THE DIESEL
ENGINE OPTION ALSO HAVE AN AUTOMATIC
SHUTDOWN (ASD) RELAY LOCATED IN THE
POWER DISTRIBUTION CENTER (PDC), IN THE
ENGINE COMPARTMENT. HOWEVER, REMOVAL OF
THE ASD RELAY MAY NOT PREVENT THE DIESEL
ENGINE FROM STARTING. BE CERTAIN TO ALSO
DISCONNECT THE FUEL SHUTDOWN SOLENOID
WIRE HARNESS CONNECTOR ON MODELS WITH A
DIESEL ENGINE. FAILURE TO DO SO MAY RESULT
IN PERSONAL INJURY.
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:
²The battery is fully-charged and load tested
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - STANDARD PROCEDURE).
²Fully engage the parking brake.
²If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
²Verify that all lamps and accessories are turned
off.
²To prevent a gasoline engine from starting,
remove the Automatic ShutDown (ASD) relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC), in the engine compartment. See the fuse
and relay layout label affixed to the underside of the
PDC cover for ASD relay identification and location.
To prevent a diesel engine from starting, disconnect
the fuel shutdown solenoid wire harness connector
(Fig. 20).
(1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 21). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.
NOTE: If the vehicle is equipped with a dual battery
system, Step 1 must be performed twice, once for
each battery.
(2) Connect the positive lead of the voltmeter to
the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 22). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. Ifvoltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post.
Fig. 20 Fuel Shutdown Solenoid Connector - Diesel
Engine
1 - AIR TEMPERATURE SENSOR
2 - SENSOR ELECTRICAL CONNECTOR
3 - SOLENOID ELECTRICAL CONNECTOR
4 - FUEL SHUTDOWN SOLENOID
5 - INTAKE MANIFOLD (UPPER HALF)
Fig. 21 Test Battery Negative Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
8F - 20 BATTERY SYSTEMBR/BE
BATTERY CABLE (Continued)

NOTE: If the vehicle is equipped with a dual battery
system, Step 2 must be performed twice, once for
each battery.
(3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 23). 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 con-
nection 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.
NOTE: If the vehicle is equipped with a dual battery
system, Step 3 must be performed on the driver
side battery only.
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 24). 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.
NOTE: If the vehicle is equipped with a dual battery
system, Step 4 must be performed twice, once for
each battery.
REMOVAL
POSITIVE CABLE REMOVAL - GASOLINE
ENGINE
Both the battery negative cable and the battery
positive cable are serviced in the battery wire har-
ness. If either battery cable is damaged or faulty, the
battery wire harness assembly must be replaced.
(1) Remove the positive battery cable from the bat-
tery.
(2) Remove the cover from the PDC.
(3) Remove the positive battery cable from the
PDC.
Fig. 22 Test Battery Positive Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 23 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 24 Test Ground Circuit
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
BR/BEBATTERY SYSTEM 8F - 21
BATTERY CABLE (Continued)