2008 ELECTRICAL

Battery System - Service Information - Liberty

BATTERY SYSTEM - SERVICE INFORMATION

DESCRIPTION

BATTERY SYSTEM

This vehicle is equipped with a single 12-volt battery. All of the components of the battery system are located
within the engine compartment of the vehicle. The battery system for this vehicle contains the following
components:

 Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy
within the vehicle.
 Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to

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the vehicle electrical system.
 Battery Hold down - The battery hold down hardware secures the battery in the battery tray.
 Battery Thermal Guard - The battery thermal guard insulates the battery to protect it from engine
compartment temperature extremes.
 Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an
anchor point for the battery hold down hardware.

For battery system maintenance schedules, refer to DESCRIPTION . For the proper jump starting procedures,
refer to STANDARD PROCEDURE .

OPERATION

BATTERY SYSTEM

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 accessory 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 system 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 tested as a
complete system. In order for the engine to st y 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 thoroughly tested and inspected any time a battery needs to be charged or
replaced. The cause of abnormal battery 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 information to make it easier to locate the specific
information you are seeking. However, when attempting to diagnose any of these systems, it is important that
you keep their interdependency 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/ohmmeter, 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 Trouble Code (DTC). The PCM
will store a DTC in electronic memory for any failure it detects. Refer to DIAGNOSIS AND TESTING for the
proper charging system on-board diagnostic test procedures.

MICRO 420 ELECTRICAL SYSTEM TESTER

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The Micro 420 automotive battery system tester is designed to help diagnose the cause of a defective battery.
See STANDARD PROCEDURE for directions on using the Micro 420 battery tester.

BATTERY SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS WEAK 1. The electrical system 1. See STANDARD PROCEDURE for the
OR DEAD WHEN ignition-off draw is proper test procedures. Repair the excessive
ATTEMPTING TO START THE excessive. ignition-off draw, as required.
ENGINE. 2. The charging system is 2. Determine if the charging system is
inoperative. performing to specifications, refer to
DIAGNOSIS AND TESTING . Repair the
inoperative charging system, as required.
3. The battery is 3. Determine the battery state-of-charge
discharged. using the Micro 420 battery tester, see
STANDARD PROCEDURE. Charge the
battery as required.
4. The battery terminal 4. See DIAGNOSIS AND TESTING.
connections are loose or Clean and tighten the battery terminal
corroded. connections, as required.
5. The battery has an 5. See SPECIFICATIONS for the proper
incorrect size or rating size and rating. Replace an incorrect
for this vehicle. battery, as required.
6. The battery is 6. Determine the battery cranking capacity
inoperative. using the Micro 420 battery tester, see
STANDARD PROCEDURE. Replace the
inoperative battery, as required.
7. The starting system is 7. Determine if the starting system is
inoperative. performing to specifications. Refer to
DIAGNOSIS AND TESTING . Repair the
 inoperative starting system, as required.
8. The battery is 8. Inspect the battery for loose terminal
physically damaged. posts or a cracked and leaking case. Replace
the damaged battery, as required.
THE BATTERY STATE OF 1. The battery has an 1. See SPECIFICATIONS for the proper
CHARGE CANNOT BE incorrect size or rating size and rating. Replace an incorrect
MAINTAINED. for this vehicle. battery, as required.
2. The battery terminal 2. See DIAGNOSIS AND TESTING.
connections are loose or Clean and tighten the battery terminal
corroded. connections, as required.
3. The electrical system 3. See STANDARD PROCEDURE for the
ignition-off draw is proper test procedures. Repair the
excessive. inoperative electrical system, as required.
4. The battery is 4. Test the battery using the Micro 420
inoperative. battery tester, see STANDARD
PROCEDURE. Replace the inoperative
battery, as required.

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5. The starting system is 5. Determine if the starting system is
inoperative. performing to specifications. Refer to
DIAGNOSIS AND TESTING . Repair the
inoperative starting system, as required.
6. The charging system is 6. Determine if the charging system is
inoperative. performing to specifications, refer to
DIAGNOSIS AND TESTING . Repair the
inoperative charging system, as required.
7. Electrical loads exceed 7. Inspect the vehicle for aftermarket
the output of the electrical equipment which might cause
charging system. excessive electrical loads.
8. Slow driving or 8. Advise the vehicle operator, as required.
prolonged idling with
high-amperage draw
systems in use.
THE BATTERY WILL NOT 1. The battery is 1. Test the battery using the Micro 420
ACCEPT A CHARGE. inoperative. battery tester, see STANDARD
PROCEDURE. Replace the inoperative
battery, as required.

