Jeep XJ. Manual — part 85
(20) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
(21) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
(22) 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.
BATTERY HOLD DOWNS
All of the battery hold down hardware except for
the T-bolts can be serviced without removal of the
battery or the battery tray. The battery tray must be
removed from the vehicle to service the T-bolts. If the
T-bolts require service replacement, refer to Battery
Tray in the index of this service manual for the loca-
tion of the proper battery tray removal and installa-
tion procedures.
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.
(4) Remove the nut with washer from the threaded
end of each of the two T-bolts (Fig. 19).
(5) Remove the screw with washer that secures the
end of the battery support strap with a slotted hole
to the top of the upper radiator crossmember.
(6) Remove the battery support strap from the
threaded end of the T-bolt nearest to the front of the
vehicle.
(7) Remove the battery hold down bracket from
the threaded ends of the two T-bolts and the top of
the battery case.
INSTALLATION
(1) Clean and inspect the battery hold down hard-
ware. Refer to Battery in the index of this service
manual for the location of the proper battery hold
down hardware cleaning and inspection procedures.
(2) Position the battery hold down bracket onto the
threaded ends of the two T-bolts and across the top of
the battery case.
(3) Position the battery support strap with the
round hole over the threaded end of the T-bolt near-
est to the front of the vehicle and the slotted hole
over the mounting hole in the top of the upper radi-
ator crossmember.
(4) Install and tighten the screw with washer that
secures the end of the battery support strap with a
slotted hole to the top of the upper radiator cross-
member. Tighten the screw to 8.7 N·m (77 in. lbs.).
(5) Install and tighten the nut with washer onto
the threaded end of each of the two T-bolts. Tighten
the nuts to 2.2 N·m (20 in. lbs.).
(6) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
Fig. 19 Battery Hold Downs Remove/Install
1 – SCREW AND WASHER (1)
2 – NUT AND WASHER (2)
3 – T-BOLT (2)
4 – RETAINER (2)
5 – BATTERY TRAY
6 – UPPER RADIATOR CROSS MEMBER
7 – BRACKET
8 – STRAP
8A - 20
BATTERY
XJ
REMOVAL AND INSTALLATION (Continued)
BATTERY
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post (Fig. 20).
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Remove the battery hold downs from the bat-
tery. Refer to Battery Hold Downs in the index of
this service manual for the location of the proper bat-
tery hold down removal procedures.
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.
(7) Remove the battery and the battery thermo-
guard from the battery tray as a unit.
(8) Remove the battery thermoguard from the bat-
tery case. Refer to Battery Thermoguard in the
index of this service manual for the location of the
proper battery thermoguard removal procedures.
INSTALLATION
(1) Clean and inspect the battery. Refer to Bat-
tery in the index of this service manual for the loca-
tion of the proper battery cleaning and inspection
procedures.
(2) Reinstall the battery thermoguard onto the
battery case. Refer to Battery Thermoguard in the
index of this service manual for the location of the
proper battery thermoguard installation procedures.
(3) Position the battery and the battery thermo-
guard onto the battery tray as a unit. Ensure that
the battery positive and negative terminal posts are
correctly positioned. The battery cable terminal
clamps must reach the correct battery terminal post
without stretching the cables (Fig. 21).
(4) Reinstall the battery hold downs onto the bat-
tery. Refer to Battery Hold Downs in the index of
this service manual for the location of the proper bat-
tery hold down installation procedures.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
(5) Clean the battery cable terminal clamps and
the battery terminal posts. Refer to Battery in the
index of this service manual for the location of the
proper battery cleaning and inspection procedures.
(6) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
(7) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
Fig. 20 Remove Battery Cable Terminal Clamp -
Typical
1 – BATTERY
2 – BATTERY TERMINAL PULLER
Fig. 21 Battery Cables
1 – RADIATOR CROSSMEMBER
2 – WHEELHOUSE INNER PANEL
3 – NEGATIVE CABLE
4 – POSITIVE CABLE
5 – BATTERY
XJ
BATTERY
8A - 21
REMOVAL AND INSTALLATION (Continued)
(8) Apply a thin coating of petroleum jelly or chas-
sis grease to the exposed surfaces of the battery cable
terminal clamps and the battery terminal posts.
