Jeep XJ. Manual - part 84

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. 17). 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.

SERVICE PROCEDURES

BATTERY CHARGING

Battery charging is the means by which the bat-

tery can be restored to its full voltage potential. A
battery is fully-charged when:

• All of the battery cells are gassing freely during

battery charging.

• A green color is visible in the sight glass of the

battery built-in test indicator.

• Three hydrometer tests, taken at one-hour inter-

vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.

• Open-circuit voltage of the battery is 12.4 volts

or above.

Fig. 15 Test Battery Positive Connection Resistance

- Typical

1 – VOLTMETER
2 – BATTERY

Fig. 16 Test Battery Positive Cable Resistance -

Typical

1 – BATTERY
2 – VOLTMETER
3 – STARTER MOTOR

Fig. 17 Test Ground Circuit Resistance - Typical

1 – VOLTMETER
2 – BATTERY
3 – ENGINE GROUND

8A - 16

BATTERY

DIAGNOSIS AND TESTING (Continued)

WARNING:

•

IF THE BATTERY SHOWS SIGNS OF FREEZ-

ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.

•

EXPLOSIVE HYDROGEN GAS FORMS IN AND

AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.

•

THE BATTERY CONTAINS SULFURIC ACID,

WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT 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.

•

IF THE BATTERY IS EQUIPPED WITH REMOV-

ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

CAUTION:

•

Always disconnect and isolate the battery neg-

ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.

•

Battery electrolyte will bubble inside the bat-

tery case during normal battery charging. Electro-
lyte 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.

•

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 continuing
the charging operation. Damage to the battery may
result.

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 accept
charging 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 Battery in the index of
this service manual for the location of the battery
diagnosis and testing procedures for more informa-
tion on the proper battery load testing procedures. If
the battery will endure a load test, return the bat-
tery 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 in the index of this service
manual for the location of the proper battery clean-
ing and 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. 18). 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-
turer of the battery charger for details on how to
bypass the polarity-sensing circuitry.

Fig. 18 Voltmeter Accurate to 1/10 Volt Connected -

Typical

BATTERY

8A - 17

SERVICE PROCEDURES (Continued)

(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 chart. 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.

CHARGING TIME REQUIRED

The time required to charge a battery will vary,

depending upon the following factors:

• Battery Capacity

A completely discharged heavy-duty battery requires
twice the charging time of a small capacity battery.

• Temperature

A longer time will be needed to charge a battery at
-18° C (0° F) than at 27° C (80° F). When a fast bat-
tery charger is connected to a cold battery, the cur-
rent accepted by the battery will be very low at first.
As the battery warms, it will accept a higher charg-
ing current rate (amperage).

• Charger 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 charging time.

• State-Of-Charge

A completely discharged battery requires more charg-
ing time than a partially discharged battery. Electro-
lyte is nearly pure water in a completely discharged
battery. At first, the charging current (amperage) will
be low. As the battery charges, the specific gravity of
the electrolyte will gradually rise.

WARNING: NEVER

EXCEED

TWENTY AMPERES

WHEN CHARGING A COLD (-1° C or 30° F) BAT-
TERY. THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.

REMOVAL AND INSTALLATION

BATTERY CABLES

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.

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.

(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) Unlatch and remove the B(+) terminal stud

cover from the front of the Power Distribution Center
(PDC).

(7) Remove the nut that secures the battery posi-

tive cable eyelet terminal and the generator output
cable eyelet terminal to the B(+) terminal stud on the
PDC.

(8) Remove the battery positive cable eyelet termi-

nal and the generator output cable eyelet terminal
from the B(+) terminal stud on the PDC.

(9) Disconnect the battery wire harness connector

from the headlamp and dash wire harness connector
located below the front of the PDC.

Charge Rate

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

Battery Charging Timetable

Charging

Amperage

Amperes

Open

Circuit

Voltage

Hours Charging at 21° C (70° 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

*Refer to Charging A Completely Discharged Battery

8A - 18

BATTERY

SERVICE PROCEDURES (Continued)

(10) Remove the screw that secures the battery

negative cable eyelet terminal to the inner fender
shield near the battery.

(11) On LHD models with air conditioning, discon-

nect the compressor clutch wire harness connector
from the battery wire harness connector.

(12) Unlatch and remove the cover from the gener-

ator output terminal stud housing on the back of the
generator.

