BATTERY

CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
BATTERY MOUNTING . . . . . . . . . . . . . . . . . . . . . 3
BATTERY SIZE AND RATINGS . . . . . . . . . . . . . . 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUILT-IN TEST INDICATOR . . . . . . . . . . . . . . . . 6
HYDROMETER TEST . . . . . . . . . . . . . . . . . . . . . 7
IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 10
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . 8
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL INFORMATION
OVERVIEW
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the battery, Group 8B covers the
starti ng system, and Group 8C covers the chargi ng
system. Refer to Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams. We have
separated these systems to make i t easi er to l ocate
the i nformati on you are seeki ng wi thi n thi s Servi ce
Manual . However, when attempti ng to di agnose any
of these systems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods, to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of a i nducti on mi l l i ampere ammeter, vol t/
ohmmeter, battery charger, carbon pi l e rheostat (l oad
tester), and 12-vol t test l amp may be requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See the
On-Board Di agnosti cs Test i n Group 8C - Chargi ng
System for more i nformati on.
INTRODUCTION
Thi s secti on covers onl y battery di agnosti c and ser-
vi ce procedures. For battery mai ntenance procedures,
refer to Group 0 - Lubri cati on and Mai ntenance.
Whi l e battery chargi ng can be consi dered a mai nte-
nance procedure, battery chargi ng i nformati on i s
l ocated i n thi s group. Thi s was done because the bat-
tery must be ful l y-charged before any di agnosi s can
be performed.
The factory-i nstal l ed l ow-mai ntenance battery has
removabl e battery cel l caps. Water can be added to
thi s battery. The battery i s not seal ed and has vent
hol es i n the cel l caps (Fi g. 1). The chemi cal composi -
ti on wi thi n the l ow-mai ntenance battery reduces bat-
tery gassi ng and water l oss, at normal charge and
di scharge rates.
Fig. 1 Low-Maintenance Battery - Typical
ZJ BATTERY 8A - 1
Rapi d l oss of el ectrol yte can be caused by an over-
chargi ng condi ti on. Be certai n to di agnose the charg-
i ng system before returni ng the vehi cl e to servi ce.
Refer to Group 8C - Chargi ng System for more i nfor-
mati on.
The factory-i nstal l ed battery al so has a bui l t-i n
test i ndi cator (hydrometer). The col or vi si bl e i n the
si ght gl ass of the i ndi cator wi l l reveal the battery
condi ti on. See Bui l t-I n Test I ndi cator i n thi s group
for more i nformati on.
I t i s i mportant that the battery, starti ng, and
chargi ng systems be thoroughl y tested and i nspected
any ti me a battery needs to be charged or repl aced.
The cause of abnormal di scharge, overchargi ng, or
earl y battery fai l ure must be di agnosed and corrected
before a battery i s repl aced or returned to servi ce.
DESCRIPTION AND OPERATION
BATTERY
The storage battery i s a devi ce used to store el ec-
tri cal energy potenti al i n a chemi cal form. When an
el ectri cal l oad i s appl i ed to the battery termi nal s, an
el ectrochemi cal reacti on occurs wi thi n the battery.
Thi s reacti on causes the battery to di scharge el ectri -
cal current.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups made of l ead oxi de, and nega-
ti vel y charged pl ate groups made of sponge l ead.
These di ssi mi l ar metal pl ates are submerged i n a
sul furi c aci d and water sol uti on cal l ed an el ectrol yte.
As the battery di scharges, a gradual chemi cal
change takes pl ace wi thi n each cel l . The sul furi c aci d
i n the el ectrol yte combi nes wi th the pl ate materi al s,
causi ng both pl ates to sl owl y change to l ead sul fate.
At the same ti me, oxygen from the posi ti ve pl ate
materi al combi nes wi th hydrogen from the sul furi c
aci d, causi ng the el ectrol yte to become mai nl y water.
The chemi cal changes wi thi n the battery are
caused by the movement of excess or free el ectrons
between the posi ti ve and negati ve pl ate groups. Thi s
movement of el ectrons produces a fl ow of el ectri cal
current through the l oad devi ce attached to the bat-
tery termi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery, the battery di schargi ng process i s
reversed.
