Tab 9 JEEP LIBERTY 2002 KJ / 1.G Manual Online

ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING.......................1
BODY CONTROL MODULE
DESCRIPTION..........................2
OPERATION............................5
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE.............................7
REMOVAL.............................7
INSTALLATION..........................7
COMMUNICATION
DESCRIPTION..........................8
OPERATION............................8
CONTROLLER ANTILOCK BRAKE
REMOVAL.............................10
INSTALLATION.........................10
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR....10
OPERATION - DATA LINK CONNECTOR......10
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION - PCM..................11
DESCRIPTION - MODES OF OPERATION . . . 11
DESCRIPTION - 5 VOLT SUPPLIES.......13
DESCRIPTION - IGNITION CIRCUIT SENSE . 13DESCRIPTION - POWER GROUNDS......13
DESCRIPTION - SENSOR RETURN.......14
OPERATION
OPERATION - PCM....................14
OPERATION - 5 VOLT SUPPLIES.........15
OPERATION - IGNITION CIRCUIT SENSE . . . 15
REMOVAL.............................15
INSTALLATION.........................15
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION.........................15
OPERATION...........................16
REMOVAL.............................17
INSTALLATION.........................18
TRANSMISSION CONTROL MODULE
DESCRIPTION.........................18
OPERATION...........................18
STANDARD PROCEDURE - TCM QUICK
LEARN..............................21
HEATED SEAT MODULE
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE............................22
REMOVAL.............................24
INSTALLATION.........................24
ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit, or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relays and sole-
noids) and shorted circuits (i.e. pull-ups, drivers,
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has been set.
When a PCM (JTEC) and the SKIM are replaced
at the same time, perform the following steps in
order:
(1) Program the new PCM (JTEC).(2) Program the new SKIM.
(3) Replace all ignition keys and program them to
the new SKIM.
PROGRAMMING THE PCM (JTEC)
The SKIS Secret Key is an ID code that is unique
to each SKIM. This code is programmed and stored
in the SKIM, the PCM, and the ignition key tran-
sponder chip(s). When replacing the PCM, it is nec-
essary to program the secret key into the new PCM
using the DRBIIItscan tool. Perform the following
steps to program the secret key into the PCM.
(1) Turn the ignition switch to the On position
(transmission in Park/Neutral).
(2) Use the DRBIIItand select THEFT ALARM,
SKIM, then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
(5) Select ENTER to update PCM VIN.
KJELECTRONIC CONTROL MODULES 8E - 1

