Battery Testing & Inspection (Non-Hp2)

CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be off, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

NOTE:

The battery test using the Battery Tester (J-42000) requires correct connections to the battery terminals. A failure to obtain the correct connections during the test may result in a failed test on a good battery.
Use the Out of Vehicle test for each battery when testing a vehicle with dual batteries.

Follow these instructions in order to avoid an incorrect diagnosis because of connections:

If testing the vehicle with the battery cables still connected, wiggle the battery tester clips on the terminal bolt. This may cut through any coating or through any oxidation that may be present on the bolt. Even NEW bolts contain a protective coating that may insulate or cause a resistance in the test circuit.
If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following steps:
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Install the test adapters on the terminals.
4. Follow the instructions for testing a removed battery.
If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the vehicle with the battery cables connected, perform the following steps:
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Install the tester adapters.
  NOTE: Always write the test code displayed by the tester on the repair order for any warranty purposes. The number is a unique code that describes the test data for a particular battery at a particular time. The test code may occasionally repeat when you retest the same battery. More often, each test will result in a different code. Use the test code from the second, or Out of Vehicle test.
4. Follow the instructions for testing a removed battery.
5. Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result. Use the test code from the second test for any warranty purposes.
Use the correct terminal adapters. DO NOT use any common bolts or a combination of bolts, of nuts, and of washers as adapters when testing the battery. Use the test adapters that are provided with the battery tester or GM Terminal Adapters (12303040). If the adapters that are provided with the battery tester require replacement, use GM (12303040). Any other adapter may not contact the correct areas of the battery terminal, causing a resistance that may result in an invalid battery test result.

NOTE: Manufacturer recommends using Battery Tester (J-42000) for testing battery. Follow instructions provided with tester.

Inspect battery for a cracked, broken or damaged case. If battery is okay, go to next step. If battery case is not okay, go to step 19.

Compare battery Cold Cranking Amperage (CCA) and Reserve Capacity (RC) to specifications. See BATTERY SPECIFICATIONS table. If battery meets or exceeds specifications, go to next step. If battery does not meet or exceed specifications, go to step 19.

BATTERY SPECIFICATIONS

Application			Specification
C/K Series (Pickup & Utility)
Standard
Replacement Battery Number			78-6YR
Cold Cranking Amps			600 Amps
Reserve Capacity			115 Minutes
Optional
Replacement Battery Number			78-7YR
Cold Cranking Amps			770 Amps
Reserve Capacity			115 Minutes
Optional (Dual Batteries)			GM Pt.# 19001814

Inspect battery hydrometer display. If hydrometer display shows a Yellow dot, go to next step. If hydrometer display does not show a Yellow dot, go to step 5.
Using a small screwdriver, tap top of hydrometer display to dislodge any air bubbles inside. If hydrometer display still shows a Yellow dot, go to step 19. If hydrometer display does not show a Yellow dot, go to next step.
Turn ignition switch off. Attempt to rotate negative battery cable connector clockwise with light finger pressure. If negative connector rotates, go to next step. If negative connector does not rotate, go to step 7.
Use a torque wrench in order to verify the torque to loosen the negative battery terminal bolt. If torque is equal to or greater than specification, go to step 8. If torque is less than specification, go to next step.
Disconnect negative battery cable and go to step 9.
Disconnect negative battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
Attempt to rotate positive battery cable connector clockwise with light finger pressure. If battery cable rotates, go to next step. If battery cable does not rotate, go to step 11.
Use a torque wrench in order to verify the torque to loosen the positive battery terminal bolt. If torque is equal to or greater than specification, go to step 12. If torque is below specification, go to next step.
Disconnect positive battery cable and go to step 13.
Disconnect positive battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
Clean and wire brush lead face of both battery terminals and metal contact surfaces on both cable connectors. Remove bolts from both battery cable connectors and inspect for corrosion and defects. Repair or replace as necessary. If battery and cables terminals are clean and in good condition, go to next step.
Connect positive battery cable to battery and tighten bolt to specification. See TORQUE SPECIFICATIONS . Go to next step.
Connect negative battery cable to battery and tighten bolt to specification. See TORQUE SPECIFICATIONS . Go to next step.
Ensure all electrical loads are off. Follow manufacturers instructions and install Battery Tester (J-42000) to vehicle battery. Follow any instructions displayed on battery tester. If battery tester passed battery, go to next step. If battery tester did not pass battery, go to step 18.
Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Did you complete this action? If so, battery is okay.
Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Replace battery.
Replace battery.