Battery Cables - Installation

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.





1. Clean and inspect the battery cable terminal clamps and the battery terminal posts, Battery Cleaning and Inspection.
2. Position the battery wire harness assembly (10) into the vehicle.





3. Raise the vehicle on a hoist, Service and Repair.
4. Install the battery wire harness retaining clips (7) AND (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 Nm (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 Nm (95 in. lbs.).
9. Lower the vehicle.





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 Nm (125 in. lbs.).





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 Nm (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).





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 Nm (105 in. lbs.).





22. Close and latch the covers on the PDC (1) and IPM (2).





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 Nm (20.5 ft. lbs.).





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 Nm (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 Nm (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.