EXJ_8A99 jeep xj service manual

7/29/2019 EXJ_8A99 jeep xj service manual

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BATTERY

CONTENTS

page page

GENERAL INFORMATIONINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DESCRIPTION AND OPERATION

BATTERY MOUNTING . . . . . . . . . . . . . . . . . . . . 3BATTERY SIZE AND RATINGS . . . . . . . . . . . . . . 2BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIAGNOSIS AND TESTINGBATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3BUILT-IN TEST INDICATOR . . . . . . . . . . . . . . . . 4HYDROMETER TEST . . . . . . . . . . . . . . . . . . . . . 6

IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 9LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 7VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . 10

SERVICE PROCEDURESBATTERY CHARGING . . . . . . . . . . . . . . . . . . . 11

REMOVAL AND INSTALLATION

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13SPECIFICATIONS

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GENERAL INFORMATION

OVERVIEW

T h e ba t t e r y , s t a r t in g , a n d ch a r g in g sy st e m s o p e r -

a t e w i t h o n e a n o t h e r , a n d m u s t b e t e s t e d a s a c o m -

p let e s y s t em . I n or d er f or t h e v e h icl e t o s t a r t a n d

ch a r g e p r op er ly, a l l of t h e com p on e n t s in volved in

these systems must perform within specifications.

Group 8A covers the battery, Group 8B covers the

s t a r t i n g s y s t e m , a n d G r o u p 8 C c o v e r s t h e c h a r g i n g

s y s t em . R ef er t o G r o up 8W - Wi r in g D i a g r a m s f or

complete circuit descriptions and diagrams. We have

s e p a r a t e d t h e s e s y s t e m s t o m a k e i t e a s i e r t o l o c a t et h e in f o r m a t io n y o u a r e se e k in g w it h in t h is Se r vice

Ma n u a l . Ho w e ve r , w h e n a t t e m p t in g t o d ia g n o se a n y

o f t h e se sy st e m s, i t is im p o r t a n t t h a t y o u k e e p t h e ir

interdependency in mind.

Th e d ia g n ost ic p r oced u r es u sed in t h e se g r ou p s

include the most basic conventional diagnostic meth-

ods, to the more sophisticated On-Board Diagnostics

(O B D ) b ui lt i nt o t h e P o w er t r a in C on t r ol M od ul e

(P CM). Use of a induction milliam pere a mmeter, volt/

ohmmeter, ba tt ery char ger, car bon pile rheostat (load

tester), and 12-volt test lamp may be required.

Al l O B D -s en s ed s ys t em s a r e m on it or ed b y t h e

PCM. Ea ch m o n it o r e d cir cu it is a ssig n e d a D ia g n o s-tic Trouble Code (DTC). The P CM w ill store a DTC in

electronic memory for any failure it detects. See the

O n -B o a r d D ia g n o st ics Te st in Gr o u p 8C - Ch a r g in g

System for more information.

INTRODUCTION

This section covers only ba ttery diagnostic a nd ser-

vice procedures. For ba ttery ma intenance procedures,

r ef er t o G r o up 0 - L u b r ica t i on a n d M a i n t en a n ce .

W h ile ba t t e r y ch a r g in g ca n be co n sid e r e d a m a in t e -

n a n ce p roce du r e, b a t t e ry ch a r g in g i n for m a t i on i s

located in this group. This was done because the bat-

t e r y m u st be f u l ly -ch a r g ed bef or e a n y d ia g n osis ca n

be performed.

The factory-installed low-maintenance battery has

r e m ova ble ba t t e r y ce ll ca p s. Wa t e r ca n be a d d ed t o

t h is ba t t e r y . T h e ba t t e r y is n o t se a le d a n d h a s ve n t

holes in the cell caps (Fig. 1). The chemical composi-

tion within the low-maintenance battery reduces bat-

t er y g a s si ng a n d w a t e r l os s, a t n or m a l ch a r ge a n d

d isch a r g e r a t e s.

Rapid loss of electrolyte can be caused by an over-

charging condition. Be certain to diagnose the charg-

in g sy st e m bef or e r e t u r n in g t h e veh icle t o ser vice .

Refer to Group 8C - Charging System for more infor-

mation.

