water JEEP LIBERTY 2002 KJ / 1.G Repair Manual

RADIATOR FAN - ELECTRIC
DESCRIPTION
The fan (Fig. 11) is electrically controlled by the
powertrain control module (PCM) through the fan
control relay. This relay is located on the left wheel
house in the engine compartment.
OPERATION
The electric radiator cooling fan is controlled by
the Powertrain Control Module (PCM) through the
radiator cooling fan relay. The PCM regulates fan
operation based on input from the engine coolant
temperature sensor, battery temperature sensor,air
conditioning select switch and vehicle speed.
The fan is not energized during engine cranking
regardless of the electrical input from the tempera-
ture sensors and ,air conditioning switch. However, if
engine operation conditions warrant fan engagement,
the fan will run once engine starts.
On vehicles NOT equipped with AC:The relay
is energized when the coolant temperature is above
80É C (176É F), or battery temperature sensor above ±
12É C (10É F). It will then de-energize when coolant
temperature drops below 82É C (180É F), or batter
temperature sensor below ± 9É C ( 16É F).
Vehicles Equipped with AC:In addition to using
coolant temperature and battery temperature sensorto control cooling fan operation, the cooling fan will
also be engaged when the ,air conditioning system is
activated. The relay is also energized when, air con-
ditioning is selected and coolant temperature is
above 95É C ( 203É F), or , air conditioning is selected
and battery temperature sensor is above 41É C (106É
F). It will then de-energize when , air conditioning is
selected and coolant temperature is below 92É C
(198É F), or , air conditioning is selected and battery
temperature is below 38É C (100É F).
REMOVAL
If the fan blade is bent, warped, cracked or dam-
aged in any way, it must be replacedonlywith a
replacement fan blade.Do not attempt to repair a
damaged fan blade.
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the viscous fan cannot be
removed seperate from the shroud. Both fan and
shroud must be removed together.
(1) Disconnect battery negative cable.
(2) Using special tool 6958 spanner wrench and
8346 adapters, remove the viscous fan from the
water pump (Fig. 12).
(3) Gently lay fan into shroud.
(4) Disconnect the electrical connector for the elec-
tric fan, then disconnect connector from shroud.
Fig. 11 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 12 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
7s - 26 ENGINEKJ

(5) Remove the two fan shroud mounting bolts con-
necting the fan shroud to the radiator (Fig. 13).
(6) Remove the shroud and fan from the vehicle.
INSTALLATION
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the viscous fan cannot be
installed seperate from the shroud. Both fan and
shroud must be installed together.
(1) Gently lay viscous fan into shroud.
(2) Install fan shroud assembly into the vehicle.
Tighten fan shroud to radiator bolts to (5.5 N´m (50
in. lbs.).
(3) Using special tool 6958 spanner wrench and
8346 adapters, install the viscous fan on the water
pump.
(4) Connect fan motor wire connector to harness
connector, and attach connector to shroud.
(5) Connect battery negative cable.
(6) Start engine and check fan operation.
WATER PUMP - 2.4L
DESCRIPTION
The water pump has a cast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the block (Fig. 14). The cylin-
der block to water pump seal is provided by a rubber
O-ring. The water pump is driven by the engine tim-
ing belt.
OPERATION
The water pump is the heart of the cooling system.
The coolant is pumped through the engine block, cyl-
inder head, heater core, and radiator.
REMOVAL - 2.4L ENGINE
(1) Disconnect negative cable from battery.
(2) Raise vehicle on a hoist.
(3) Remove the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the belt tensioner.
(5) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(6) Remove the generator.
(7) Remove the power steering pump.
(8) Remove the A/C compressor.
Fig. 13 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 14 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
KJENGINE7s-27
RADIATOR FAN - ELECTRIC (Continued)

(9) Remove the accessory drive bracket.
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- REMOVAL).
(11) Remove timing belt idler pulley.
(12) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(13) Remove the timing belt rear cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(14) Remove water pump to engine attaching
screws (Fig. 15).
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION - 2.4L ENGINE
(1) Install new O-ring gasket in water pump body
O-ring locating groove (Fig. 16).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 103.4 Kpa (15 psi) with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(5) Install camshaft sprockets and target ring.
Torque bolts to 101 N´m (75 ft. lbs.) while holding
camshaft sprocket with Special tool C-4687 and
adaptor C-4687-1.
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
Fig. 15 Water Pump - 2.4L
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 16 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
7s - 28 ENGINEKJ
WATER PUMP - 2.4L (Continued)