(13) Remove the nut that secures the generator

output cable eyelet terminal to the generator output
terminal stud.

(14) Remove the generator output cable eyelet ter-

minal from the generator output terminal stud.

(15) Disconnect the battery wire harness connector

from the generator field terminal connector recepta-
cle on the back of the generator.

(16) Remove the nut that secures the battery neg-

ative cable ground eyelet terminal to the stud on the
right side of the engine block.

(17) Remove the battery negative cable ground

eyelet terminal from the engine block stud.

(18) On models with a 2.5L engine, remove the nut

that secures the battery wire harness locator clip to
the stud on the right side engine block oil pan rail
below and forward of the engine oil filter adapter.

(19) On models with a 4.0L engine, remove the

screw that secures the battery wire harness locator
clip to the right side of the engine block between and
below the right engine mount and the oil filter
adapter.

(20) Remove the nut that secures the battery pos-

itive cable eyelet terminal to the B(+) terminal stud
on the starter solenoid.

(21) Remove the battery positive cable eyelet ter-

minal from the B(+) terminal stud on the starter
solenoid.

(22) Disconnect the battery wire harness connector

from the connector receptacle on the starter solenoid.

(23) Remove the battery wire harness from the

engine compartment.

INSTALLATION

(1) Clean and inspect the battery cable terminal

clamps and the battery terminal posts. Refer to Bat-
tery in the index of this service manual for the loca-
tion of the proper battery cable terminal clamp and
battery terminal post cleaning and inspection proce-
dures.

(2) Position the battery wire harness into the

engine compartment.

(3) Reconnect the battery wire harness connector

to the connector receptacle on the starter solenoid.

(4) Install the battery positive cable eyelet termi-

nal onto the B(+) terminal stud on the starter sole-
noid.

(5) Install and tighten the nut that secures the

battery positive cable eyelet terminal to the B(+) ter-
minal stud on the starter solenoid. Tighten the nut to
10 N·m (90 in. lbs.).

(6) On models with a 2.5L engine, install and

tighten the nut that secures the battery wire harness
locator clip to the stud on the right side engine block
oil pan rail below and forward of the engine oil filter
adapter. Tighten the nut to 8.4 N·m (75 in. lbs.).

(7) On models with a 4.0L engine, install and

tighten the screw that secures the battery wire har-
ness locator clip to the right side of the engine block
between and below the right engine mount and the
oil filter adapter. Tighten the screw to 8.4 N·m (75 in.
lbs.).

(8) Install the battery negative cable ground eyelet

terminal onto the stud on the right side of the engine
block.

(9) Install and tighten the nut that secures the

battery negative cable ground eyelet terminal to the
stud on the right side of the engine block. Tighten
the nut to 15.8 N·m (140 in. lbs.).

(10) Reconnect the battery wire harness connector

to the generator field terminal connector receptacle
on the back of the generator.

(11) Install the generator output cable eyelet ter-

minal onto the generator output terminal stud.

(12) Install and tighten the nut that secures the

generator output cable eyelet terminal to the genera-
tor output terminal stud. Tighten the nut to 8.4 N·m
(75 in. lbs.).

(13) Position the cover for the generator output

terminal stud housing onto the back of the generator
and snap it into place.

(14) On LHD models with air conditioning, recon-

nect the compressor clutch wire harness connector to
the battery wire harness connector.

(15) Install and tighten the screw that secures the

battery negative cable eyelet terminal to the inner
fender shield near the battery. Tighten the screw to
24.8 N·m (220 in. lbs.).

(16) Reconnect the battery wire harness connector

to the headlamp and dash wire harness connector
located below the front of the PDC.

(17) Install the battery positive cable eyelet termi-

nal and the generator output cable eyelet terminal
onto the PDC B(+) terminal stud.

(18) Install and tighten the nut that secures the

battery positive cable eyelet terminal and the gener-
ator output cable eyelet terminal to the PDC B(+)
terminal stud. Tighten the nut to 10.7 N·m (95 in.
lbs.).

(19) Engage the tabs on the lower edge of the B(+)

terminal stud cover in the slots on the front of the
PDC housing, then engage the latch on the top of the
cover with the latch tabs on the PDC housing.

BATTERY

8A - 19

REMOVAL AND INSTALLATION (Continued)

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