STANDARD PROCEDURE

BATTERY CONNECTION PROCEDURE

NOTE: This reconnection procedure is to be performed anytime the battery has been
disconnected.

1. Connect the battery negative cable to the battery post and tighten the clamp nut.
2. Install the rear compartment floor trim panel.
 CAUTION: Once the battery has been connected, review and perform the following
information as applicable.

ELECTRONIC STABILITY PROGRAM (ESP)

If the vehicle is equipped with ESP, once the battery is reconnected, the Steering Angle Sensor (SAS) in the
clockspring needs to be calibrated. The SAS requires calibration anytime the battery or an ABS (ESP)
component has been disconnected for any length of time. If the SAS is not calibrated following battery
reconnection, the ESP/BAS indicator lamp is illuminated following five ignition cycles indicating the need
for calibration.

To calibrate, perform the following:

1. Start the engine.

2. Center the steering wheel.
3. Turn the steering wheel all the way to the left until the internal stop in the steering gear is met, then turn

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the wheel all the way to the right until the opposite internal stop in the steering gear is met.
4. Center the steering wheel.
5. Stop the engine.

CLEANING

BATTERY SYSTEM

The following information details the recommended cleaning procedures for the battery and related
components. In addition to the maintenance schedules found in this service information and the Owner's
Manual, it is recommended that these procedures be performed any time the battery or related components must
be removed for vehicle service.
Fig. 1: Cleaning Battery Cable Terminal Clamps Of All Corrosion And Removing Any Corrosion Using
Wire Brush
Courtesy of CHRYSLER LLC

1. Clean the battery cable terminal clamps (2) of all corrosion. Remove any corrosion using a wire brush (1)
or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning
solution.
2. Clean the battery tray and battery hold down 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.

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Fig. 2: Removing Acid Film
Courtesy of CHRYSLER LLC

3. If the removed battery is to be reinstalled, clean the outside of the battery case (3) and the top cover with
a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning
brush (1) to remove any acid film. 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. See
SPECIFICATIONS for the factory-installed battery specifications. Confirm that the replacement battery
is the correct size and has the correct ratings for the vehicle.
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.
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Fig. 3: Cleaning Any Corrosion From Battery Terminal Posts With Wire Brush Or Post And
Terminal Cleaner
Courtesy of CHRYSLER LLC

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.

INSPECTION

BATTERY SYSTEM

The following information details the recommended inspection procedures for the battery and related
components. In addition to the maintenance schedules found in this service information and the owner's manual,
it is recommended that these procedures be performed any time the battery or related components must be
removed for vehicle service.

1. Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or
deformed terminal clamp.
2. Inspect the battery tray and battery hold down hardware for damage. Replace any damaged parts.
3. Slide the thermal guard off of the battery case (if equipped). Inspect the battery case for cracks or other
damage that 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 (if equipped). Replace
any battery thermal guard that has been damaged.
5. Inspect the battery built-in test indicator sight glass (if equipped) for an indication of the battery
condition. If the battery is discharged, charge as required.

SPECIFICATIONS
BATTERY SYSTEM

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.

 Group Size - The outside dimensions and terminal 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 replacement.
 Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (in
amperes) the battery can deliver for thirty seconds at -18° C (0° 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.
 Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery
terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the

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battery fully-charged at 26.7° C (80° F). This rating estimates how long the battery might last after a
charging system failure, under minimum electrical load.
 Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can
deliver steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating
is also sometimes identified as the twenty-hour discharge rating.
 Load Test Amperage - The Load Test Amperage rating specifies the current (in amperes) that a battery
should be tested at with the battery load test equipment. This value should always be 50 percent of the
CCA. For example: if the CCA for this battery is 700 amps, the Load Test Amperage is 50 percent of that
or 350 amps.