(8) Install the accessory drive mounting bracket
(Fig. 17).(9) Install the power steering pump.
(10) Install the generator.
(11) Install the A/C compressor.
(12) Install the belt tensioner.
(13) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(14) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(15) Lower vehicle and connect battery cable.
Fig. 17 ACCESSORY DRIVE BRACKET
1- UPPER TIMING BELT COVER
2- LOWER TIMING BELT COVER
3- BELT TENSIONER
4- ACCESSORY DRIVE BRACKET
KJENGINE7s-29
WATER PUMP - 2.4L (Continued)

TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION.........................30STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES.................30
TRANS COOLER
DESCRIPTION
An internal high capacity/high efficiency cooler is
used on all vehicles, these coolers are an oil-to-cool-
ant type, which consists of plates mounted in the
radiator outlet tank.Because the internal oil cooler is
so efficient, no auxiliary oil cooler is offered. The
cooler is not serviceable separately from the radiator.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
The only recommended procedure for flushing cool-
ers and lines is to use Tool 6906-B Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES. KEEP LIGHTED CIGARETTES,
SPARKS, FLAMES, AND OTHER IGNITION
SOURCES AWAY FROM THE AREA TO PREVENT
THE IGNITION OF COMBUSTIBLE LIQUIDS AND
GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN
THE AREA WHERE THE FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.DO NOT LET
FLUSHING SOLVENT COME IN CONTACT WITH
YOUR EYES OR SKIN: IF EYE CONTAMINATION
OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20
SECONDS. REMOVE CONTAMINATED CLOTHING
AND WASH AFFECTED SKIN WITH SOAP AND
WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.(2) Reinstall filler plug on Tool 6906-B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
7s - 30 TRANSMISSIONKJ

