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Battery Cables: Installation

NOTE: Both the battery negative cable and the battery positive cable are serviced in the battery wire harness. If either battery cable is damaged or inoperative, the battery wire harness assembly must be replaced.
Fig 1: Removing/Installing Battery Wire Harness
GC0029013Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean and inspect the battery cable terminal clamps and the battery terminal posts, (Refer to ELECTRICAL/BATTERY SYSTEM - CLEANING) .
  2. Position the battery wire harness assembly (10) into the vehicle.
    Fig 2: Remove/Install Battery Wire Harness
    GC0029014Courtesy of DAIMLERCHRYSLER CORP.
  3. Raise the vehicle on a hoist, (Refer to LUBRICATION & MAINTENANCE/LIFT POINTS - STANDARD PROCEDURE) .
  4. Install the battery wire harness retaining clips (7) & (9) to the engine.
  5. Reconnect the battery wire harness connector (2) to the connector receptacle on the starter solenoid.
  6. Install the battery positive cable eyelet terminal (3) onto the B(+) terminal stud on the starter solenoid.
  7. Install and tighten the nut (4) that secures the battery positive cable eyelet terminal (3) to the B(+) terminal stud on the starter solenoid. Tighten the nut to 11 N.m (95 in. lbs.).
  8. Install and tighten the bolt (5) that secures the battery negative cable ground eyelet terminal (6) to the engine block (10). Tighten the bolt to 11 N.m (95 in. lbs.).
  9. Lower the vehicle.
    Fig 3: Remove/Install Battery Wire Harness Retaining Clips
    GC0029015Courtesy of DAIMLERCHRYSLER CORP.
  10. Install the battery wire harness retaining clips (2) to the valve cover studs.
  11. On 5.7L engines, reconnect the battery wire harness connector (6) to the generator field terminal connector receptacle on the back of the generator.
  12. Install the generator output cable eyelet terminal (4) onto the generator output terminal stud.
  13. Install and tighten the nut (5) that secures the generator output cable eyelet terminal (4) to the generator output terminal stud. Tighten the nut to 14 N.m (125 in. lbs.).
    Fig 4: Removing/Installing Battery Wire Harness
    GC0029013Courtesy of DAIMLERCHRYSLER CORP.
  14. On 3.7L and 4.7L engines, reconnect the battery wire harness connector (8) to the generator field terminal connector receptacle on the back of the generator.
  15. Install the generator output cable eyelet terminal (7) onto the generator output terminal stud.
  16. Install and tighten the nut (6) that secures the generator output cable eyelet terminal (7) to the generator output terminal stud. Tighten the nut to 14 N.m (125 in. lbs.).
  17. Install the battery wire harness retaining clip (9) onto the valve cover stud.
  18. Install the battery wire harness three pin connector (11) onto the battery tray (12).
  19. Connect the battery wire harness three pin connector (11).
    Fig 5: Remove/Install Battery Positive Cable Eyelet Terminals
    GC0029016Courtesy of DAIMLERCHRYSLER CORP.
  20. Install both battery positive cable eyelet terminals onto the B(+) terminal studs in the Power Distribution Center (PDC) and Integrated Power Module (IPM).
  21. Install and tighten the nuts that secure the battery positive cable eyelet terminals onto the B(+) terminal studs in the PDC and IPM. Tighten the nut to 11.5 N.m (105 in. lbs.).
    Fig 6: Identifying Battery System Components, Power Distribution Center & Integrated Power Module
    GC0027613Courtesy of DAIMLERCHRYSLER CORP.
  22. Close and latch the covers on the PDC (1) and IPM (2).
    Fig 7: Remove/Install Battery Negative Cable Eyelet Terminal
    GC0029017Courtesy of DAIMLERCHRYSLER CORP.
  23. Install and tighten the screw (1) that secures the battery negative cable eyelet terminal (2) to the inner fender (3). Tighten the screw to 28 N.m (20.5 ft. lbs.).
    Fig 8: Removing/Installing Battery Wire Harness
    GC0029013Courtesy of DAIMLERCHRYSLER CORP.
  24. Reconnect the battery positive cable terminal clamp (4) to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 5.5 N.m (50 in. lbs.).
  25. Secure the battery positive cable terminal clamp cover (3) over the battery positive cable terminal clamp (4).
  26. Reconnect the battery negative cable terminal clamp (2) to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 5.5 N.m (50 in. lbs.).
  27. Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.
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