Chargi ng the battery gradual l y changes the sul -
fated l ead pl ates back i nto sponge l ead and l ead
oxi de, and the water back i nto sul furi c aci d. Thi s
acti on restores the di fference i n the el ectron charges
deposi ted on the pl ates, and the vol tage potenti al of
the battery cel l s.
For a battery to remai n useful , i t must be abl e to
produce hi gh-amperage current over an extended
peri od. A battery must al so be abl e to accept a
charge, so that i ts vol tage potenti al may be restored.
I n addi ti on to produci ng and stori ng el ectri cal energy,
the battery serves as a capaci tor, or vol tage stabi l i zer,
for a vehi cl es el ectri cal system. I t absorbs most abnor-
mal or transi ent vol tages caused by the swi tchi ng of any
of the vehi cl es el ectri cal components.
The battery i s vented to rel ease excess hydrogen gas
that i s created when the battery i s bei ng charged or di s-
charged. However, even wi th these vents, the hydrogen
gas can col l ect i n or around the battery. I f hydrogen gas
i s exposed to fl ame or sparks, i t may i gni te.
I f the el ectrol yte l evel i s l ow, the battery may arc
i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
BATTERY SIZE AND RATINGS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced.
See the Battery Cl assi fi cati ons and Rati ngs chart
i n Speci fi cati ons at the back of thi s group for more
i nformati on. Battery si zes and rati ngs are di scussed
i n more detai l bel ow.
GROUP SIZE
The outsi de di mensi ons and termi nal pl acement of
the battery conform to standards establ i shed by the
Battery Counci l I nternati onal (BCI ). Each battery i s
assi gned a BCI Group Si ze number to hel p i denti fy a
correctl y-si zed repl acement.
COLD CRANKING AMPERAGE
The Col d Cranki ng Amperage (CCA) rati ng speci -
fi es how much current (i n amperes) the battery can
del i ver for thi rty seconds at -18 C (0 F). Termi nal
vol tage must not fal l bel ow 7.2 vol ts duri ng or after
the thi rty second di scharge peri od. The CCA requi red
i s general l y hi gher as engi ne di spl acement i ncreases,
dependi ng al so upon the starter current draw
requi rements.
8A - 2 BATTERY ZJ
GENERAL INFORMATION (Continued)
RESERVE CAPACITY
The Reserve Capaci ty (RC) rati ng speci fi es the
ti me (i n mi nutes) i t takes for battery termi nal vol t-
age to fal l bel ow 10.5 vol ts, at a di scharge rate of 25
amperes. RC i s determi ned wi th the battery ful l y-
charged at 26.7 C (80 F). Thi s rati ng esti mates how
l ong the battery mi ght l ast after a chargi ng system
fai l ure, under mi ni mum el ectri cal l oad.
AMPERE-HOURS
The Ampere-Hours (AH) rati ng speci fi es the cur-
rent (i n amperes) that a battery can del i ver steadi l y
for twenty hours, wi th the vol tage i n the battery not
fal l i ng bel ow 10.5 vol ts. Thi s rati ng i s al so someti mes
referred to as the twenty-hour di scharge rati ng.
BATTERY MOUNTING
The battery i s mounted to a mol ded pl asti c tray
l ocated i n the ri ght front corner of the engi ne com-
partment. A U-nut i s hel d i n a formati on on each si de
of the battery tray. A hol ddown strap fi ts across the
top of the battery case and thermoguard. To secure
the battery i n the tray, a bol t passes through the
hol ddown strap on each si de of the battery, and i s
threaded i nto the U-nut on each si de of the battery
tray.
The battery tray i s secured wi th three screws to
the front wheel house extensi on panel , forward of the
ri ght front wheel . The tray i s al so secured to the
ri ght fender i nner shi el d wi th two screws.
A vacuum reservoi r for the vehi cl e speed control
and heater-A/C systems i s mounted to the undersi de
of the battery tray. Refer to Group 8H - Vehi cl e
Speed Control System or Group 24 - Heati ng and Ai r
Condi ti oni ng for more i nformati on on the vacuum
reservoi r.
On some model s, a hol e i n the bottom of the bat-
tery tray i s fi tted wi th a battery temperature sensor.