BATTERY CLASSIFICATIONS & RATINGS

BCI Group Size Cold Cranking Reserve Ampere - Load Test
Part Number
Classification Amperage Capacity Hours Amperage
04609365AE 34 600 120 Minutes 66 300
05148004AA 27 800 150 Minutes 75 400

SPECIFICATIONS-TORQUE BATTERY

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Battery Terminal Clamp
5 - 45
Pinch-Bolt Hex Nut
Battery Hold Down Bolt 7 - 62
Starter Solenoid B(+)
13 - 115
Terminal Stud Nut
Battery Negative Cable 16.5 - 145
Ground Eyelet Terminal
To Engine Block Bolt
Generator Output 14 - 125
 Terminal Stud Nut
Totally Integrated Power 10 - 90
Module B(+) Terminal
Stud Nut
Battery Negative Cable
Eyelet Terminal To The 12 9 -
Inner Fender Bolt
Battery Tray Nut 10.5 - 93

SPECIAL TOOLS

SPECIAL TOOLS

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Fig. 4: Battery System Special Tools
Courtesy of CHRYSLER LLC

BATTERY

DESCRIPTION

BATTERY

Low-maintenance conventional batteries are used on vehicles equipped with a gasoline engine, these batteries
have non-removable battery cell caps. Under normal service, the composition of this battery reduces gassing
and water loss at normal charge rates.

Conventional batteries are made up of six individual cells that are connected in series. Each cell contains
positive charged cell groups made of lead oxide, and negatively charged cell groups made of sponge lead. The
cells are submerged in a sulfuric acid and water solution called electrolyte.
The battery is used to store electrical energy potential in a chemical form. When an electrical load is applied to
the battery terminals, an electrochemical reaction occurs within the battery. This reaction causes the battery to
discharge electrical current.

OPERATION

BATTERY

The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the
terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge
electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within
each cell. The sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly
change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from
the sulfuric acid, causing the electrolyte to become mainly water. The chemical changes within the battery are
caused by the movement of excess or free electrons between the positive and negative plate groups. This
movement of electrons produces a flow of electrical current through the load device attached to the battery
terminals.

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As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage
potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery
itself, the battery discharging process is reversed. Charging the battery gradually changes the sulfated lead
plates back into sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the
difference in the electron charges deposited on the plates, and the voltage potential of the battery cells. For a
battery to remain useful, it must be able to produce high-amperage current over an extended period. A battery
must also be able to accept a charge, so that its voltage potential may be restored.

The battery is vented to release excess hydrogen gas that is created when the battery is being charged or
discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas
is exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may arc internally and
explode. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is
below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the
electrolyte level becomes low.

DIAGNOSIS AND TESTING

BATTERY

The battery must be completely charged and the terminals should be properly cleaned and inspected before
diagnostic procedures are performed. See CLEANING, and INSPECTION for the proper battery cleaning and
inspection procedures. See STANDARD PROCEDURE for the proper battery charging procedures.

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery tester is designed to help diagnose the cause of an inoperative battery. See
STANDARD PROCEDURE for instructions on the use of the Micro 420 battery tester.

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
BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE 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.

A battery that will not accept a charge is inoperative, 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 inoperative and must be replaced.

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NOTE: Completely discharged batteries may take several hours to accept a charge.

STANDARD PROCEDURE

CONVENTIONAL BATTERY CHARGING

CAUTION: Vehicles equipped with a diesel engine utilize a unique spiral cell battery.
This battery has a maximum charging voltage that must be used in order
to restore the battery to its full potential, failure to use the spiral cell
battery charging procedure could result in damage to the battery or
personal injury. See STANDARD PROCEDURE for the appropriate
procedure.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is
fully-charged when:

Micro 420 battery tester indicates battery is OK.

Open-circuit voltage of the battery is 12.65 volts or above.
Battery passes Load Test multiple times.

WARNING: If the battery shows signs of freezing, leaking, 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 battery. Personal injury and/or
vehicle damage 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 is in place and tight before the battery is returned to service.
Personal injury and/or vehicle damage may result from loose or missing
cell caps.

CAUTION: Always disconnect and isolate the battery negative cable before charging
a battery. Do not exceed sixteen volts while charging a battery. Damage to
the vehicle electrical system components may result.

CAUTION: Battery electrolyte will bubble inside the battery case during normal
battery charging. Electrolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition. Immediately reduce the

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

After the battery has been charged to an open-circuit voltage reading of 12.4 volts or greater, retest the battery
with the Micro 420 tester or perform a load test to determine the battery cranking capacity. See STANDARD
PROCEDURE for the proper battery test procedures. If the battery passes a load test, return the battery to
service. If the battery fails 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. See
CLEANING for the proper battery system cleaning procedures. See INSPECTION for the proper battery
system inspection procedures.

CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is
properly followed, a good battery may be needlessly replaced.
Fig. 5: Conventional Battery Charger
Courtesy of CHRYSLER LLC

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1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the reading is
below ten volts, the battery charging current will be low. It could take some time before the battery
accepts a current greater than a few milliamperes. 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 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.
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 measurable at the end of the charging time, the battery is faulty
and must be replaced. If the charging current is measurable during the charging time, the battery may be
good and the charging should be completed in the normal manner.

CONVENTIONAL BATTERY CHARGE RATE TABLE

Voltage Minutes
16.0 volts maximum up to 10 min.
14.0 to 15.9 volts up to 20 min.
13.9 volts or less up to 30 min.

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 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).
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 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 battery charges, the specific gravity of the electrolyte
will gradually rise.

The CONVENTIONAL BATTERY CHARGING TIME TABLE gives an indication of the time required to
charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

CONVENTIONAL BATTERY CHARGING TIME TABLE

Charging
5 Amps 10 Amps 20 Amps
Amperage
Open
Circuit Hours Charging @ 21° C (70° F)

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Voltage
12.25 to 6 hours 3 hours 1.5 hours
12.49
12.00 to 10 hours 5 hours 2.5 hours
12.24
10.00 to 14 hours 7 hours 3.5 hours
11.99
Below 10.00 18 hours 9 hours 4.5 hours

IGNITION-OFF DRAW TEST

NOTE: Verify all vehicle electronic modules are in "sleep mode" prior to performing
this test. Failure to do so could result in inaccurate digital multi-meter readings.

The term Ignition-Off Draw (IOD) identifies a normal 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 Control 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 approximately 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 Totally
Integrated Power Module (TIPM). This will reduce battery discharging.

Excessive IOD can be caused by:

Electrical items left on.

Faulty or improperly adjusted switches
 Faulty or shorted electronic modules and components.
An internally shorted generator.
Intermittent shorts in the wiring.

If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing 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 illuminated 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.
2. Determine that the underhood lamp is operating 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

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disconnected battery negative cable terminal 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 to three 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 battery 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.
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 Totally Integrated Power Module (TIPM),
one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate
wiring information for complete TIPM 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
DIAGNOSIS AND TESTING for the proper charging system diagnosis and testing procedures. After
the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage
scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and
correct all sources of excessive IOD. It is now safe to select the lowest milliampere 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-amperage IOD should not exceed thirty-five milliamperes
(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.

OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery.

Before proceeding with this test, completely charge the battery. Refer to the appropriate battery charging
procedure.

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Fig. 6: Circuit Voltage Tester
Courtesy of CHRYSLER LLC

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, negative cable first.
3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the
voltmeter), measure the open-circuit voltage.

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.

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%

USING MICRO 420 BATTERY TESTER

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Fig. 7: Micro 420 Battery Tester
Courtesy of CHRYSLER LLC

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 procedure 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 testing. If
the battery is equipped with side post terminals, install and tighten the supplied lead terminal stud
adapters. Do not use steel bolts. Failure to properly install the stud adapters, or using stud adapters that
are dirty or worn-out may result in false test readings.
2. If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF,
including the ignition.
3. Connect the tester to the battery, the red clamp to the positive (+) terminal and the black clamp to the
negative (-) terminal.

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 select in or out of vehicle testing and press ENTER to make a selection.
5. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery
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 BATTERY TEST RESULTS TABLE.
 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
disconnecting the vehicle's battery cables from the battery, 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

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NOTE: The SERVICE CODE is required on every warranty claim submitted for battery
replacement.

REMOVAL

BATTERY

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty
rubber gloves should be worn when removing or servicing a battery.
Safety glasses also should be worn.

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery

current.
Fig. 8: Battery Negative Cable, Bolt, Retainer, Battery Tray, Battery & Battery Positive Cable
Courtesy of CHRYSLER LLC

NOTE: Left hand drive shown in illustration, right hand drive similar.

1. Loosen the pinch clamp bolt and disconnect and isolate the battery negative cable (1).
2. Loosen the pinch clamp bolt and disconnect the battery positive cable (6).
3. Loosen bolt (2) and remove the retainer (3) that holds the battery (5) to the battery tray (4).

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Fig. 9: Thermal Guard & Battery
Courtesy of CHRYSLER LLC

4. Remove the battery from the vehicle.

5. Remove thermal guard (1) from battery (2).

INSTALLATION

BATTERY

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty
rubber gloves should be worn when removing or servicing a battery.
Safety glasses also should be worn.

