battery replacement DODGE RAM 2003 Service Repair Manual

OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes.
The DTC can also be accessed through the
DRBIIItscan tool. Refer to the appropriate Power-
train Diagnostic Procedures information for diagnos-
tic information and operation of the DRBIIItscan
tool.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE COOLING SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
Factory installed thermostat housings on 5.9L
engine is installed on a gasket with an anti-stick
coating. This will aid in gasket removal and clean-up.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system until the coolant level
is below the thermostat (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Air Conditioned vehicles: Remove the support
bracket (generator mounting bracket-to-intake mani-
fold) located near the rear of the generator (Fig. 19).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) (Fig. 20).
(5) Remove the generator mounting bolts. Do not
remove any of the wiring at the generator. If
equipped with 4WD, unplug the 4WD indicator lamp
wiring harness (located near rear of generator).
(6) Remove the generator. Position the generator
to gain access for the thermostat gasket removal.
Fig. 18 Thermostat - 5.7L/5.9L Gas Powered
Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
Fig. 19 Generator Support Bracket ± 5.9L Engine
1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
4 - SCREW AND WASHER
7 - 48 ENGINEDR
ENGINE COOLANT THERMOSTAT- 5.7L/5.9L (Continued)

emissions and crankcase condensation. This conden-
sation can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer tothe Diagnosis section of this group for other probable
causes.
The DTC can also be accessed through the
DRBIIItscan tool. Refer to the appropriate Power-
train Diagnostic Procedures information for diagnos-
tic information and operation of the DRBIIItscan
tool.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE COOLING SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Raise and support the vehicle.
(4) Remove the splash shield.
(5) Remove the lower radiator hose clamp and the
lower radiator hose at the thermostat housing.
(6) Remove the thermostat housing mounting
bolts, thermostat housing and thermostat (Fig. 26).
INSTALLATION
(1) Clean the mating areas of the timing chain
cover and the thermostat housing.
(2) Install the thermostat (spring side down) into
the recessed machined groove on the timing chain
cover (Fig. 26).
(3) Position the thermostat housing on the timing
chain cover.
(4) Install the housing-to-timing chain cover bolts.
Tighten the bolts to 13 N´m (112 in. lbs.).
CAUTION: The housing must be tightened evenly
and the thermostat must be centered into the
recessed groove in the timimg chain cover. If not, it
may result in a cracked housing, damaged timing
chain cover threads or coolant leaks.
(5) Install the lower radiator hose on the thermo-
stat housing.
(6) Install the splash shield.
(7) Lower the vehicle.
(8) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(9) Connect negative battery cable.
(10) Start and warm the engine. Check for leaks.
Fig. 25 Thermostat Cross Section View 3.7L/4.7L
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
DRENGINE 7 - 51
ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued)

This system capacity will not effect warm up or
cold weather operating characteristics if the thermo-
stat is operating properly. This is because coolant
will be held in the engine until it reaches the ther-
mostat ªsetº temperature.
Diesel engines, due to their inherent efficiency are
slower to warm up than gasoline powered engines,
and will operate at lower temperatures when the
vehicle is unloaded. Because of this, lower tempera-
ture gauge readings for diesel versus gasoline
engines may, at times be normal.
Typically, complaints of low engine coolant temper-
ature are observed as low heater output when com-
bined with cool or cold outside temperatures.
To help promote faster engine warm-up, the elec-
tric engine block heater must be used with cool or
cold outside temperatures. This will help keep the
engine coolant warm when the vehicle is parked. Use
the block heater if the outside temperature is below
4ÉC (40ÉF).Do not use the block heater if the
outside temperature is above 4ÉC (40ÉF).
A ªCold Weather Coverº is available from the parts
department through the Mopar Accessories product
line. This accessory cover is designed to block airflow
entering the radiator and engine compartment to
promote faster engine warm-up. It attaches to the
front of the vehicle at the grill opening.The cover is
to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tion.
(1) To determine if the thermostat is defective, it
must be removed from the vehicle (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT THERMO-
STAT - REMOVAL).
(2) After the thermostat has been removed, exam-
ine the thermostat and inside of thermostat housing
for contaminants. If contaminants are found, the
thermostat may already be in a ªstuck openº position.
Flush the cooling system before replacing thermostat
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Place the thermostat into a container filled
with water.
(4) Place the container on a hot plate or other suit-
able heating device.
(5) Place a commercially available radiator ther-
mometer into the water.
(6) Apply heat to the water while observing the
thermostat and thermometer.
(7) The thermostat will begin to open at 85.5 Ð
89.4ÉC. (186 Ð193ÉF ). If the valve starts to move
before this temperature is reached, it is opening too
early. Replace thermostat. The thermostat should be
fully open (valve will stop moving) at 97ÉC (207ÉF). Ifthe valve is still moving when the water temperature
reaches 97ÉC (207ÉF), it is opening too late. Replace
thermostat. If the valve refuses to move at any time,
replace thermostat.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Disconnect the battery negative cables.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove radiator hose clamp and hose from
thermostat housing.
(4) Remove the three (3) water outlet-to-cylinder
head bolts and remove the water outlet connector
(Fig. 28).
(5) Clean the mating surfaces of the water outlet
connector and clean the thermostat seat groove at
the top of the thermostat housing (Fig. 28).
INSTALLATION
(1) Inspect thermostat seal for cuts or nicks.
Replace if damaged.
(2) Install the thermostat into the groove in the
top of the cylinder head (Fig. 28).
(3) Install the thermostat housing and bolts.
Tighten the bolts to 10 N´m (88 in. lbs.) torque.
(4) Install the radiator upper hose and clamp.
(5) Fill the cooling system with coolant (Refer to 7
- COOLING - STANDARD PROCEDURE).
(6) Connect the battery negative cables.
DRENGINE 7 - 53
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)

DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW
Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow-
ing to the radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drain a small amount of coolant from the radi-
ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal
operating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.
REMOVAL
(1) Disconnect battery negative cables.WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter and the correct
width.
(3) Remove the hose clamps and hoses from radia-
tor.
(4) Remove the coolant reserve/overflow tank hose
from the radiator filler neck.
(5) Remove the coolant reserve/overflow tank
(5.9L) or the coolant degas container(3.7L/4.7L) from
the fan shroud (pull straight up). The tank slips into
slots on the fan shroud.
(6) Unclip the power steering hoses from the fan
shroud.
(7) Disconnect the electrical connectors at the
windshield washer reservoir tank and remove the
tank.
(8) Remove the fan shroud mounting bolts and pull
up and out of the radiator tank clips (Fig. 33). Posi-
tion shroud rearward over the fan blades towards
engine.
(9) Disconnect the transmission cooler lines from
the transmission cooler, then plug the transmission
lines and cooler to prevent leakage.
(10) Disconnect the power steering lines from the
power steering cooler, then plug the power steering
lines and cooler to prevent leakage.
(11) Remove the two radiator upper mounting
bolts (Fig. 34).
(12) Lift the radiator straight up and out of the
engine compartment. Take care not to damage cool-
ing fins or tubes on the radiator and oil coolers when
removing.
Fig. 32 Radiator Ð Typical
1 - SCREW
2 - SCREW
3 - LOWER MOUNT
4 - RADIATOR
5 - DRAINCOCK
6 -LOWER MOUNT
DRENGINE 7 - 57
RADIATOR (Continued)

(12) Install coolant reserve/overflow container or
degas container to fan shroud and tighten the bolts
to 8.5 N´m (75 in. lbs.).
(13) Connect upper radiator hose and install
clamp.
(14) Install battery negative cable.
(15) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Operate the engine until it reaches normal
operating temperature. Check cooling system fluid
levels.
RADIATOR - 5.9L DIESEL
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 35).
This radiator does not contain an internal trans-
mission oil cooler
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radiator core to cool the engine.
DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW
Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow-
ing to the radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drain a small amount of coolant from the radi-
ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal
operating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.
REMOVAL
(1) Disconnect both battery negative cables.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove air box and turbocharger inlet tube.
(4) Remove coolant tank hose, washer bottle hose
and the positive battery cable from the fastening
clips located on top of the radiator.
(5) Remove hose clamps and hoses from radiator.
Fig. 35 Radiator Ð Typical
1 - SCREW
2 - SCREW
3 - LOWER MOUNT
4 - RADIATOR
5 - DRAINCOCK
6 -LOWER MOUNT
DRENGINE 7 - 59
RADIATOR (Continued)

radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
OPERATIONÐWATER PUMP BYPASS
When the thermostat is in the closed position the
bypass gallery is not obstructed allowing 100% flow.
When the thermostat is in the open position the stub
shaft enters the bypass gallery obstructing bypass
coolant flow by 50%. This design allows the coolant
to reach operating temperature quickly when cold,
while adding extra cooling during normal tempera-
ture operation.
REMOVAL
The water pump on 3.7L/4.7L engines is bolted
directly to the engine timing chain case cover.
(1) Disconnect the negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from
water pump (Fig. 46) (Refer to 7 - COOLING/EN-
GINE/FAN DRIVE VISCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter and width.
(4) If the water pump is being replaced, do not
unbolt the fan blade assembly from the thermal vis-
cous fan drive.
(5) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove accessory drive belt (Fig. 47) (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the lower radiator hose clamp and
remove the lower hose at the water pump.
(8) Remove the water pump mounting bolts.
Fig. 44 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
2 - TIMING CHAIN COVER
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 45 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
DRENGINE 7 - 65
WATER PUMP - 3.7L/4.7L (Continued)

(2) Tighten bolts. Refer to torque specifications.
(3) Check pin connectors in the PCM and the three
32±way connectors (four 38±way connectors if
equipped with NGC) for corrosion or damage. Also,
the pin heights in connectors should all be same.
Repair as necessary before installing connectors.
(4) Install three 32±way connectors (four 38±way
connectors if equipped with NGC).
(5) Install cover over electrical connectors. Cover
snaps onto PCM.
(6) Install negative battery cable.
(7) Use the DRB scan tool to reprogram new PCM
with vehicles original Vehicle Identification Number
(VIN) and original vehicle mileage.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key Immobilizer Module (SKIM) con-
tains a Radio Frequency (RF) transceiver and a cen-
tral processing unit, which includes the Sentry Key
Immobilizer System (SKIS) program logic. The SKIS
programming enables the SKIM to program and
retain in memory the codes of at least two, but no
more than eight electronically coded Sentry Key
transponders. The SKIS programming also enables
the SKIM to communicate over the Programmable
Communication Interface (PCI) bus network with the
Powertrain Control Module (PCM), and/or the
DRBIIItscan tool.
OPERATION
The SKIM transmits and receives RF signals
through a tuned antenna enclosed within a molded
plastic ring that is integral to the SKIM housing.
When the SKIM is properly installed on the steering
column, the antenna ring is oriented around the igni-
tion lock cylinder housing. This antenna ring must be
located within eight millimeters (0.31 inches) of the
Sentry Key in order to ensure proper RF communica-
tion between the SKIM and the Sentry Key tran-
sponder.
For added system security, each SKIM is pro-
grammed with a unique ªSecret Keyº code and a
security code. The SKIM keeps the ªSecret Keyº code
in memory. The SKIM also sends the ªSecret Keyº
code to each of the programmed Sentry Key tran-
sponders. The security code is used by the assembly
plant to access the SKIS for initialization, or by the
dealer technician to access the system for service.
The SKIM also stores in its memory the Vehicle
Identification Number (VIN), which it learns through
a PCI bus message from the PCM during initializa-
tion.The SKIM and the PCM both use software that
includes a rolling code algorithm strategy, which
helps to reduce the possibility of unauthorized SKIS
disarming. The rolling code algorithm ensures secu-
rity by preventing an override of the SKIS through
the unauthorized substitution of the SKIM or the
PCM. However, the use of this strategy also means
that replacement of either the SKIM or the PCM
units will require a system initialization procedure to
restore system operation.
When the ignition switch is turned to the ON or
START positions, the SKIM transmits an RF signal
to excite the Sentry Key transponder. The SKIM then
listens for a return RF signal from the transponder
of the Sentry Key that is inserted in the ignition lock
cylinder. If the SKIM receives an RF signal with
valid ªSecret Keyº and transponder identification
codes, the SKIM sends a ªvalid keyº message to the
PCM over the PCI bus. If the SKIM receives an
invalid RF signal or no response, it sends ªinvalid
keyº messages to the PCM. The PCM will enable or
disable engine operation based upon the status of the
SKIM messages.
The SKIM also sends messages to the Instrument
Cluster which controls the VTSS indicator LED. The
SKIM sends messages to the Instrument Cluster to
turn the LED on for about three seconds when the
ignition switch is turned to the ON position as a bulb
test. After completion of the bulb test, the SKIM
sends bus messages to keep the LED off for a dura-
tion of about one second. Then the SKIM sends mes-
sages to turn the LED on or off based upon the
results of the SKIS self-tests. If the VTSS indicator
LED comes on and stays on after the bulb test, it
indicates that the SKIM has detected a system mal-
function and/or that the SKIS has become inopera-
tive.
If the SKIM detects an invalid key when the igni-
tion switch is turned to the ON position, it sends
messages to flash the VTSS indicator LED. The
SKIM can also send messages to flash the LED as an
indication to the customer that the SKIS has been
placed in it's ªCustomer Learnº programming mode.
See Sentry Key Immobilizer System Transponder
Programming in this section for more information on
the ªCustomer Learnº programming mode.
For diagnosis or initialization of the SKIM and the
PCM, a DRBIIItscan tool and the proper Powertrain
Diagnostic Procedures manual are required. The
SKIM cannot be repaired and, if faulty or damaged,
the unit must be replaced.
DRELECTRONIC CONTROL MODULES 8E - 13
POWERTRAIN CONTROL MODULE (Continued)