Model s wi thout the battery temperature sensor have
a pl ug fi tted to thi s hol e. Refer to Group 8C - Charg-
i ng System for more i nformati on on the battery tem-
perature sensor.
When i nstal l i ng a battery, be certai n that the hol d-
down fasteners are ti ghtened to the proper speci fi ca-
ti ons. I mproper hol ddown fastener ti ghtness, whether
too l oose or too ti ght, can resul t i n damage to the
battery. See the Battery Removal and I nstal l ati on
procedures i n thi s group for the correct hol ddown fas-
tener ti ghtness speci fi cati ons.
DIAGNOSIS AND TESTING
BATTERY
The battery must be compl etel y charged and the
top, posts, and termi nal cl amps shoul d be properl y
cl eaned before di agnosti c procedures are performed.
See the Battery Chargi ng procedure i n thi s group for
more i nformati on.
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.
The condi ti on of a battery i s determi ned by two cri -
teri a:
1. State-Of-Charge - Thi s can be determi ned by
vi ewi ng the bui l t-i n test i ndi cator, by checki ng the
speci fi c gravi ty of the el ectrol yte (hydrometer test),
or by checki ng the battery vol tage (open-ci rcui t vol t-
age test).
2. Cranking Capacity - Thi s can be determi ned
by performi ng a battery l oad test, whi ch measures
the abi l i ty of the battery to suppl y hi gh-amperage
current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, vi ew the test i ndi cator to
determi ne the state-of-charge. I f the battery has no
test i ndi cator, but has removabl e cel l caps, perform
the hydrometer test to determi ne the state-of-charge.
I f the cel l caps are not removabl e, or a hydrometer i s
not avai l abl e, perform the open-ci rcui t vol tage test to
determi ne the state-of-charge.
ZJ BATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)
The battery must be charged before proceedi ng
wi th a l oad test i f:
The bui l t-i n test i ndi cator has a bl ack or dark
col or vi si bl e.
The temperature corrected speci fi c gravi ty i s
l ess than 1.235.
The open-ci rcui t vol tage i s l ess than 12.4 vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. See Charging A
Completely Discharged Battery in this group for
more information.
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or greater.
8A - 4 BATTERY ZJ
DIAGNOSIS AND TESTING (Continued)
Battery Diagnosis
Condition Possible Causes Correction
The battery seems
weak or dead
when attempting
to start the engine.
1. The battery has an incorrect size or
rating for this vehicle.
2. The battery is physically damaged.
3. The battery terminal connections are
loose or corroded.
4. The battery is discharged.
5. The electrical system is faulty.
6. The battery is faulty.
7. The starting system is faulty.
8. The charging system is faulty.
1. See Specifications in this group. Replace the
incorrect battery with the correct battery, if
required.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the battery, if
damaged.
3. See the Voltage Drop Test in this group. Clean
and tighten the battery terminal connections, if
required.
4. See the Test Indicator, the Hydrometer Test, or
the Open-Circuit Voltage Test in this group to
determine the battery state-of-charge. Charge the
battery, if required.
5. See the Ignition-Off Draw Test in this group.
Repair the electrical system, if required.
6. See the Load Test in this group to determine
the battery condition. Replace the battery, if
required.
7. Refer to Group 8B - Starting Systems for more
information. Repair the starting system, if required.
8. Refer to Group 8C - Charging Systems for
more information. Repair the charging system, if
required.
The battery
state-of-charge
cannot be
maintained.
1. The battery has an incorrect size or
rating for this vehicle.
2. The battery terminal connections are
loose or corroded.
3. The generator drive belt is loose or
worn.
4. The electrical system is faulty.
5. The battery is faulty.
6. The starting system is faulty.
7. The charging system is faulty.
8. Electrical loads exceed the output of
the charging system.
9. Slow driving or prolonged idling with
high-amperage draw systems in use.
1. See Specifications in this group. Replace the
incorrect battery with the correct battery, if
required.
2. See the Voltage Drop Test in this group. Clean
and tighten the battery terminal connections, if
required.
3. Refer to Group 7 - Cooling Systems for more
information. Replace or adjust the generator drive
belt, if required.
4. See the Ignition-Off Draw Test in this group.
Repair the electrical system, if required.