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery

current.
Fig. 10: Thermal Guard & Battery
Courtesy of CHRYSLER LLC

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NOTE: Left hand drive shown in illustration, right hand drive similar.

NOTE: When replacing battery, the thermal guard MUST be transferred to the new
battery.

1. Carefully install the thermal guard (1) onto the battery (2).

Fig. 11: Battery Negative Cable, Bolt, Retainer, Battery Tray, Battery & Battery Positive Cable
Courtesy of CHRYSLER LLC

2. Install battery (5) into the vehicle making sure that the thermal guard is present and battery is properly
positioned on battery tray (4).
3. Install the battery hold down retainer (3) and bolt (2) making sure that it is properly positioned on battery
(5). Tighten the hold down bolt to 7 N.m (62 in. lbs.)
 4. Connect the battery positive cable (6) and tighten the pinch clamp nut to 5 N.m (45 in. lbs.)
5. Connect the battery negative cable (1) and tighten the pinch clamp nut to 5 N.m (45 in. lbs.)
6. Verify proper vehicle operation.

BATTERY CABLES

DESCRIPTION

BATTERY CABLE

The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber
insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high
electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of
stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at
the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite
end of the battery cable wire and then soldered. The battery positive cable wires feature a larger female battery
terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires

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have a smaller female battery terminal clamp.

Both the battery positive and negative cables are available for service replacement only as a unit with the
battery wire harness, which may include portions of the wiring circuits for the generator and other components
on some vehicles.

OPERATION

BATTERY CABLE

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 restoring 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
provide secure and reliable connection of the battery cables to the vehicle electrical system.

One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally
Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp
has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a
ground connection, typically on the engine cylinder block.

DIAGNOSIS AND TESTING

BATTERY CABLES

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or
the battery cable. If excessive resistance is found in the battery cable connections, the connection point should
be disassembled, cleaned of all corrosion 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 important to remember that the voltage drop is giving an indication
of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing
the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp
and to the battery positive 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:

The battery is fully-charged and load tested.

Fully engage the parking brake.

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If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park
position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the
Neutral position and block the clutch pedal in the fully depressed position.
Verify that all lamps and accessories are turned off.
To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can
be found in the Fuse Block located in the left front bumper fascia. See the fuse and relay layout label
affixed to the underside of the Fuse Block cover for ASD relay identification and location.

Fig. 12: Connecting Positive Lead Of Voltmeter To Battery Negative Terminal Post
Courtesy of CHRYSLER LLC

1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the
negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the
ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor
connection between the battery negative cable terminal clamp and the battery negative terminal post.
 Fig. 13: Connecting Positive Lead Of Voltmeter To Battery Positive Terminal Post
Courtesy of CHRYSLER LLC

2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the
negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the

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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.

Fig. 14: Connecting Voltmeter To Measure Between Battery Positive Cable Terminal Clamp And
Starter Solenoid B(+) Terminal Stud
Courtesy of CHRYSLER LLC

3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter
solenoid B(+) terminal stud (3). 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
connection 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.
 Fig. 15: Connecting Voltmeter To Measure Between Battery Negative Cable Terminal Clamp And
Good Clean Ground On Engine Block
Courtesy of CHRYSLER LLC

4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good
clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe

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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

BATTERY CABLE

Fig. 16: Battery Cable Assembly

Courtesy of CHRYSLER LLC

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery

current.
NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and
diesel similar.

1. Loosen the pinch clamp bolt and disconnect and isolate the battery negative cable (2).
2. Loosen the pinch clamp bolt and disconnect the battery positive cable (1).
3. Remove the negative cable retaining stud (7) from the mounting surface on the inner fender. Remove the
cable (6) from the stud.
4. Disconnect the cable assembly routing clips from the inner fender.

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Fig. 17: TIPM Positive Cable Retaining Nut, Cable, Mounting Stud & Totally Integrated Power
Module (TIPM) Cover
Courtesy of CHRYSLER LLC

5. Remove the positive cable retaining nut (1) from the mounting stud on the Totally Integrated Power
Module (3). Remove the cable (2) from the stud.
 cardiagn.com
Fig. 18: Removing/Installing Positive Battery Cable Nut From/To B+ Terminal Of Generator &
Cable From/To Generator
Courtesy of CHRYSLER LLC

6. Remove the positive battery cable nut (1) from the B+ terminal of the generator (5). Remove the cable (2)
from the generator.