Th e f a ct or y -i n st a l l ed b a t t e r y a l s o h a s a b u il t -i n

test indicat or (hydrometer). The color visible in the

s ig h t g la s s of t h e i n di ca t o r w i ll r ev ea l t h e b a t t e r y

Fig. 1 Low-Maintenance Battery - Typical

ELECTROLYTELEVELPOSITIVEPOST VENT TEST INDICA-TOR VENT NEGATIVEPOSTGREEN BALLPLATE GROUPSLOW-MAINTE-N ANC E BAT-TERY

XJ BATTERY 8 A - 1


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con d it ion . Se e B u il t -I n Te st I n d ica t o r in t h is g r ou p

for more information.

I t i s im por t a nt t h a t t h e b a tt er y, s t a rt in g, a n d

charging systems be thoroughly tested and inspected

a n y t im e a ba t t e r y n e e d s t o be ch a r g e d o r r e p la ce d .

Th e ca u se of a bn o r m a l d isch a r g e , ove rch a r g in g , or

early battery failure must be diagnosed and correctedbefore a battery is replaced or returned to service.

NOTE: This group covers both Left-Hand Drive(LHD) and Right-Hand Drive (RHD) versions of thismodel. Whenever required and feasible, the RHD

versions of affected vehicle components have beenconstructed as mirror-image of the LHD versions.While most of the illustrations used in this grouprepresent only the LHD version, the diagnostic and

service procedures outlined can generally beapplied to either version. Exceptions to this rulehave been clearly identified as LHD or RHD, if a

special illustration or procedure is required.

DESCRIPTION AND OPERATION

BATTERY

Th e st or a g e ba t t e r y is a d e vice u sed t o st or e e le c-

t r ica l e n e r g y p o t e n t ia l in a ch e m ica l f o r m . W h e n a n

e le ct r ica l loa d is a p plie d t o t h e ba t t e r y t e r m in a ls , a n

e le ct r o ch e m ica l r e a ct ion occur s w it h in t h e ba t t e r y.

This reaction causes the battery to discharge electri-

cal current.

T h e ba t t e r y is m a d e u p o f s ix in d ivid u a l ce l ls t h a t

are connected in series. Each cell contains posit ively

ch a r g e d p la t e g r o u p s m a d e o f le a d o x id e , a n d n e g a -

t i ve ly ch a r g ed p la t e g r ou ps m a d e of s pon g e l ea d .

Th es e d is s im i la r m et a l p la t e s a r e s u bm er g ed i n a

sulfuric acid and water solution called an electrolyte.

As t h e b a t t er y d is ch a r ges , a g ra d u a l ch em ica l

change t akes place within each cell. The sulfuric acid

in t h e e le ct r o ly t e com bin es w it h t h e p la t e m a t e r ia ls ,

ca u sin g bo t h p la t e s t o slo w ly ch a n g e t o le a d su lf a t e .

At t h e s a m e t i m e, ox yg en f r om t h e p os it i ve p la t e

m a t e r ia l com bin es w it h h y d r og e n f r o m t h e su lfu r ic

acid, causing the electrolyte to become mainly water.

Th e ch em ica l ch a n ges w i th in t h e b a tt er y a r ecaused by the movement of excess or free electrons

between the posit ive and negative plate groups. This

movement of electrons produces a f low of electrical

cu r r e n t t h r o u g h t h e lo a d d e vice a t t a ch e d t o t h e ba t -

t e r y t e r m in a ls .

As the plate materials become more similar chem-

ically, and the electrolyte becomes less acid, the volt-

a g e p ot e n t ia l of e a ch cel l is r e d uce d . H ow e ver, by

ch a r g in g t h e b a t t e ry w i t h a v ol t a g e h ig h er t h a n t h a t

of t h e b a t t e ry, t h e b a t t e ry d is ch a r g in g p roce ss i s

reversed.

C h a r g i ng t h e b a t t e r y g r a d u a ll y c h a n g es t h e s u l -

f a t ed l ea d p la t e s b a ck i nt o s pon g e l ea d a n d l ea d

ox id e, a n d t h e w a t er b a ck i n t o s u l fu r ic a c id . Th i s

action restores the difference in the electron charges

d e p o sit e d o n t h e p la t e s, a n d t h e vo lt a g e p o t e n t ia l o f

t h e ba t t e r y cel ls.