There are two different versions of the BCM: base
and premium. The base BCM is a subset of the com-
ponents in the premium version. Basically, the base
version BCM does not support the following features:
Compass Mini-Trip Computer (CMTC), fog lamps
(front and/or rear), Remote Keyless Entry (RKE),
remote radio switches, or Vehicle Theft Security Sys-
tem (VTSS). Both versions of the BCM utilize inte-
grated circuitry and information carried on the
Programmable Communications Interface (PCI) databus network along with many hard wired inputs to
monitor many sensor and switch inputs throughout
the vehicle. In response to those inputs, the internal
circuitry and programming of the BCM allow it to
control and integrate many electronic functions and
features of the vehicle through both hard wired out-
puts and the transmission of electronic message out-
puts to other electronic modules in the vehicle over
the PCI data bus. The electronic functions and fea-
tures that the BCM supports or controls include the
following:
²A/C Select Switch Status- The BCM monitors
an input from, and transmits the status of the A/C
switch on the heater-A/C control.
²Ambient Temperature Data- The premium
BCM monitors and transmits the ambient tempera-
ture sensor input data.
²Cargo Lamp Disable- The BCM monitors an
input from the cargo lamp switch to provide an inte-
rior lighting disable feature.
²Chimes- The chime tone generator is located
on the ElectroMechanical Instrument Cluster (EMIC)
circuit board, but the EMIC goes to sleep with the
ignition switch in the Off position. The BCM provides
a wake-up output to the EMIC based upon inputs
from the key-in ignition switch or the exterior light-
ing switch, then sends electronic chime request mes-
sages to the EMIC for the headlamps-on warning
and key-in ignition warning.
²Door Lock Inhibit- The BCM monitors the
key-in ignition switch and the driver side front door
ajar switch to provide a door lock inhibit feature.
²Exterior Lamp Load Shedding- The BCM
provides a battery saver feature which will automat-
ically turn off exterior lamps that remain on after a
timed interval.
²Exterior Lamp Status- The BCM monitors
the status of the park lamp, low beam, high beam or
Daytime Running Lamp (DRL - Canada only), front
fog lamp (optional), and rear fog lamp (in required
markets only) relays.
²Exterior Lighting Control- The BCM pro-
vides exterior lamp control for standard head and
park lamps, as well as Daytime Running Lamps
(DRL - Canada only), front fog lamps (optional), and
rear fog lamps (in required markets only). This
includes support for features including optical horn
(also known as flash-to-pass) and headlamp time
delay.
²Flip-Up Glass Control- The BCM monitors
the tailgate cylinder lock switch, the tailgate handle
switch, the Remote Keyless Entry (RKE) module
inputs and the rear wiper switch to provide control
for the rear flip-up glass actuator.
Fig. 1 Body Control Module Location
1 - DRIVER DOOR
2 - INSTRUMENT PANEL END BRACKET
3 - JUNCTION BLOCK
4 - BODY CONTROL MODULE
Fig. 2 Body Control Module
1 - BODY CONTROL MODULE (FRONT VIEW)
2 - REMOTE KEYLESS ENTRY MODULE RECEPTACLE
3 - BCM-RKE CONNECTOR
4 - BODY CONTROL MODULE (BACK VIEW)
5 - JB-BCM CONNECTOR
6 - CONNECTOR RECEPTACLE (2)
KJELECTRONIC CONTROL MODULES 8E - 3
BODY CONTROL MODULE (Continued)