ponents. In addition to the maintenance schedules
found in this service manual and the owner's man-
ual, it is recommended that these procedures be per-
formed any time the battery or related components
must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all
corrosion. 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 (Fig. 1).
(2) Clean the battery tray and battery holddown
hardware of all corrosion. Remove any corrosion
using a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal.
(3) If the removed 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 using a stiff bristle
parts cleaning brush to remove any acid film (Fig. 2).
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 System Specifications for
the factory-installed battery specifications. Confirm
that the replacement battery is the correct size and
has the correct ratings for the vehicle.
(4) Clean the battery thermal guard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.(5) 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 (Fig. 3).
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
DRBATTERY SYSTEM 8F - 5
BATTERY SYSTEM (Continued)

INSPECTION
The following information details the recommended
inspection procedures for the battery and related
components. In addition to the maintenance sched-
ules found in this service manual and the owner's
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp.
(2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case
(if equipped). 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 terminal posts
must be replaced.
(4) Inspect the battery thermal guard (if equipped)
for tears, cracks, deformation or other damage.
Replace any battery thermal guard that has been
damaged.
(5) Inspect the battery built-in test indicator sight
glass (if equipped) for an indication of the battery
condition. If the battery is discharged, charge as
required. Refer to Standard Procedures for the
proper battery built-in indicator test procedures. Also
refer to Standard Procedures for the proper battery
charging procedures.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can befound on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
56029449AB 65 600 120 Minutes 66 300
56029451AB 65 750 150 Minutes 75 375
56028450AA 65 600 120 Minutes 66 300
56028452AA 65 750 150 Minutes 75 375
56028452AB 65 700 130 Minutes 70 350
56029396AA 65 700 130 Minutes 70 350
56029382AA 65 700 130 Minutes 70 350
8F - 6 BATTERY SYSTEMDR
BATTERY SYSTEM (Continued)

WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) If testing the battery OUT-OF-VEHICLE, clean
the battery terminals with a wire brush before test-
ing. If the battery is equipped with side post termi-
nals, install and tighten the supplied lead terminal
stud adapters. Do not use steel bolts. Failure to prop-
erly install the stud adapters, or using stud adapters
that are dirty or worn-out may result in false test
readings.
(2) If testing the battery IN-THE-VEHICLE, make
certain all of the vehicle accessory loads are OFF,
including the ignition.The preferred test position
is at the battery terminal. If the battery is not
accessible, you may test using both the positive and
negative jumper posts. Select TESTING AT JUMPER
POST when connecting to that location.
(3) Connect the tester (Fig. 9) to the battery or
jumper posts, the red clamp to positive (+) and the
black clamp to negative (±).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Using the ARROW key selectinoroutof vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
tery rating for your area (see menu). The tester will
then run its self programmed test of the battery and
display the results. Refer to the test result table
noted below.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicle's cables and battery exists. After discon-
necting the vehicle's battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) While viewing the battery test result, press the
CODE button and the tester will prompt you for the
last 4 digits of the VIN. Use the UP/DOWN arrow
buttons to scroll to the correct character; then press
ENTER to select and move to the next digit. Then
press the ENTER button to view the SERVICE
CODE. Pressing the CODE button a second time will
return you to the test results.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
REMOVAL
(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 (Fig. 10).
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post (Fig. 10).
(6) Remove the battery hold down retaining bolt.
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 BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
Fig. 10 Removing Battery Cable Terminal Clamp
1 - BATTERY
2 - BATTERY TERMINAL PULLER
DRBATTERY SYSTEM 8F - 13
BATTERY (Continued)