5. See the Load Test in this group to determine
the battery condition. Replace the battery, if
required.
6. Check whether the starting system is
performing to specifications. Refer to Group 8B -
Starting Systems for more information. Repair the
starting system, if required.
7. Refer to Group 8C - Charging Systems for
more information. Repair the charging system, if
required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will
not accept a
charge.
1. The battery is faulty. 1. See Battery Charging in this group. Replace the
faulty battery, if required.
ZJ BATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued)
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. Corroded or l oose battery posts and termi nal
cl amps.
2. A l oose or worn generator dri ve bel t.
3. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
4. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
5. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw. See the I gni ti on-Off Draw Test pro-
cedure i n thi s group for more i nformati on.
6. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Group 8C - Chargi ng System for more
i nformati on.
7. A faul ty or i ncorrect battery.
BUILT-IN TEST INDICATOR
A test i ndi cator (hydrometer) bui l t i nto the top of
the battery case provi des vi sual i nformati on for bat-
tery testi ng (Fi g. 2). Li ke a hydrometer, the bui l t-i n
test i ndi cator measures the speci fi c gravi ty of the
el ectrol yte. The test i ndi cator reveal s the battery
state-of-charge; however, i t wi l l not reveal the crank-
i ng capaci ty of the battery. A l oad test must be per-
formed to determi ne the battery cranki ng capaci ty.
See the Load Test procedure i n thi s group for more
i nformati on.
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.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n test i ndi -
cator, i t i s i mportant that the battery be l evel and
have a cl ean si ght gl ass. Addi ti onal l i ght may be
requi red to vi ew the i ndi cator. Do not use open
flame as a source of additional light.
To read the bui l t-i n test i ndi cator, l ook i nto the
si ght gl ass and note the col or of the i ndi cator (Fi g. 3).
Refer to the fol l owi ng descri pti on, as the col or i ndi -
cates:
Green - i ndi cates 75% to 100% state-of-charge.
The battery i s adequatel y charged for further testi ng
or return to use. I f the vehi cl e wi l l not crank for a
mi ni mum of fi fteen seconds wi th a ful l y-charged bat-
tery, perform the Load Test procedure as descri bed i n
thi s group.
Black or Dark - i ndi cates 0% to 75% state-of-
charge. The battery i s i nadequatel y charged and
must be charged unti l a green i ndi cati on i s vi si bl e i n
the si ght gl ass (12.4 vol ts or more), before the bat-
tery i s tested further or returned to servi ce. See the
Battery Chargi ng procedure i n thi s group for more
i nformati on. Al so see Abnormal Battery Di schargi ng
i n thi s group for possi bl e causes of the di scharged
condi ti on.
Clear or Bright - i ndi cates a l ow el ectrol yte
l evel . The el ectrol yte l evel i n the battery i s bel ow the
test i ndi cator. A mai ntenance-free battery wi th non-
removabl e cel l caps must be repl aced i f the el ectro-
l yte l evel i s l ow. Water must be added to a l ow-
mai ntenance battery wi th removabl e cel l caps before
i t i s charged. See the Battery Chargi ng procedure i n
thi s group for more i nformati on. A l ow el ectrol yte
l evel may be caused by an overchargi ng condi ti on.
Refer to Group 8C - Chargi ng System to di agnose an
overchargi ng condi ti on.
Fig. 2 Built-In Test Indicator
8A - 6 BATTERY ZJ
DIAGNOSIS AND TESTING (Continued)
HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
trol yte. Thi s test cannot be performed on
mai ntenance-free batteri es wi th non-removabl e cel l
caps. I f the battery has non-removabl e cel l caps, see
the Bui l t-I n Test I ndi cator or the Open-Ci rcui t Vol t-
age Test procedures i n thi s group.
Speci fi c gravi ty i s a compari son of the densi ty of
the el ectrol yte to the densi ty of pure water. Pure
water has a speci fi c gravi ty of 1.000, and sul furi c
aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the el ectrol yte by
wei ght, or 24% by vol ume.
I n a ful l y-charged battery the el ectrol yte wi l l have
a temperature-corrected speci fi c gravi ty of 1.260 to
1.290. However, a speci fi c gravi ty of 1.235 or above i s
sati sfactory for battery l oad testi ng and/or return to
servi ce.