²Fog Lamp Control- The premium BCM pro-
vides fog lamp control for front fog lamps (optional),
and rear fog lamps (in required markets only).
²Front Wiper System Status- The BCM moni-
tors the status of the front wiper motor park switch.
²Fuel Economy and Distance to Empty Cal-
culations- The BCM calculates and transmits the
fuel economy and Distance To Empty (DTE) data.
²Headlamp Time Delay- The BCM provides a
headlamp time delay feature with the ignition switch
in the Off position.
²Heated Rear Glass Control- The BCM pro-
vides control and timer functions for the heated rear
glass feature and transmits the system status.
²Ignition On/Off Timer- The BCM monitors
and transmits the elapsed ignition On timer data
and monitors the ignition Off time.
²Ignition Switch Position Status- The BCM
monitors and transmits the status of the ignition
switch.
²Instrument Panel Dimming- The BCM mon-
itors and transmits the selected illumination inten-
sity level of the panel lamps dimmer switch.
²Interior Lamp Load Shedding- The BCM
provides a battery saver feature which will automat-
ically turn off all interior lamps that remain on after
a timed interval.
²Interior Lighting Control- The BCM moni-
tors inputs from the interior lighting switch, the door
ajar switches, the flip-up glass ajar switch, the tail-
gate ajar switch, the cargo lamp switch, the reading
lamp switches, and the Remote Keyless Entry (RKE)
module to provide courtesy lamp control. This
includes support for timed illuminated entry with
theater-style fade-to-off and courtesy illumination
defeat features.
²Intermittent Wipe and Front Wiper System
Control- The BCM monitors inputs from the front
wiper and washer switch and the front wiper motor
park switch to provide front wiper system control
through the wiper on/off and high/low relays. This
includes support for adjustable intermittent wipe,
mist wipe (also known as pulse wipe), and wipe-after-
wash features.
²Key-In-Ignition Switch Status- The BCM
monitors and transmits the status of the key-in-igni-
tion switch.
²Panic Mode- The BCM provides support for
the Remote Keyless Entry (RKE) system panic mode
feature.
²Parade Mode- The BCM provides a parade
mode (also known as funeral mode) that allows the
interior Vacuum Fluorescent Displays (VFD) to be
illuminated at full intensity while driving in daylight
with the exterior lamps On.²Power Locks- The BCM monitors inputs from
the power lock switches and the Remote Keyless
Entry (RKE) module (optional) to provide control of
the power lock motors through outputs to the lock,
unlock, and driver unlock (RKE only) relays. This
includes support for rolling door locks (also known as
automatic door locks) and a door lock inhibit mode.
²Programmable Features- The BCM provides
support for several standard and optional program-
mable features, including: rolling door locks, head-
lamp time delay interval, Remote Keyless Entry
(RKE) driver-door-only or unlock-all-doors, RKE opti-
cal chirp, and RKE audible chirp.
²Remote Keyless Entry- The premium BCM
provides the optional Remote Keyless Entry (RKE)
system features, including support for the RKE Lock,
Unlock (with optional driver-door-only unlock, and
unlock-all-doors), rear flip-up glass control, Panic,
audible chirp, optical chirp, and illuminated entry
modes, as well as the ability to be programmed to
recognize up to four RKE transmitters.
²Rolling Door Locks- The BCM provides sup-
port for the power lock system rolling door locks fea-
ture (also known as automatic door locks).
²Tailgate and Flip-Up Glass Ajar Status- The
BCM monitors and transmits the status of the tail-
gate and rear flip-up glass ajar switches.
²Remote Radio Switch Interface- The pre-
mium BCM monitors and transmits the status of the
optional remote radio switches.
²Self-Diagnostics- The BCM provides support
for diagnostics through communication with the
DRBIIItscan tool over the PCI data bus network.
Each analog and digital input can be verified, and
each output can be actuated through the use of this
diagnostic protocol. The BCM also stores Diagnostic
Trouble Codes (DTCs) to assist in troubleshooting
this unit.
²Vacuum Fluorescent Display Synchroniza-
tion- The BCM transmits panel lamp intensity data
which allows modules with Vacuum Fluorescent Dis-
plays (VFD) to coordinate their illumination inten-
sity.
²Vehicle Speed System- The BCM monitors a
vehicle speed input from the vehicle speed sensor
(without Antilock Brake System [ABS]) or from the
Controller Antilock Brake (CAB)(with ABS), calcu-
lates the vehicle speed based upon a programmed
axle ratio/tire size (electronic pinion factor), and
transmits the vehicle speed information to the Pow-
ertrain Control Module (PCM) on a hard wired out-
put circuit.
²Vehicle Theft Security System- The pre-
mium BCM monitors inputs from the door cylinder
lock switches, the tailgate cylinder lock switch, the
door ajar switches, the tailgate ajar switch, the
8E - 4 ELECTRONIC CONTROL MODULESKJ
BODY CONTROL MODULE (Continued)

Schedule Condition Expected Operation
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F- Delayed 2-3 upshift
- Delayed 3-4 upshift
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE - TCM QUICK LEARN
The quick learn procedure requires the use of the
DRBtscan tool.
This program allows the electronic transmission
system to recalibrate itself. This will provide the
proper transmission operation. The quick learn pro-
cedure should be performed if any of the following
procedures are performed:
²Transmission Assembly Replacement
²Transmission Control Module Replacement
²Solenoid Pack Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
²The shift lever position must stay in PARK until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the DRBt
indicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
HEATED SEAT MODULE
DESCRIPTION
The heated seat module is also known as the Seat
Heat Interface Module. The heated seat module (Fig.
14) is located under the left front seat cushion, where
it is secured to a mounting bracket via two push-pin
retainers. The heated seat module has a single con-
nector receptacle that allows the module to be con-
nected to all of the required inputs and outputs
through the seat wire harness.
The heated seat module is an electronic micropro-
cessor controlled device designed and programmed to
use inputs from the heated seat relay, the two heatedseat switches and the two heated seat sensors to
operate and control the heated seat elements in both
front seats and the two heated seat indicator lamp
Light-Emitting Diodes (LEDs) in each heated seat
switch. The heated seat module is also programmed
to perform self-diagnosis of certain heated seat sys-
tem functions and provide feedback of that diagnosis
through the heated seat switch indicator lamps.
The heated seat module cannot be repaired. If the
heated seat module is damaged or faulty, the entire
module must be replaced.
OPERATION
The heated seat module operates on fused battery
current received from a fuse in the junction block.
The module is grounded at all times. 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 cur-
rent to the heated seat elements and sensors, and
Fig. 14 Heated Seat Module
1 - Mounting Tabs (Not Used On KJ)
2 - Heated Seat Module
3 - Connector Receptacle
KJELECTRONIC CONTROL MODULES 8E - 21
TRANSMISSION CONTROL MODULE (Continued)

