Battery Cable: Service and Repair
Excessive resistance caused by poor terminal connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent the normal starter operation and cause hard starting.Whenever the battery cables are replaced, use a replacement cable that is the same in the type, the diameter, and the length. Some positive cables have additional teed wires attached to them and some of the negative cables have additional ground leads attached.
INSPECTION PROCEDURE
TOOLS REQUIRED
J 39200 Digital Multimeter
CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks:
1. Place the transmission in park.
2. Engage the parking brakes and block the wheels.
3. Disconnect the battery feed at the distributor.
1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame.
Place one probe of the J 39200 on the grounded battery post (not on the cable clamp) and the other on the frame.
Operate the starter and note the voltage reading.
2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating.
3. Check the voltage drop between the starter housing and the frame with the starter operating.
4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit.
In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned.
If the cables are frayed or the clamps are corroded, the cables should be replaced. When selecting the new cables, ensure that the new cables are the same length and the same diameter as the original cables being replaced.
REMOVAL PROCEDURE
Battery Negative Cable
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the battery negative cable bolt from the battery.
2. Disconnect the battery negative cable from the engine.
3. Disconnect any additional ground leads attached to the battery negative cable.
4. Remove the battery negative cable.
Battery Positive Cable
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the battery positive cable bolt from the battery.
2. Disconnect the battery positive cable from the starter motor.
3. Disconnect the additional battery positive cable lead to the electrical convenience center.
4. Remove the battery positive cable.
INSTALLATION PROCEDURE
Battery Negative Cable
1. For RWD, install the battery negative cable in the same position as the original.
2. For A4WD, install the battery negative cable in the same position as the original.
NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Connect the battery negative cable to the engine.
Tighten
Tighten the nut to 40 N.m (29 lb ft).
4. Install the engine harness to the stud.
Tighten
Tighten the nut to 25 N.m (18 lb ft).
5. Connect the battery negative cable ground lead to the radiator support.
Tighten
Tighten the stud to 45 N.m (33 lb ft).
6. Connect the battery negative terminal bolt to the battery.
Tighten
Tighten the bolt to 15 N.m (11 lb ft).
Battery Positive Cable
1. For RWD, install the battery positive cable in the same position as the original.
2. For A4WD, install the battery positive cable in the same position as the original.
NOTE:
^ When installing the positive battery cable to the starter solenoid, the inner nut on the solenoid battery terminal must be tightened before the battery cable and the other leads are installed. Failure to do so will result in the solenoid or the solenoid terminal damage.
^ Refer to Fastener Notice in Cautions and Notices.
3. Connect the battery positive cable to the starter solenoid.
Tighten
Tighten the nut to 9 N.m (80 lb in).
4. Connect the additional battery positive cable lead to the underhood electrical center.
Tighten
Tighten the nut to 9 N.m (80 lb in).
5. Connect the battery positive terminal bolt to the battery.
Tighten
Tighten the bolt to 15 N.m (11 lb ft).