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.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the cel l caps and check the el ectrol yte l evel .
Add di sti l l ed water i f the el ectrol yte l evel i s bel ow
the top of the battery pl ates.
Refer to the i nstructi ons suppl i ed wi th the hydrom-
eter for recommendati ons on the correct use of the
hydrometer. Remove onl y enough el ectrol yte from the
battery cel l so that the fl oat i s off the bottom of the
hydrometer barrel wi th pressure on the bul b
rel eased.
CAUTION: Exercise care when inserting the tip of
the hydrometer into a cell to avoid damaging the
plate separators. Damaged plate separators can
cause early battery failure.
To read the hydrometer correctl y, hol d i t wi th the
top surface of the el ectrol yte at eye l evel (Fi g. 4).
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7 C (80
F). When testi ng the speci fi c gravi ty at any other
temperature, a correcti on factor i s requi red.
The correcti on factor i s approxi matel y a speci fi c
gravi ty val ue of 0.004, referred to as four poi nts of
speci fi c gravi ty. For each 5.5 C above 26.7 C (10 F
above 80 F), add four poi nts. For each 5.5 C bel ow
26.7 C (10 F bel ow 80 F), subtract four poi nts.
Al ways correct the speci fi c gravi ty for temperature
Fig. 3 Built-In Test Indicator Sight Glass
Fig. 4 Hydrometer - Typical
ZJ BATTERY 8A - 7
DIAGNOSIS AND TESTING (Continued)
vari ati on. Test the speci fi c gravi ty of the el ectrol yte
i n each battery cel l .
EXAMPLE: A battery i s tested at -12.2 C (10 F)
and has a speci fi c gravi ty of 1.240. Determi ne the
actual speci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7 C (80 F):
26.6 C - -12.2 C = 38.8 C (80 F -
10 F = 70 F)
(2) Di vi de the resul t from Step 1 by 5.5 (10):
38.8 C 5.5 = 7 (70 F 10 = 7)
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004):
7 X 0.004 = 0.028
(4) The temperature at testi ng was bel ow 26.7 C
(80 F); therefore, the temperature correcti on factor
i s subtracted:
1.240 - 0.028 = 1.212
The corrected speci fi c gravi ty of the battery i n thi s
exampl e i s 1.212.
I f the speci fi c gravi ty of al l cel l s i s above 1.235, but
the vari ati on between cel l s i s more than fi fty poi nts
(0.050), the battery shoul d be repl aced. I f the speci fi c
gravi ty of one or more cel l s i s l ess than 1.235, charge
the battery at a rate of approxi matel y fi ve amperes.
Conti nue chargi ng the battery unti l three consecu-
ti ve speci fi c gravi ty tests, taken at one-hour i nter-
val s, are constant. I f the cel l speci fi c gravi ty
vari ati on i s more than fi fty poi nts (0.050) at the end
of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
cranki ng capaci ty. See the Load Test procedure i n
thi s group for more i nformati on.
OPEN-CIRCUIT VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the state-of-charge of a battery. Thi s test can be
used i n pl ace of the hydrometer test when a hydrom-
eter i s not avai l abl e, or for mai ntenance-free batter-
i es wi th non-removabl e cel l caps.
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.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the head l amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (refer to the i nstructi ons provi ded wi th the
vol tmeter), measure the open-ci rcui t vol tage (Fi g. 5).
See the Open-Ci rcui t Vol tage chart. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty. See the Load Test procedure i n thi s group
for more i nformati on.
Fig. 5 Testing Open-Circuit Voltage - Typical
8A - 8 BATTERY ZJ
DIAGNOSIS AND TESTING (Continued)
LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng Amper-
age (CCA) rati ng of the battery. Refer to the battery
l abel , or see the Battery Cl assi fi cati ons and Rati ngs
chart i n Speci fi cati ons at the back of thi s group for the
CCA rati ng of the factory-i nstal l ed battery.
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.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean.
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 6) to the battery posts (Fi g. 7). Refer to the
operati ng i nstructi ons provi ded wi th the tester bei ng
used. Check the open-ci rcui t vol tage (no l oad) of the
battery. Open-ci rcui t vol tage must be 12.4 vol ts or
greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 8). Thi s wi l l remove the surface
charge from the battery.