F o r a b a t t e r y t o r e m a i n u s e f u l , i t m u s t b e a b l e t op r od u ce h ig h -a m p e r a g e cur r e n t over a n e xt e n d ed

per iod . A b a t t er y m u st a l s o b e a b le t o a c cept a

ch a r g e , so t h a t i t s vo lt a g e p ot e n t ia l m a y be r e st or e d.

I n a d d i t ion t o p rod u ci n g a n d s t or i ng e le ct r i ca l

e n er g y, t h e ba t t e r y se r ve s a s a ca p a cit or, or volt a g e

stabilizer, for a vehicles electrical system. It absorbs

m os t a b n or m a l or t r a n s i en t v ol t a g es ca u s ed b y t h e

sw it ch in g of a n y of t h e ve hicles e le ct r ica l com p o-

nents.

Th e ba t t e r y is ven t e d t o r e le a se e xcess h y d r og en

g a s t h a t is cr ea t e d w h e n t h e ba t t e r y is be in g ch a r g e d

or d isch a r g e d . H ow e ver, e ven w it h t h e se ve n t s, t h e

h y d r o g e n g a s ca n co lle ct in o r a r o u n d t h e ba t t e r y . I fh y d r og en g a s is e x pose d t o f la m e or sp a r k s, i t m a y

ignite.

I f t h e e le ct r o ly t e le ve l is lo w , t h e ba t t e r y m a y a r c

i n t er n a l ly a n d e xp lod e. I f t h e b a t t e r y i s e qu i pp ed

w it h r e m o va ble ce l l ca p s, a d d d ist i l le d w a t e r w h e n -

ev er t h e e le ct r ol yt e l ev el i s b el ow t h e t op of t h e

plates. I f the battery cell caps cannot be removed, the

b a t t e ry m u s t b e r ep la c ed i f t h e el ect r ol y t e l ev el

becomes low.

BATTERY SIZE AND RATINGS

The battery Group Size number, the Cold Cranking

Am pe ra g e (C C A) r a t i n g , a n d t h e R es er v e C a p a c it y(R C ) r a t i n g or Am p er e-H o ur s (AH ) r a t i n g ca n b e

f ou n d on t h e or i gi n a l e q ui pm en t b a t t e ry l a b el . B e

ce rt a i n t h a t a r ep la c em en t b a t t e r y h a s t h e cor r ect

G r o u p S i z e n u m b e r , a s w e l l a s C C A , a n d R C o r A H

r a t in g s t h a t e q u a l o r e x ce e d t h e o r ig in a l e q u ip m e n t

specification for the vehicle being serviced.

S e e t h e B a t t e r y C l a s s i f i c a t i o n s a n d R a t i n g s c h a r t

in Sp ecif ica t ion s a t t h e ba ck o f t h is g r ou p f o r m o r e

in f o r m a t io n . B a t t e r y siz e s a n d r a t in g s a r e d iscu sse d

in more detail below.

GROUP SIZE

The outside dimensions and terminal placement oft h e ba t t e r y co n f o r m t o st a n d a r d s e st a blish e d by t h e

B a t t e r y Co u n cil I n t e r n a t io n a l (B CI ) . Ea ch ba t t e r y is

a ssig n ed a B C I Gr o u p Siz e n u m ber t o h elp id en t i f y a

correctly-sized replacement.

COLD CRANKING AMPERAGE

The Cold Cranking Amperage (CCA) rating speci-

f ie s h o w m u ch cu r r e n t ( in a m p e r e s) t h e ba t t e r y ca n

deliver for thirt y s econds a t -18 C (0 F). Terminal

vo lt a g e m u st n o t f a l l be lo w 7.2 vo lt s d u r in g o r a f t e r

the thirty second discharge period. The C CA required

8 A - 2 BATTERY XJ

GENERAL INFORMATION (Continued)


3/16

is generally higher as engine displacement increases,

d epen din g a l so u pon t h e s t a rt er cu rr en t d ra w

requirements.