Fig. 19: Negative Battery Cable Nut, Mounting Stud, Starter Motor, Positive Battery Cable Nut,
Battery Cable Retaining Pushpins & Cables
Courtesy of CHRYSLER LLC

7. Remove the positive battery cable nut (4) from the B+ terminal of the starter motor (3). Remove the cable
(7) from the starter.
8. Remove the negative battery cable nut (1) from the mounting stud (2) on the engine block. Remove the
 cable (8) from the stud.
9. One at a time, trace any remaining battery cable retaining pushpins (6), fasteners and routing clips until
the cables are free from the vehicle.
10. Remove the battery cables from the engine compartment.

INSTALLATION

BATTERY CABLE

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Fig. 20: Negative Battery Cable Nut, Mounting Stud, Starter Motor, Positive Battery Cable Nut, Battery
Cable Retaining Pushpins & Cables
Courtesy of CHRYSLER LLC

WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery

current.

NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and
diesel similar.

1. Position the battery cables in the engine compartment.

2. One at a time, install the battery cable retaining pushpins (6), fasteners and routing clips until the cables
are installed exactly where they were in the vehicle.
3. Install the negative battery cable (8) to the mounting stud (2) on the engine block. Install the negative
battery cable retaining nut (1).
4. Connect the positive battery cable (7) to the B+ terminal of the starter motor (3). Install the retaining nut
(4) and tighten it to 13 N.m (115 in. lbs.).
 cardiagn.com
Fig. 21: Removing/Installing Positive Battery Cable Nut From/To B+ Terminal Of Generator &
Cable From/To Generator
Courtesy of CHRYSLER LLC

5. Connect the positive battery cable (2) to the B+ terminal of the generator (5). Install the retaining nut (1)
and tighten it to 14 N.m (125 in. lbs.).

Fig. 22: TIPM Positive Cable Retaining Nut, Cable, Mounting Stud & Totally Integrated Power
Module (TIPM) Cover
Courtesy of CHRYSLER LLC

6. Position the Totally Integrated Power Module (TIPM) positive cable (2) onto the mounting stud (3) and
install the retaining nut (1). Tighten the nut to 9 - 11 N.m (80 - 100 in. lbs.). Close the TIPM cover (4).
 cardiagn.com
Fig. 23: Battery Cable Assembly
Courtesy of CHRYSLER LLC

7. Connect the battery cable assembly routing clips to the inner fender.
8. Position the negative battery cable (6) onto the mounting stud (7). Install the mounting stud onto the inner
fender and tighten to 12 N.m (9 ft. lbs.)
9. Connect the battery positive cable (1). Tighten the cable clamp nut to 5 N.m (45 in. lbs.)
10. Connect the battery negative cable (2). Tighten the cable clamp nut to 5 N.m (45 in. lbs.)

BATTERY TRAY

DESCRIPTION

BATTERY TRAY

Fig. 24: Nuts, Plastic Battery Tray & Inner Fender

Courtesy of CHRYSLER LLC

NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and
diesel similar.

The battery is placed and secured in a plastic battery tray (2). The battery tray is located in the left front side of
the vehicle and is secured to the inner fender (3) with three nuts (1).

REMOVAL

BATTERY TRAY

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Fig. 25: Electrical Connector, Battery, Battery Tray & Solenoid
Courtesy of CHRYSLER LLC

NOTE: Left hand drive gasoline engine shown in illustration, right hand drive and
diesel similar.

1. Disconnect and isolate the battery negative cable.

2. Remove the battery. See REMOVAL.
3. On gasoline engine equipped vehicles, disconnect the purge solenoid vacuum hose and electrical
connector (1). Using an appropriate flat bladed tool, remove the solenoid (4) from the battery tray (3) by
disengaging the solenoid mounting clip and lifting it up off the battery tray mounting tab.
 Fig. 26: TIPM Positive Cable Retaining Nut, Cable, Mounting Stud & Totally Integrated Power
Module (TIPM) Cover
Courtesy of CHRYSLER LLC

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4. Open the Totally Integrated Power Module (TIPM) cover (4).
5. Remove the TIPM positive cable retaining nut (1) and remove the cable (2) from the mounting stud (3).