Open Circuit Voltage
Open Circuit Volts
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%
Fig. 6 Volt-Ammeter-Load Tester - Typical
Fig. 7 Volt-Ammeter-Load Tester Connections -
Typical
Fig. 8 Remove Surface Charge from Battery -
Typical
ZJ BATTERY 8A - 9
DIAGNOSIS AND TESTING (Continued)
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
9). After fi fteen seconds, record the l oaded vol tage
readi ng, then return the l oad control knob to the Off
posi ti on.
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature chart
for the proper l oaded vol tage readi ng.
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21 C (70 F), the
battery i s faul ty and must be repl aced.
IGNITION-OFF DRAW TEST
I gni ti on-Off Draw (I OD) refers to power bei ng
drai ned from the battery wi th the i gni ti on swi tch i n
the Off posi ti on. A normal vehi cl e el ectri cal system
wi l l draw from fi ve to thi rty mi l l i amperes (0.005 to
0.030 ampere) wi th the i gni ti on swi tch i n the Off
posi ti on, and al l non-i gni ti on control l ed ci rcui ts i n
proper worki ng order. The thi rty mi l l i amperes are
needed to enabl e the memory functi ons for the Pow-
ertrai n Control Modul e (PCM), di gi tal cl ock, el ectron-
i cal l y tuned radi o, and other modul es whi ch may
vary wi th the vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on
Faul ty or i mproperl y adjusted swi tches
Faul ty or shorted el ectroni c modul es and compo-
nents
An i nternal l y shorted generator
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty mi l l i amperes, the probl em
must be found and corrected before repl aci ng a bat-
tery. I n most cases, the battery can be charged and
returned to servi ce after the excessi ve I OD condi ti on
has been corrected.
DIAGNOSIS
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th a i l l umi -
nated entry system or el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes.
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then unpl ug the l amp wi re harness con-
nector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e
cl amp and the battery negati ve termi nal post. Make
sure that the doors remai n cl osed so that the i l l umi -
nated entry system i s not acti vated. The mul ti -meter
amperage readi ng may remai n hi gh for up to three
mi nutes, or may not gi ve any readi ng at al l whi l e set
i n the hi ghest amperage scal e, dependi ng upon the
el ectri cal equi pment on the vehi cl e. The mul ti -meter
l eads must be securel y cl amped to the battery nega-
ti ve cabl e cl amp and the battery negati ve termi nal
post. I f conti nui ty between the battery negati ve ter-
Fig. 9 Load 50% CCA Rating - Note Voltage - Typical
Load Test Temperature
Minimum Voltage
Temperature
F C
9.6 volts 70
and
above
21
and
above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
8A - 10 BATTERY ZJ
DIAGNOSIS AND TESTING (Continued)
mi nal post and the negati ve cabl e cl amp i s l ost dur-
i ng any part of the I OD test, the el ectroni c ti mer
functi on wi l l be acti vated and al l of the tests wi l l
have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment on the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove each fuse or ci rcui t breaker
(refer to Group 8W - Wi ri ng Di agrams for more i nfor-
mati on) unti l the amperage readi ng becomes very
l ow, or nonexi stent. Thi s wi l l i sol ate each ci rcui t and
i denti fy the source of the hi gh-amperage I OD. I f the
amperage readi ng remai ns hi gh after di sconnecti ng
each fuse and ci rcui t breaker, unpl ug the wi re har-
ness connector from the generator. I f the amperage
readi ng now becomes very l ow or nonexi stent, refer
to Group 8C - Chargi ng System to di agnose the
faul ty chargi ng system. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker removal process
to i denti fy and correct the sources of excessi ve I OD.
I t i s now safe to sel ect the l owest mi l l i ampere scal e
of the mul ti -meter to check the l ow-amperage I OD.