RESERVE CAPACITY

Th e R es er v e C a p a c it y (R C ) r a t i n g s pe ci fi es t h e

t im e ( in m in u t e s) i t t a k e s f o r ba t t e r y t e r m in a l vo lt -

a g e t o f a l l be low 10.5 volt s , a t a d isch a r g e r a t e o f 25

a m p er es . R C i s d et e rm i n ed w i t h t h e b a t t e ry f ul ly -

charged at 26.7 C (80 F). This rat ing estimates how

l o n g t h e b a t t e r y m i g h t l a s t a f t e r a c h a r g i n g s y s t e m

failure, under minimum electrical load.

AMPERE-HOURS

The Ampere-Hours (AH) rat ing specifies the cur-

r e n t ( in a m p e r e s) t h a t a ba t t e r y ca n d e live r st e a d ily

f o r t w e n t y h o u r s, w it h t h e vo lt a g e in t h e ba t t e r y n o t

falling below 10.5 volts. This r at ing is also sometimes

r e fe r r ed t o a s t h e t w e n t y -h ou r d isch a r g e r a t in g .

BATTERY MOUNTING

Th e b a t t e ry i s m ou n t ed t o a m ol d ed p la s t i c t r a y

loca t e d in t h e r ig h t f r on t cor n e r o f t h e e n gin e com -

par tm ent. Two T-bolts a re held in format ions on each

s id e of t h e t r a y b y p us h -on r et a i n er s , a n d ex t en d

upward on each side of the battery. A holddown strap

f i t s a c r o s s t h e t o p o f t h e b a t t e r y c a s e a n d t h e r m o -

guard. The ends of the T-bolts pass through the hold-

d ow n s t r a p o n e a ch s id e o f t h e b a t t er y, a n d a n u t

secures the h olddow n st ra p to th e T-bolts. One end of

a s u pp or t s t r a p i s l oca t e d u n d er t h e f or w a r d -m os t

h o ld d o w n st r a p n u t , a n d t h e o t h e r e n d is se cu r e d t o

the upper radiator crossmember by a bolt .Th e b a t t er y t r a y i s s ecu red w i t h t h r ee n ut s t o

three studs that protrude from the wheelhouse inner

p a n e l, f o r w a r d of t h e r ig h t f r on t w h e el .

O n so m e m o d e ls, a h o le in t h e bo t t o m o f t h e ba t -

t e r y t r a y is f i t t e d w it h a ba t t e r y t e m p e r a t u r e se n so r .

Mod e ls w it h o ut t h e ba t t e r y t e m pe r a t u r e se n sor h a ve

a p lu g f i t t e d t o t h is h o le. Re f er t o G r ou p 8C - Ch a r g -

in g Sy st e m f or m or e in f or m a t io n o n t h e ba t t e r y t e m -

pera ture sensor.

When installing a battery, be certain that the hold-

down fasteners are t ightened to the proper specifica-

tions. Improper holddown fast ener t ightness, w hether

t oo l oos e o r t oo t i g h t , c a n r es u lt i n d a m a g e t o t h eb a t t e r y. S e e t h e B a t t e ry R em ov a l a n d I n s t a l la t i on

p r oce d ur e s f or t h e cor r e ct h old d ow n f a st e n er t ig h t -

ness specifications.

DIAGNOSIS AND TESTING

BATTERY

Th e ba t t e r y m u st be com p le t ely ch a r g e d a n d t h e

t o p, p ost s , a n d t e r m in a l cla m p s sh ou ld be p r op er ly

cleaned before diagnostic procedures are performed.

Se e t h e B a t t e r y Ch a r g in g p r oce d ur e in t h is g r o u p f or

more informat ion.

WARNING:

IF THE BATTERY SHOWS SIGNS OF FREEZ-ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORCHARGE. 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 DAMAGEMAY RESULT. THE BATTERY CONTAINS SULFURIC ACID,

WHICH IS POISONOUS AND CAUSTIC. AVOID CON-TACT WITH THE SKIN, EYES, OR CLOTHING. INTHE EVENT OF CONTACT, FLUSH WITH WATER

AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN. IF THE BATTERY IS EQUIPPED WITH REMOV-

ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-

SONAL INJURY AND/OR VEHICLE DAMAGE MAYRESULT FROM LOOSE OR MISSING CELL CAPS.

The condition of a bat tery is determined by tw o cri-

t e r ia :

1. State-Of-Charge - This can be determined byview in g t h e bu il t -in t e st in d ica t or, by ch eck in g t h e

specific gra vity of t he electrolyte (hydrometer test),or by checking the battery voltage (open-circuit volt-

age test).