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING SYSTEM....................... 22STARTING SYSTEM....................... 32
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM.............................2
CLEANING.............................5
INSPECTION...........................6
SPECIFICATIONS........................6
SPECIAL TOOLS........................7
BATTERY
DESCRIPTION..........................7
DIAGNOSIS AND TESTING - BATTERY.......8
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.........................14STANDARD PROCEDURE - USING
MIDTRONICS ELECTRICAL TESTER.......15
REMOVAL.............................16
INSTALLATION.........................16
BATTERY HOLDDOWN
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................17
BATTERY CABLES
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - BATTERY
CABLES............................19
THERMAL GUARD
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
BATTERY TRAY
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The service infor-
mation for the battery system in this vehicle covers
the following related components, which are covered
in further detail elsewhere in this service manual: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.
KJENGINE SYSTEMS 8F - 1

²Battery Thermal Guard- The battery thermal
guard insulates the battery to protect it from engine
compartment temperature extremes.
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 proper battery jump start-
ing procedures. While battery charging can be consid-
ered a maintenance procedure, the battery charging
procedures and related information are located in the
service procedures section of this service manual.
This was done because the battery must be fully-
charged before any battery system diagnosis or test-
ing procedures can be performed. Refer to Standard
Procedures for the proper battery charging proce-
dures.
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 testedas 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 SYSTEMKJ
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 charging should only be performed when
absolutely necessary due to time restraints. A battery
is fully-charged when:
²All of the battery cells are gassing freely during
battery charging.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.65 volts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1É C [30É F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
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 acceptcharging 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. 6). 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-
Fig. 6 Voltmeter - Typical
KJBATTERY SYSTEM 8F - 9
BATTERY (Continued)

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 be
very 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 - 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.
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.
Fig. 7 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
8F - 10 BATTERY SYSTEMKJ
BATTERY (Continued)

Test the specific gravity of the electrolyte in each
battery cell. If the specific gravity of all cells is above
1.235, but the variation between cells is more than
fifty points (0.050), the battery should be replaced. If
the specific gravity of one or more cells is less than
1.235, charge the battery at a rate of approximately
five amperes. Continue charging the battery until
three consecutive specific gravity tests, taken at one-
hour intervals, are constant. If the cell specific grav-
ity variation is more than fifty points (0.050) at the
end of the charge period, replace the battery.
When the specific gravity of all cells is above 1.235,
and the cell variation is less than fifty points (0.050),
the battery may be load tested to determine its
cranking capacity. Refer to Standard Procedures for
the proper battery load test 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. 10).
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%
STANDARD PROCEDURE - LOAD TEST
A battery load test will verify the battery cranking
capacity. The test is based on the Cold Cranking
Amperage (CCA) rating of the battery. To determine
the battery CCA rating, see the label affixed to the
battery case or refer to Battery Specifications for the
proper factory-installed specifications.
Before proceeding with this test, completely charge
the battery (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
Fig. 9 Hydrometer - Typical
1 - BULB
2 - SURFACE COHESION
3 - SPECIFIC GRAVITY READING
4 - TEMPERATURE READING
5 - HYDROMETER BARREL
6 - FLOAT
Fig. 10 Testing Open-Circuit Voltage - Typical
8F - 12 BATTERY SYSTEMKJ
BATTERY (Continued)