JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

(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.
²Temperature- A longer time will be needed to
charge a battery at -18É C (0É F) than at 27É C (80É
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will bevery low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
²Charger Capacity- A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies
twenty amperes or more will require a shorter charg-
ing time.
²State-Of-Charge- A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
The Battery Charging Time Table gives an indica-
tion of the time required to charge a typical battery
at room temperature based upon the battery state-of-
charge and the charger capacity.
BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps10
Amps20 Amps
Open Circuit
VoltageHours Charging @ 21É C (70É
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - USING MICRO 420
ELECTRICAL TESTER
Always use the Micro 420 Instruction Manual that
was supplied with the tester as a reference. If the
Instruction Manual is not available the following pro-
cedure can be used:
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.
Fig. 5 Voltmeter - Typical
8F - 10 BATTERY SYSTEMWJ
BATTERY (Continued)

(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. 6) 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.
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
An indicator (hydrometer) built into the top of the
battery case provides visual information for battery
testing (Fig. 7). Like a hydrometer, the built-in indi-
cator measures the specific gravity of the battery
electrolyte. The specific gravity of the electrolyte
reveals the battery state-of-charge; however, it will
not reveal the cranking capacity of the battery. A load
test must be performed to determine the battery
cranking capacity. Refer to Standard Procedures for
the proper battery load test procedures.
Fig. 6 MICRO 420 BATTERY AND CHARGING
SYSTEM TESTER
Fig. 7 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
WJBATTERY SYSTEM 8F - 11
BATTERY (Continued)

Before testing, visually inspect the battery for any
damage (a cracked case or cover, loose posts, etc.)
that would cause the battery to be faulty. In order to
obtain correct indications from the built-in indicator,
it is important that the battery be level and have a
clean sight glass. Additional light may be required to
view the indicator.Do not use open flame as a
source of additional light.
To read the built-in indicator, look into the sight
glass and note the color of the indication (Fig. 8). The
battery condition that each color indicates is
described in the following list:
²Green- Indicates 75% to 100% battery state-of-
charge. The battery is adequately charged for further
testing or return to service. If the starter will not
crank for a minimum of fifteen seconds with a fully-
charged battery, the battery must be load tested.
Refer to Standard Procedures for the proper battery
load test procedures.
²Black or Dark- Indicates 0% to 75% battery
state-of-charge. The battery is inadequately charged
and must be charged until a green indication is visi-
ble in the sight glass (12.4 volts or more), before the
battery is tested further or returned to service. Refer
to Standard Procedures for the proper battery charg-
ing procedures. Also refer to Diagnosis and Testing
for more information on the possible causes of the
discharged battery condition.
²Clear or Bright- Indicates a low battery elec-
trolyte level. The electrolyte level in the battery is
below the built-in indicator. A maintenance-free bat-
tery with non-removable cell caps must be replaced if
the electrolyte level is low. Water must be added to a
low-maintenance battery with removable cell caps
before it is charged. Refer to Standard Procedures for
the proper battery filling procedures. A low electro-
lyte level may be caused by an overcharging condi-
tion. Refer to Charging System for the proper
charging system diagnosis and testing procedures.STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used in place of the hydrometer test
when a hydrometer is not available, or for mainte-
nance-free batteries with non-removable cell caps.
Before proceeding with this test, completely charge
the battery (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize.
(2) Disconnect and isolate both battery cables, neg-
ative cable first.
(3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts or
greater, it may be load tested to reveal its cranking
capacity (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
Fig. 8 Built-In Indicator Sight Glass Chart
Fig. 9 Testing Open-Circuit Voltage - Typical
8F - 12 BATTERY SYSTEMWJ
BATTERY (Continued)

STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from five
to thirty-five milliamperes (0.005 to 0.035 ampere)
with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working
order. Up to thirty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the
vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Power Distribution Center (PDC). This will
reduce battery discharging.Excessive IOD can be caused by:
²Electrical items left on.
²Faulty or improperly adjusted switches.
²Faulty or shorted electronic modules and compo-
nents.
²An internally shorted generator.
²Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to three minutes. See the Electronic Module Igni-
tion-Off Draw Table for more information.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
ModuleTime Out?
(If Yes, Interval And Wake-Up Input)IODIOD After Time
Out
Radio No1to3
milliamperesN/A
Audio Power
AmplifierNoup to 1
milliampereN/A
Body Control Module
(BCM)No5.90
milliamperes
(max.)N/A
Powertrain Control
Module (PCM)No 0.95 milliampere N/A
Transmission Control
Module (TCM) 4.7L
w/45RFEYES (20 minutes, ignition on) 130 milliamperes 0.64 milliampere
ElectroMechanical
Instrument Cluster
(EMIC)No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
(2) Determine that the underhood lamp is operat-
ing properly, then disconnect the lamp wire harness
connector or remove the lamp bulb.
(3) Disconnect the battery negative cable.
(4) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
between the disconnected battery negative cable ter-
minal clamp and the battery negative terminal post.
Make sure that the doors remain closed so that the
illuminated entry system is not activated. The multi-
meter amperage reading may remain high for up tothree minutes, or may not give any reading at all
while set in the highest amperage scale, depending
upon the electrical equipment in the vehicle. The
multi-meter leads must be securely clamped to the
battery negative cable terminal clamp and the bat-
tery negative terminal post. If continuity between the
battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD
test, the electronic timer function will be activated
and all of the tests will have to be repeated.
WJBATTERY SYSTEM 8F - 13
BATTERY (Continued)

(5) After about three minutes, the high-amperage
IOD reading on the multi-meter should become very
low or nonexistent, depending upon the electrical
equipment in the vehicle. If the amperage reading
remains high, remove and replace each fuse or circuit
breaker in the Power Distribution Center (PDC) and
then in the Junction Block (JB), one at a time until
the amperage reading becomes very low, or nonexist-
ent. Refer to the appropriate wiring information in
this service manual for complete PDC and JB fuse,
circuit breaker, and circuit identification. This will
isolate each circuit and identify the circuit that is the
source of the high-amperage IOD. If the amperage
reading remains high after removing and replacing
each fuse and circuit breaker, disconnect the wire
harness from the generator. If the amperage reading
now becomes very low or nonexistent, refer to Charg-
ing System for the proper charging system diagnosis
and testing procedures. After the high-amperage IOD
has been corrected, switch the multi-meter to pro-
gressively lower amperage scales and, if necessary,
repeat the fuse and circuit breaker remove-and-re-
place process to identify and correct all sources of
excessive IOD. It is now safe to select the lowest mil-
liampere scale of the multi-meter to check the low-
amperage IOD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the multi-meter reading. The low-am-
perage IOD should not exceed thirty-five milliam-
peres (0.035 ampere). If the current draw exceeds
thirty-five milliamperes, isolate each circuit using the
fuse and circuit breaker remove-and-replace process
in Step 5. The multi-meter reading will drop to
within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this
circuit as required; whether a wiring short, incorrect
switch adjustment, or a component failure is at fault.
STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The following procedure can be used to check the
battery electrolyte level.
(1) Remove the battery cell caps (Fig. 10).
(2) Look through the battery cap holes to deter-
mine the level of the electrolyte in the battery (Fig.
11). The electrolyte should be approximately 1 centi-
meter above the battery plates or until the hook
inside the battery cap holes is covered.
(3) Add only distilled water until the electrolyte
level is approx. one centimeter above the plates.
Fig. 10 Battery Caps - Export Battery
1 - BATTERY CAP
2 - BATTERY
Fig. 11 Hook Inside Battery Cap Holes - Export
Battery
1 - BATTERY SURFACE COVER
2 - HOOK
8F - 14 BATTERY SYSTEMWJ
BATTERY (Continued)

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. 12).
(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.
(6) Remove the battery hold down from the bat-
tery. Refer toBattery Hold Downin this section of
the service manual for the procedure.
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.
(7) Remove the battery from the battery tray.
INSTALLATION
(1) Clean and inspect the battery. Refer to the pro-
cedures in this section.
(2) Position the battery onto the battery tray as a
unit. Ensure that the battery positive and negative
terminal posts are correctly positioned. The battery
cable terminal clamps must reach the correct battery
terminal post without stretching the cables (Fig. 13)
or (Fig. 14).
(3) Reinstall the battery hold downs onto the bat-
tery. Refer toBattery Hold DownsCAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reverse battery polarity may damage
electrical components of the vehicle.
(4) Clean the battery cable terminal clamps and
the battery terminal posts.
Fig. 12 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
Fig. 13 Battery Cables - 4.0L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
Fig. 14 Battery Cables - 4.7L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
WJBATTERY SYSTEM 8F - 15
BATTERY (Continued)