2. Cranking Capacity - This can be determinedb y p er f or m in g a b a t t e ry l oa d t e st , w h i ch m ea s u r es

t h e a b i li t y of t h e b a t t e ry t o s u pp ly h i gh -a m p er a g e

current.

F ir st , d e t er m in e t h e ba t t e r y st a t e -of -ch a r g e. Th is

ca n be d on e in o n e of t h r e e w a y s. I f t h e ba t t e r y h a s a

b ui lt -i n t e st i n di ca t o r, v ie w t h e t e st i n di ca t o r t o

d e t e r m in e t h e st a t e - o f - ch a r g e . I f t h e ba t t e r y h a s n o

t e st in d ica t or , bu t h a s r e m ova ble ce ll ca p s, p er f or m

the hydrometer test to determine the state-of-charge.

If the cell caps are not removable, or a hydrometer isnot a vaila ble, perform the open-circuit volta ge test to

determine the sta te-of-charge.

Th e ba t t e r y m u st be ch a r g e d bef or e p r oce ed in g

w i t h a l oa d t e st i f:

Th e bu il t -in t e st in d ica t o r h a s a bla ck or d a r k

color visible.

Th e t e m pe r a t u r e cor r e ct e d sp ecif ic g r a vit y is

less than 1.235.

The open-circuit voltage is less than 12.4 volts.

A ba t t e r y t h a t w i ll n ot a c cep t a ch a r g e i s f a u lt y,

a n d m us t be r epla ced . F ur th er t es tin g is n ot

XJ BATTERY 8 A - 3

DESCRIPTION AND OPERATION (Continued)


4/16

required. A fully-charged battery must be load tested

t o d e t e r m in e i t s cr a n k in g ca p a cit y . A ba t t e r y t h a t is

f u ll y-ch a r g ed , b u t d oe s n ot p a s s t h e l oa d t e st , i s

f a u lt y a n d m u st be r e p la ce d .

NOTE: Completely discharged batteries may takeseveral hours to accept a charge. See Charging ACompletely Discharged Battery in this group for

more information.

A battery is fully-charged when:

All cells are gassing freely during charging.

A g r ee n color is visible in t h e sig h t g la ss of t h e

built-in test indicator.

Th r e e cor r e ct e d sp ecif ic g r a vit y t e st s , t a k en a t

on e -h ou r in t er va ls , in d ica t e n o in cr e a se in t h e sp e-

cific gravity.

Open-circuit voltage is 12.4 volts or greater.

ABNORMAL BATTERY DISCHARGING

Any of the following conditions can result in abnor-

m a l ba t t e r y d isch a r g in g :

1. C or r od ed or l oos e b a t t e r y p os t s a n d t e rm i n a l

clamps.

2. A loose or worn generat or drive belt .

3. E l ect r i ca l l oa d s t h a t e xce ed t h e ou t pu t of t h e

ch a r gi ng s ys t em . Th is ca n b e d u e t o eq u ipm en t

i n st a l l ed a f t e r m a n u f a ct u r e, or r ep ea t e d s h or t t r i p

use.

4. Slow driving speeds (heavy tra ffic conditions) or

p r olon g ed id lin g , w it h h ig h -a m p e r a g e d r a w sy st e m s

in use.

5. A faulty circuit or component causing excessiveignition-off draw. S ee the Ig nition-Off Dr a w Test pro-

cedure in this group for more information.

6. A f a u lt y or in cor r e ct ch a r g in g sy st e m com p o-

n e n t . Re f er t o G r ou p 8C - Ch a r g in g Sy st e m f or m or e

information.

7. A faulty or incorrect battery.

BUILT-IN TEST INDI CATOR

A t e st in d ica t or (h y d r om e t er ) bu ilt in t o t h e t o p o f

t h e ba t t e r y ca se p r o vid e s visu a l in f o r m a t io n f o r ba t -

tery testing (Fig. 2). L ike a hydrometer, t he built-in

t e st i n di ca t o r m ea s u r es t h e s pe ci fi c g r a v it y of t h e

e le ct r ol yt e . Th e t e st i n di ca t o r r ev ea l s t h e b a t t e rystate-of-charge; however, it will not reveal the crank-

in g ca p a cit y o f t h e ba t t e r y . A lo a d t e st m u st be p e r -

f or m e d t o d e t er m in e t h e ba t t e r y cra n k in g ca p a cit y.