ever occurs first. The overspeed warning feature is
only enabled on a BCM that has been programmed
with a Middle East Gulf Coast Country (GCC) coun-
try code.
²No Airbag Indicator Message Warning- The
EMIC chime tone generator will generate one, short,
ªbong-likeº chime tone and turn on the ªAirbagº indi-
cator when the ignition switch is in the On position,
and a PCI data bus ªAirbagº indicator on or off mes-
sage is not received from the ACM for six consecutive
seconds.
²No Antilock Brake Indicator Message Warn-
ing- The EMIC chime tone generator will generate
one, short, ªbong-likeº chime tone and turn on the
ªABSº indicator when the ignition switch is in the On
position, and a PCI data bus ªABSº indicator on or
off message is not received from the CAB for six con-
secutive seconds.
²No Fuel Level Message Warning- The EMIC
chime tone generator will generate one, short, ªbong-
likeº chime tone and turn on the ªLow Fuelº indica-
tor when the ignition switch is in the On position,
and a PCI data bus fuel level message is not received
from the PCM for twelve consecutive seconds.
²Remote Keyless Entry Transmitter Pro-
gramming- On vehicles so equipped, the EMIC
chime tone generator will generate a single ªbong-
likeº chime tone when an electronic message is
received over the PCI data bus from the BCM indi-
cating that a Remote Keyless Entry (RKE) transmit-
ter has been successfully programmed by the
customer into the RKE module memory.
²Sentry Key Immobilizer System Transpon-
der Programming- On vehicles so equipped, the
EMIC chime tone generator will generate a single
ªbong-likeº chime tone when an electronic message is
received over PCI data bus message from the Sentry
Key Immobilizer Module (SKIM) indicating that the
Sentry Key Immobilizer System (SKIS) has been
placed in the ªCustomer Learnº programming mode,
and again each time a new SKIS transponder has
been successfully programmed by the customer.
²Turn Signal Cancel Warning- The EMIC
chime tone generator will generate repetitive ªbong-
likeº chime tones at a slow rate when the vehicle is
driven for a distance of about 3.2 kilometers (about
two miles) with a turn signal indicator flashing. The
EMIC uses an electronic message received over the
PCI data bus from the PCM, and a hard wired input
from the turn signal switch circuitry of the multi-
function switch to determine when to sound the turn
signal cancel warning. The PCM uses internal pro-
gramming and distance pulse information received
over a hard wired vehicle speed pulse input from the
BCM to determine the proper vehicle speed messages
to send to the EMIC. The BCM uses an internallyprogrammed electronic pinion factor and a hard
wired input from the rear wheel speed sensor to cal-
culate the proper distance pulse information to send
to the PCM. The electronic pinion factor represents
the proper tire size and axle ratio information for the
vehicle. These chimes will continue to sound until
the turn signal is turned Off, until the hazard warn-
ing system is turned On, or until the ignition switch
is turned to the Off position, whichever occurs first.
²Water-In-Fuel Warning- On vehicles equipped
with a diesel engine, each time the ignition switch is
turned to the On position, the EMIC chime tone gen-
erator will generate a single ªbong-likeº chime tone
the first time an electronic message is received over
the PCI data bus from the PCM requesting ªWater-
in-Fuelº indicator illumination. The PCM uses inter-
nal programming and a hard wired input from the
water-in-fuel sensor to determine the proper water-
in-fuel messages to send to the EMIC. This warning
will only occur once during an ignition cycle.
The EMIC provides chime service for all available
features in the chime warning system. The EMIC
relies upon its internal programming and hard wired
inputs from the turn signal (multi-function) switch,
the washer fluid level switch, and the engine coolant
level sensor (diesel engine only) to provide chime ser-
vice for the turn signal cancel warning, the low
washer fluid warning, and the low coolant warning
respectively. The EMIC relies upon electronic mes-
sage inputs received from other electronic modules
over the PCI data bus network to provide chime ser-
vice for all of the remaining chime warning system
features. Upon receiving the proper inputs, the EMIC
activates the integral chime tone generator to pro-
vide the audible chime warning to the vehicle opera-
tor. The internal programming of the EMIC
determines the priority of each chime request input
that is received, as well as the rate and duration of
each chime tone that is to be generated. See the own-
er's manual in the vehicle glove box for more infor-
mation on the features provided by the chime
warning system.
The hard wired chime warning system inputs to
the EMIC, as well as other hard wired circuits for
this system may be diagnosed and tested using con-
ventional diagnostic tools and procedures. However,
conventional diagnostic methods may not prove con-
clusive in the diagnosis of the EMIC, the PCI data
bus network, or the electronic message inputs used
by the EMIC to provide chime warning system ser-
vice. The most reliable, efficient, and accurate means
to diagnose the EMIC, the PCI data bus network,
and the electronic message inputs for the chime
warning system requires the use of a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
KJCHIME/BUZZER 8B - 5
CHIME WARNING SYSTEM (Continued)

ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging:
²A faulty or incorrect charging system compo-
nent. Refer to Charging System for the proper charg-
ing system diagnosis and testing procedures.
²A faulty or incorrect battery. Refer to Standard
Procedures for the proper battery diagnosis and test-
ing procedures. Refer to Battery System Specifica-
tions for the proper specifications.
²A faulty circuit or component causing excessive
ignition-off draw.
²Electrical loads that exceed the output of the
charging system. This can be due to equipment
installed after manufacture, or repeated short trip
use.
²A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures.
²Corroded or loose battery posts and terminal
clamps.
²A loose or worn generator drive belt.
²Slow driving speeds (heavy traffic conditions) or
prolonged idling, with high-amperage draw systems
in use.
CLEANING
The following information details the recommended
cleaning procedures for the battery and related com-
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.
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
KJBATTERY SYSTEM 8F - 5
BATTERY SYSTEM (Continued)

(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).
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.
Inspect the battery case for cracks or other damagethat 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 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 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 Pro-
cedures 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 be
found 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.
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
8F - 6 BATTERY SYSTEMKJ
BATTERY SYSTEM (Continued)

BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
56041380AA 86 525 100 Minutes 60 250
SPECIAL TOOLS
BATTERY
DESCRIPTION
A large capacity, low-maintenance storage battery
(Fig. 5) is standard factory-installed equipment on
this model. Refer to Battery Specifications for the
proper specifications of the factory-installed batteries
available on this model. Male post type terminals
made of a soft lead material protrude from the top of
the molded plastic battery case to provide the means
for connecting the battery to the vehicle electrical
system. The battery positive terminal post is physi-
cally larger in diameter than the negative terminal
post to ensure proper battery connection. The letters
POSandNEGare also molded into the top of the
battery case adjacent to their respective positive and
negative terminal posts for identification confirma-
tion. Refer to Battery Cables for more information on
the battery cables that connect the battery to the
vehicle electrical system.
The battery is made up of six individual cells that
are connected in series. Each cell contains positively
charged plate groups that are connected with leadstraps to the positive terminal post, and negatively
charged plate groups that are connected with lead
straps to the negative terminal post. Each plate con-
sists of a stiff mesh framework or grid coated with
lead dioxide (positive plate) or sponge lead (negative
plate). Insulators or plate separators made of a non-
conductive material are inserted between the positive
and negative plates to prevent them from contacting
or shorting against one another. These dissimilar
metal plates are submerged in a sulfuric acid and
water solution called an electrolyte.
The factory-installed battery has a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi-
tion. Refer to Standard Procedures for the proper
built-in indicator test procedures.The factory-in-
stalled low-maintenance battery has removable
battery cell caps.Distilled water can be added to
this battery. The battery is not sealed and has vent
holes in the cell caps. The chemical composition of
the metal coated plates within the low-maintenance
Fig. 4 MIDTRONICS BATTERY AND CHARGING
SYSTEM TESTER - Micro420
Fig. 5 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
KJBATTERY SYSTEM 8F - 7
BATTERY SYSTEM (Continued)

battery reduces battery gassing and water loss, at
normal charge and discharge rates. Therefore, the
battery should not require additional water in nor-
mal service. If the electrolyte level in this battery
does become low, water must be added. However,
rapid loss of electrolyte can be caused by an over-
charging condition. Be certain to diagnose the charg-
ing system after replenishing the water in the
battery for a low electrolyte condition and before
returning the vehicle to service. Refer to Charging
System for the proper charging system diagnosis and
testing procedures.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
top, posts and terminal clamps should be properly
cleaned and inspected before diagnostic procedures
are performed. Refer to Battery System Cleaning for
the proper cleaning procedures, and Battery System
Inspection for the proper battery inspection proce-
dures. Refer to Standard Procedures for the proper
battery charging procedures.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condition of a battery is determined by two cri-
teria:
²State-Of-Charge- This can be determined by
checking the specific gravity of the battery electrolyte
(built-in indicator test or hydrometer test), or bychecking the battery voltage (open-circuit voltage
test).
²Cranking Capacity- This can be determined
by performing a battery load test, which measures
the ability of the battery to supply high-amperage
current.
First, determine the battery state-of-charge. This
can be done in one of three ways. If the battery has a
built-in test indicator, perform the built-in indicator
test to determine the state-of-charge. If the battery
has no built-in test indicator but does have remov-
able cell caps, perform the hydrometer test to deter-
mine the state-of-charge. If the battery cell caps are
not removable, or a hydrometer is not available, per-
form the open-circuit voltage test to determine the
state-of-charge. Refer to open-circuit voltage test in
the Standard Procedures section of this group.
Second, determine the battery cranking capacity by
performing a load test. The battery must be charged
before proceeding with a load test if:
²The battery built-in test indicator has a black or
dark color visible.
²The temperature corrected specific gravity of the
battery electrolyte is less than 1.235.
²The battery open-circuit voltage is less than 12.4
volts.
A battery that will not accept a charge is faulty,
and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is
faulty and must be replaced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
A battery is fully-charged when:
²All battery cells are gassing freely during charg-
ing.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three corrected specific gravity tests, taken at
one-hour intervals, indicate no increase in the spe-
cific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.4 volts
or greater.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery charging can be performed fast or slow, it
terms of time.Slowbattery charging is the best
means of restoring a battery to full potential. Fast
8F - 8 BATTERY SYSTEMKJ
BATTERY (Continued)