BATTERY THERMOGUARD
REMOVAL
(1) Remove the battery and the battery thermo-
guard from the battery tray as a unit. Refer to Bat-
tery in the index of this service manual for the
location of the proper battery removal procedures.
(2) Carefully and evenly slide the battery thermo-
guard up off of the battery case (Fig. 22).
INSTALLATION
(1) Clean and inspect the battery thermoguard.
Refer to Battery in the index of this service manual
for the location of the proper battery thermoguard
cleaning and inspection procedures.
(2) Carefully and evenly slide the battery thermo-
guard down over the battery case.
(3) Install the battery and the battery thermo-
guard into the battery tray as a unit. Refer to Bat-
tery in the index of this service manual for the
location of the proper battery installation procedures.
BATTERY TRAY
REMOVAL
(1) Remove the battery from the battery tray.
Refer to Battery in the index of this service manual
for the location of the proper battery removal proce-
dures.
(2) Remove the battery temperature sensor from
the battery tray. Refer to Battery Temperature
Sensor in the index of this service manual for the
location of the proper battery temperature sensor
removal procedures.
(3) Remove the three nuts with washers that
secure the battery tray to the weld studs on the front
extension of the right front wheelhouse inner panel
(Fig. 23).
(4) Remove the battery tray from the weld studs
on the front extension of the right front wheelhouse
inner panel.
(5) From the top of the battery tray, remove the
plastic push-on retainers from the T-bolts that secure
them to the tray.
(6) From the bottom of the battery tray, remove
the two T-bolts from the T-bolt mounts on the tray.
INSTALLATION
(1) Clean and inspect the battery tray. Refer to
Battery in the index of this service manual for the
location of the proper battery tray cleaning and
inspection procedures.
(2) From the bottom of the battery tray, position
the two T-bolts into the T-bolt mounts on the tray.
(3) From the top of the battery tray, install the
plastic push-on retainers onto the T-bolts to secure
them to the tray.
Fig. 22 Battery Thermoguard Remove/Install
1 – THERMOGUARD
2 – BATTERY
Fig. 23 Battery Tray Remove/Install
1 – TRAY
2 – NUT AND WASHER (3)
3 – T-BOLT (2)
4 – RETAINER (2)
5 – WELD STUD (3)
8A - 22
BATTERY
XJ
REMOVAL AND INSTALLATION (Continued)
(4) Position the battery tray onto the weld studs
on the front extension of the right front wheelhouse
inner panel.
(5) Install and tighten the three nuts with washers
that secure the battery tray to the weld studs on the
front extension of the right front wheelhouse inner
panel. Tighten the nuts to 5 N·m (45 in. lbs.).
(6) Install the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
in the index of this service manual for the location of
the proper battery temperature sensor installation
procedures.
(7) Install the battery onto the battery tray. Refer
to Battery in the index of this service manual for
the location of the proper battery installation proce-
dures.
CLEANING AND INSPECTION
BATTERY
The following information details the recommended
cleaning and inspection procedures for the battery
and related components. In addition to the mainte-
nance schedules found in this service manual and the
owner’s manual, it is recommended that these proce-
dures be performed any time the battery or related
components must be removed for vehicle service.
CLEANING
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 24).
(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.
(3) If the removed battery is to be reinstalled,
clean the outside of the battery case and the top
cover with a sodium bicarbonate (baking soda) and
warm water cleaning solution using a stiff bristle
parts cleaning brush to remove any acid film (Fig.
25). 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, refer to Battery in the index of this service
manual for the location of the factory-installed bat-
tery specifications. Confirm that the replacement bat-
tery is the correct size and has the correct ratings for
the vehicle.
(4) Clean the battery thermoguard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.
Fig. 24 Clean Battery Cable Terminal Clamp -
Typical
1 – TERMINAL BRUSH
2 – BATTERY CABLE
Fig. 25 Clean Battery - Typical
1 – CLEANING BRUSH
2 – WARM WATER AND BAKING SODA SOLUTION
3 – BATTERY
XJ
BATTERY
8A - 23
REMOVAL AND INSTALLATION (Continued)
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