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 mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty mi l l i amperes
(0.030 ampere). I f the draw exceeds thi rty mi l l i am-
peres, i sol ate each ci rcui t by removi ng the ci rcui t
breakers and fuses. The mul ti -meter readi ng wi l l
drop to wi thi n the acceptabl e l i mi t when the source
of the excessi ve draw i s di sconnected. Repai r thi s ci r-
cui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
VOLTAGE DROP TEST
The vol tage drop test wi l l determi ne i f there i s
excessi ve resi stance i n the battery termi nal connec-
ti ons or the battery cabl es. When performi ng these
tests, i t i s i mportant to remember that the vol tage
drop i s gi vi ng an i ndi cati on of the resi stance between
the two poi nts at whi ch the vol tmeter probes are
attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
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.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n the fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged as descri bed i n thi s
group.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and ful l y depress the cl utch
pedal .
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent the engi ne from starti ng. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC l abel for ASD rel ay i denti fi cati on
and l ocati on.
ZJ BATTERY 8A - 11
DIAGNOSIS AND TESTING (Continued)
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 10). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 11). Rotate and hol d the i gni ti on swi tch
i n the Start posi ti on. Observe the vol tmeter. I f vol t-
age i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 12). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve termi nal post and a good cl ean ground
on the engi ne bl ock (Fi g. 13). Rotate and hol d the i gni -
ti on swi tch i n the Start posi ti on. Observe the vol tmeter.
I f the readi ng i s above 0.2 vol t, cl ean and ti ghten the
battery negati ve cabl e attachment on the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
SERVICE PROCEDURES
BATTERY CHARGING
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng battery chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or above.
Fig. 10 Test Battery Negative Connection
Resistance - Typical
Fig. 11 Test Battery Positive Connection Resistance
- Typical
Fig. 12 Test Battery Positive Cable Resistance -
Typical
Fig. 13 Test Ground Circuit Resistance - Typical
8A - 12 BATTERY ZJ
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 equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the charger
and/or the battery from bei ng damaged i f they are
i mproperl y connected. I f the battery state-of-charge
i s too l ow for the pol ari ty-sensi ng ci rcui try to detect,
the charger wi l l not operate. Thi s makes i t appear
that the battery wi l l not accept chargi ng current.
Refer to the i nstructi ons provi ded wi th the battery
charger to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. I f the battery wi l l endure a l oad
test, return the battery to use. I f the battery wi l l not
endure a l oad test, i t i s faul ty and must be repl aced.
Cl ean and i nspect the battery hol ddowns, tray, ter-
mi nal s, posts, and top before compl eti ng servi ce. See
the Battery Removal and I nstal l ati on procedures i n
thi s group for more i nformati on.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 14). I f the
readi ng i s bel ow ten vol ts, the charge current wi l l be
l ow. I t coul d take some ti me before the battery
accepts a current greater than a few mi l l i amperes.
Such l ow current may not be detectabl e on the
ammeters bui l t i nto many chargers.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the charger and/or the
battery from bei ng damaged i f they are i mproperl y
connected. I f the battery state-of-charge i s too l ow for
the pol ari ty-sensi ng ci rcui try to detect, the charger
wi l l not operate. Thi s makes i t appear that the bat-
tery wi l l not accept chargi ng current. Refer to the
i nstructi ons provi ded wi th the battery charger to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e charger
current at vari ous vol tages i s shown i n the Charge
Rate chart. I f the charge current i s sti l l not measur-
abl e at the end of the chargi ng ti me, the battery i s
faul ty and must be repl aced. I f the charge current i s
measurabl e duri ng the chargi ng ti me, the battery
Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -
Typical
ZJ BATTERY 8A - 13
SERVICE PROCEDURES (Continued)
may be good and the chargi ng shoul d be compl eted i n
the normal manner.
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast charger i s connected to a col d bat-
tery, the current accepted by the battery wi l l be very
l ow at fi rst. As the battery warms, i t wi l l accept a
hi gher chargi ng current rate (amperage).
Charger Capacity - A charger that suppl i es
onl y fi ve amperes wi l l requi re a l onger chargi ng
ti me. A charger that suppl i es twenty amperes or
more wi l l requi re a shorter chargi ng ti me.
State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C/30 F) BATTERY.
THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.
REMOVAL AND INSTALLATION
BATTERY
(1) Turn the i gni ti on swi tch to the Off posi ti on.
Make sure al l el ectri cal accessori es are turned off.