Fig. 27: Identifying Integrated Power Module (TIPM), TIPM Mounting Bracket & Mounting Tabs
Courtesy of CHRYSLER LLC

6. Using an appropriate flat bladed tool, depress the four mounting clips to disengage and remove the TIPM
housing (1) from the TIPM bracket mounting tabs (3).
 Fig. 28: Disconnecting/Connecting TIPM Wire Harness Connectors
Courtesy of CHRYSLER LLC

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7. Disconnect each of the seven TIPM wire harness connectors from the TIPM housing (2).
8. Remove the TIPM from the vehicle.

Fig. 29: TIPM Bracket Retaining Screws, Bracket, Mounting Tabs & Battery Tray
Courtesy of CHRYSLER LLC

9. Remove the TIPM bracket retaining screws (1) and slide the bracket (2) rearward to disengage the
mounting tabs (3). Remove the TIPM bracket from the battery tray (4).
 Fig. 30: Nuts, Plastic Battery Tray & Inner Fender
Courtesy of CHRYSLER LLC

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10. Remove the three nuts (1) securing the battery tray (2) to the left inner fender (3).
11. Lift the battery tray out of the engine compartment and remove from the vehicle.

INSTALLATION

INSTALLATION

Fig. 31: Nuts, Plastic Battery Tray & Inner Fender

Courtesy of CHRYSLER LLC

1. Position the battery tray (2) into the engine compartment and onto the mounting studs on the left inner
fender (3).
2. Install the nuts (1) securing the battery tray (2) to the left inner fender (3).
3. Tighten the nuts to 10.5 N.m (93 in. lbs.)
 Fig. 32: TIPM Bracket Retaining Screws, Bracket, Mounting Tabs & Battery Tray
Courtesy of CHRYSLER LLC

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4. Position the TIPM bracket (2) onto the battery tray (4). Slide the bracket (2) forward to engage the slots in
the bracket with the mounting tabs of the battery tray (3). Install the TIPM bracket retaining screws (1)
into the battery tray (4).

Fig. 33: Disconnecting/Connecting TIPM Wire Harness Connectors

Courtesy of CHRYSLER LLC

5. Position the TIPM (2) into the engine compartment.

6. Connect each of the seven TIPM wire harness connectors as shown in illustration.
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Fig. 34: Identifying Integrated Power Module (TIPM), TIPM Mounting Bracket & Mounting Tabs
Courtesy of CHRYSLER LLC

7. Position the TIPM (1) onto the mounting bracket (2) and push down until the mounting clips are fully
seated onto the mounting tabs (3).

Fig. 35: TIPM Positive Cable Retaining Nut, Cable, Mounting Stud & Totally Integrated Power
Module (TIPM) Cover
Courtesy of CHRYSLER LLC

8. Position the TIPM positive cable (2) onto the mounting stud (3) and install the retaining nut (1). Tighten
the nut to 9 - 11 N.m (80 - 100 in. lbs.).
 Fig. 36: Electrical Connector, Battery, Battery Tray & Solenoid
Courtesy of CHRYSLER LLC

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9. On gasoline engine equipped vehicles, position the purge solenoid (4) onto the mounting tab of the
battery tray (3) and push downward until the solenoid locks into place. Connect the purge solenoid
vacuum hose and electrical connector (1).
10. Install the battery. See INSTALLATION.
11. Connect the battery negative cable.
12. Close the hood.
13. Insert the ignition key and turn it to the "RUN" position and wait twelve seconds. The TIPM will collect
the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve
seconds turn the ignition key to the "OFF" position and then back to the "ON" position and verify proper
vehicle systems operation.

THERMAL GUARD

DESCRIPTION

THERMAL GUARD
Fig. 37: Thermal Guard & Battery
Courtesy of CHRYSLER LLC

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On gasoline engine equipped vehicles, a flexible thermal guard (1) wraps around the battery case (2) to enclose
the sides of the battery. The thermal guard (1) consists of a plastic cloth outer skin with a polyester based
insulator fiber.

REMOVAL

REMOVAL

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty
rubber gloves, not the household type, should be worn when removing or
servicing a battery. Safety glasses also should be worn.

1. Disconnect and isolate the battery negative cable.

2. Remove the battery. See REMOVAL.
3. Carefully lift the thermal guard off over the battery taking care not to tear it.
4. Remove the thermal guard from battery.

INSTALLATION

INSTALLATION

NOTE: When replacing battery, the thermal guard MUST be transferred to the new
battery.

1. Slip the battery thermal guard over the battery being careful not to tear it.
2. Install the battery into the vehicle. See INSTALLATION.
3. Connect the battery negative cable.