Chrysler Pacifica. Manual — part 486

black insulating jacket and a slightly 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 models. Refer to Wiring for the
location of more information on the various wiring
circuits included in the battery wire harness for the
vehicle being serviced.

OPERATION

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 to restore
the voltage potential of the battery. The female bat-
tery 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 ter-
minal 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.

The positive battery cable wire has an eyelet ter-

minal that connects to the B(+) terminal stud of the
Integrated Power Module (IPM), and an eyelet termi-
nal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
attached to the ends of two wires. One wire has an
eyelet terminal that connects the battery negative
cable to the vehicle powertrain through a stud on the
engine cylinder block. The other wire has an eyelet
terminal that connects the battery negative cable to
the vehicle body through a ground screw in the
engine compartment.

DIAGNOSIS AND TESTING - BATTERY CABLE

A voltage drop test will determine if there is exces-

sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion

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 impor-

tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached. EXAM-
PLE: When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive 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 tested. Refer to

Standard Procedures for the proper battery charging
and test procedures.

• Fully engage the parking brake.

• Place the gearshift selector lever in the Park

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 is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location.

(1) Connect the positive lead of the voltmeter to

the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 8). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.

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BATTERY SYSTEM

8F - 13

BATTERY CABLES (Continued)

(2) Connect the positive lead of the voltmeter to

the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 9). Rotate and hold the 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.

(3) Connect the voltmeter to measure between the

battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 10). 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 con-
nection at the starter solenoid B(+) terminal stud.

Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 11). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.

REMOVAL

The battery cables on this model may include por-

tions of wiring circuits for the generator and other
components on the vehicle. If battery cable replace-
ment is required, it will be necessary to extract the

Fig. 8 Test Battery Negative Connection Resistance

- Typical

1 - Voltmeter
2 - Battery

Fig. 9 Test Battery Positive Connection Resistance -

Typical

1 - Voltmeter
2 - Battery

Fig. 10 Test Battery Positive Cable Resistance -

Typical

1 - Battery
2 - Voltmeter
3 - Starter Motor

Fig. 11 Test Ground Circuit Resistance - Typical

1 - Voltmeter
2 - Battery
3 - Engine Ground

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BATTERY SYSTEM

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BATTERY CABLES (Continued)

cables out of the engine wire harness assembly. Use
care not to damage the other wires and circuits
which are also packaged into the engine wire harness
assembly.

(1) Turn the ignition switch to the Off position. Be

certain that all electrical accessories are turned off.

(2) Disconnect and isolate the negative battery

cable terminal.

(3) Remove the tape from the engine wire harness

assembly, to access the desired battery cable.

(4) One at a time, trace and disconnect the battery

cable retaining fasteners and routing clips until the
desired cable is free from the vehicle.

(5) Feed the battery cable out of the vehicle.

INSTALLATION

(1) Position the battery cable in the vehicle.
(2) One at a time, trace and install the battery

cable retaining fasteners and routing clips until the
desired cable is properly installed in the engine wire
harness assembly.

(3) Install the tape on the engine wire harness

assembly.

(4) Connect the positive battery cable terminal.

Torque to 40 in. lbs.

(5) Connect the negative battery cable terminal.

Torque to 40 in. lbs.

BATTERY TRAY

DESCRIPTION

The battery is mounted in a molded plastic battery

tray and support unit located in the left front corner
of the engine compartment. The battery tray and
support unit is secured with three fasteners, Two are
located directly under the battery and the other is
located on the right side of the tray.

The battery tray and support unit also includes a

drainage hose, located in the front of the unit.

OPERATION

The battery tray provides a secure mounting loca-

tion and supports the battery. The battery tray also
provides the anchor point for the battery holddown
hardware. The battery tray and the battery hold-
down hardware combine to secure and stabilize the
battery in the engine compartment, which prevents
battery movement during vehicle operation. Unre-
strained battery movement during vehicle operation
could result in damage to the vehicle, the battery, or
both.

The battery tray used on this model also includes a

drainage hose, which provides means for any liquid
that might collect in the bottom of the battery tray to
drain under the vehicle.

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the battery from the vehicle. Refer to

the procedure in this section.

(3) Remove the battery tray retaining fasteners

(Fig. 12).

(4) Pull battery tray up far enough to disconnect

the drain hose assembly.

(5) Remove the battery tray from the vehicle.

INSTALLATION

(1) Position the battery tray in the vehicle.
(2) Position drainage hose and install the battery

tray retaining fasteners.

(3) Install the battery in the vehicle. Refer to the

procedure in this section.

(4) Connect the negative battery cable.

Fig. 12 CS Battery Tray

1 - Battery Tray Drain Hole/Hose Attachment
2 - Battery Tray
3 - Retaining Fasteners

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BATTERY SYSTEM

8F - 15

BATTERY CABLES (Continued)

THERMOWRAP

DESCRIPTION

A one-piece slip-on thermowrap unit shields the

battery case from engine compartment heat. The
thermowrap slips over the battery case (Fig. 13) and
acts like a protective jacket.

OPERATION

The thermowrap protects the battery from engine

compartment temperature extremes. The tempera-
ture of the battery can affect battery life. The air
trapped in the padded material of the thermowrap
creates a dead air space, which helps to insulate the
sides of the battery case from the air temperature
found in the surrounding engine compartment.

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Disconnect the positive battery cable.
(3) Lift the battery thermowrap straight up to

remove from the battery.

INSTALLATION

(1) Position the thermowrap on the battery.
(2) Connect the positive then, negative battery

cables. Torque to 40 in. lbs.

Fig. 13 CS Battery/Thermowrap

1 - Positive Battery Cable
2 - Thermowrap
3 - Negative Battery Cable

8F - 16

BATTERY SYSTEM

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