(2) Loosen the cabl e termi nal cl amps and di scon-
nect both battery cabl es, negati ve cabl e fi rst. I f nec-
essary, use a pul l er to remove the termi nal cl amps
from the battery posts (Fi g. 15).
(3) I nspect the cabl e termi nal cl amps for corrosi on
and damage. Remove any corrosi on usi ng a wi re
brush or a post and termi nal cl eani ng tool , and a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on (Fi g. 16). Repl ace any cabl e that
has damaged or deformed termi nal cl amps.
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
5
Amperes
10
Amperes
20
Amperes
Open Circuit
Voltage
Hours Charging at 21C (70F)
12.25 to 12.39 6 hours 3 hours 1.5 hours
12.00 to 12.24 8 hours 4 hours 2 hours
11.95 to 11.99 12 hours 6 hours 3 hours
10.00 to 11.94 14 hours 7 hours 3.5 hours
less than 10.00 See Charging Completely
Discharged Battery
Fig. 15 Remove Battery Terminal Clamp - Typical
Fig. 16 Clean Battery Cable Terminal Clamp -
Typical
8A - 14 BATTERY ZJ
SERVICE PROCEDURES (Continued)
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(4) Remove the battery hol ddowns and remove the
battery from the vehi cl e (Fi g. 17).
(5) I nspect the battery tray and hol ddowns for cor-
rosi on or damage. Remove any corrosi on usi ng a wi re
brush and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on. Pai nt any exposed
bare metal and repl ace any damaged parts.
(6) Sl i de the thermoguard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose posts must be repl aced.
(7) Check the el ectrol yte l evel i n the battery. Use a
putty kni fe or another sui tabl e wi de fl at-bl aded tool
to pry the cel l caps off (Fi g. 18). Do not use a screw-
dri ver. Add di sti l l ed water to each cel l unti l the l i q-
ui d reaches the bottom of the vent wel l . DO NOT
OVERFI LL.
(8) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. See the
Bui l t-I n Test I ndi cator and the Battery Chargi ng pro-
cedures i n thi s group for more i nformati on.
(9) I f the battery i s to be rei nstal l ed, cl ean the out-
si de of the battery case and the top cover wi th a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on to remove any aci d fi l m (Fi g. 19).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, see the Battery Rati ngs and Cl assi fi cati ons
chart i n Speci fi cati ons at the back of thi s group. Con-
fi rm that the repl acement battery i s the correct si ze
and has the correct rati ngs for the vehi cl e.
Fig. 17 Battery Holddowns
Fig. 18 Removing Cell Caps - Typical
Fig. 19 Clean Battery - Typical
ZJ BATTERY 8A - 15
REMOVAL AND INSTALLATION (Continued)
(10) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 20).
(11) Posi ti on the battery i n the tray. Ensure that
the posi ti ve and negati ve termi nal posts are correctl y
posi ti oned. The cabl e termi nal cl amps must reach the
correct battery post wi thout stretchi ng the cabl es
(Fi g. 21).
(12) Rei nstal l the battery thermoguard by sl i di ng
i t over the battery case.
(13) Loosel y i nstal l the battery hol ddown hard-
ware. Ensure that the battery base i s correctl y posi -
ti oned i n the tray, then ti ghten the hol ddowns to 2.2
Nm (20 i n. l bs.).
CAUTION: Be certain that the battery cables are
connected to the correct battery terminals. Reverse
polarity may damage electrical components.
(14) I nstal l and ti ghten the battery posi ti ve cabl e
termi nal cl amp. Then i nstal l and ti ghten the battery
negati ve cabl e termi nal cl amp. Ti ghten both cabl e
termi nal cl amp bol ts to 8.5 Nm (75 i n. l bs.).
(15) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the cabl e
termi nal cl amps and the battery termi nal posts.
SPECIFICATIONS
BATTERY
Fig. 20 Clean Battery Terminal Post - Typical
Fig. 21 Battery Cables
Battery Classifications and Ratings
Part Number
BCI Group
Size
Classifica-
tion
Cold
Cranking
Amperage
Reserve
Capacity
Ampere-
Hours
Load Test
Amperage
56044081 34 600 120 Minutes 66 300
8A - 16 BATTERY ZJ
REMOVAL AND INSTALLATION (Continued)