(5) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (60
in. lbs.).
(6) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (
60 in. lbs.).
(7) Apply a thin coating of petroleum jelly or chas-
sis grease to the exposed surfaces of the battery cable
terminal clamps and the battery terminal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hold down hardware consists of (Fig.
15) a molded plastic lip that is integral to the out-
board edge of the battery tray and support unit, a
molded plastic hold down bracket, a single hex screw
with a coned washer and a U-nut.
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 can be ser-
viced without removal of the battery or the battery
tray and support unit.
(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 screw with washer that secures the
battery hold down bracket to the U-nut on the
inboard side of the battery tray and support unit
(Fig. 16).
(5) Remove the battery hold down bracket from
the battery tray and support unit.
INSTALLATION
All of the battery hold down hardware can be ser-
viced without removal of the battery or the battery
tray and support unit.
(1) Clean and inspect the battery hold down hard-
ware. Refer to the procedures in this section of the
service manual.
(2) Be certain that the battery is properly posi-
tioned in the battery tray and support unit. The
ledge on the outboard side of the battery case must
be engaged under the lip on the outboard side of the
battery tray and support unit.
Fig. 15 Battery Hold Downs
1 - SCREW
2 - HOLD DOWN BRACKET
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
8 - RADIATOR SUPPORT BRACKET
9 - U-NUT
10 - SCREW
11 - BATTERY TEMPERATURE SENSOR
12 - BATTERY
8F - 16 BATTERY SYSTEMWJ
BATTERY (Continued)

(3) Position the battery hold down bracket over the
ledge on the inboard side of the battery case in the
battery tray and support unit. Be certain that the
ledge on the bottom of the hold down bracket is ori-
ented towards the inboard side of the battery case.
Proper hold down bracket orientation may 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) Install and tighten the screw that secures the
battery hold down bracket to the U-nut on the
inboard side of the battery tray and support unit.
Tighten thew screw to 3.4 N´m (30 in. lbs.).(5)
Reconnect the battery negative cable terminal clamp
to the battery negative terminal post. Tighten the terminal
clamp pinch-bolt hex nut to 8.4 N´m (75 in. lbs.).
BATTERY CABLE
DESCRIPTION
Fig. 16 Battery Hold Downs Remove/Install
1 - SCREW
2 - HOLD DOWN BRACKET
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
8 - RADIATOR SUPPORT BRACKET
9 - U-NUT
10 - SCREW
11 - BATTERY TEMPERATURE SENSOR
12 - BATTERY
Fig. 17 Battery Cables - 4.0L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
Fig. 18 Battery Cables - 4.7L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
WJBATTERY SYSTEM 8F - 17
BATTERY HOLDDOWN (Continued)

The battery cables (Fig. 17) or (Fig. 18) are large
gauge, stranded copper wires sheathed within a
heavy plastic or synthetic rubber insulating jacket.
The wire used in the battery cables combines excel-
lent flexibility and reliability with high electrical cur-
rent carrying capacity. Refer toWiring Diagrams
for battery cable wire gauge information.
A clamping type female battery terminal made of
soft lead is 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 termi-
nal 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
have a red insulating jacket to provide visual identi-
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
tive terminal post. The battery negative cable wires
have a black insulating jacket and a smaller female
battery terminal clamp.
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
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer toWiring Diagramsfor more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
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 restor-
ing 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 pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is die
cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the Power Distribution
Center (PDC), and the other wire has an eyelet ter-
minal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
also die cast onto the ends of two wires. One wirehas an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the right side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
near the 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 cable. 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.
VOLTAGE DROP TEST
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 Standard Procedures for the proper battery
charging and load test procedures.
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 the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC cover
for ASD relay identification and location.
8F - 18 BATTERY SYSTEMWJ
BATTERY CABLE (Continued)

(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. 19). 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.
(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. 20). 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 to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 21). 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.
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 22). 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
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 unit must be replaced.
(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. 19 TEST BATTERY NEGATIVE CONNECTION
RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY
Fig. 20 TEST BATTERY POSITIVE CONNECTION
RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY
Fig. 21 TEST BATTERY POSITIVE CABLE
RESISTANCE - TYPICAL
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
WJBATTERY SYSTEM 8F - 19
BATTERY CABLE (Continued)