See t he Load Test procedure in this group for more

information.

WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZ-

ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-

LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORCHARGE. THE BATTERY MAY ARC INTERNALLY


AROUND THE BATTERY. DO NOT SMOKE, USEFLAME, 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. INTHE EVENT OF CONTACT, FLUSH WITH WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN.

IF THE BATTERY IS EQUIPPED WITH REMOV-ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-


B e f or e t e st in g , visu a lly in spe ct t h e ba t t e r y f or a n y

d a m a g e (a cr a ck ed ca se or cover, loose p ost s , e t c.)

t h a t w o u ld ca u se t h e ba t t e r y t o be f a u lt y . I n o r d e r t o

obtain correct indications from the built-in test indi-

ca t o r, i t i s i m p or t a n t t h a t t h e b a t t e r y b e l ev el a n d

h a v e a cl ea n s ig ht g la s s . Ad d it i on a l l ig h t m a y b e

r e q u ir e d t o view t h e in d ica t or . Do not use openflame as a source of additional light.

To r e a d t h e bu il t -in t e st in d ica t or, look in t o t h e

sight gla ss a nd note the color of t he indicator (Fig. 3).

Refer to the following description, as the color indi-

cates:

Green - ind icates 75% to 100% sta te-of-char ge.The battery is adequately charged for further testing

or r e t u r n t o u se . I f t h e ve h icle w il l n ot cra n k f or a

minimum of fifteen seconds with a fully-charged bat-

tery, perform the Load Test procedure a s described in

this group.

Black or Dark - indicat es 0% to 75% sta te-of-ch a r ge. Th e b a t t er y i s i na d eq u a t el y ch a r ged a n d

must be charged until a green indication is visible in

t h e sigh t g la ss (12.4 vo lt s or m or e ), bef or e t h e ba t -

t e r y is t e st e d f u r t h e r o r r e t u r n e d t o se r vice . Se e t h e

B a t t e r y Ch a r g in g p r oced u r e in t h is g r ou p f o r m o r e

information. Also see Abnormal Battery Discharging

in t h is g r ou p f or p ossible ca u se s of t h e d isch a r g e dcondition.

Clear or Bright - in d ica t e s a low e le ct r o ly t elevel. The electrolyte level in the bat tery is below the

t e st in d ica t or . A m a in t e n a n ce-f r ee ba t t e r y w it h n on -

removable cell caps must be replaced if t he electro-

l yt e l ev el i s l ow. Wa t e r m u st b e a d ded t o a l ow -

maintenance battery with removable cell caps before

it is ch a r g e d . Se e t h e B a t t e r y Ch a r g in g p r o ce d u r e in

t h is g r ou p f or m or e in f or m a t io n . A low e le ct r o ly t e

level m a y be ca u se d by a n over cha r g in g con d it ion .

8 A - 4 BATTERY XJ

DIAGNOSIS AND TESTING (Continued)


5/16

Battery Diagnosis

Condition Possible Causes Correction

The battery seems weak ordead when attempting to startthe engine.

1. The battery has anincorrect size or rating forthis vehicle.

2. The battery is physicallydamaged.3. The battery terminalconnections are loose or

corroded.4. The battery is discharged.5. The electrical system isfaulty.6. The battery is faulty.

7. The starting system isfaulty.8. The charging system isfaulty.

1. See Specifications in this group. Replace theincorrect battery with the correct battery, ifrequired.

2. Inspect the battery for loose terminal posts or acracked and leaking case. Replace the battery, ifdamaged.3. See the Voltage Drop Test in this group. Clean

and tighten the battery terminal connections, ifrequired.4. See the Test Indicator, the Hydrometer Test, orthe Open-Circuit Voltage Test in this group todetermine 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, ifrequired.7. Refer to Group 8B - Starting Systems for moreinformation. Repair the starting system, if

required.8. Refer to Group 8C - Charging Systems formore information. Repair the charging system, ifrequired.

The battery state-of-chargecannot be maintained.

1. The battery has anincorrect size or rating forthis vehicle.

2. The battery terminal

connections are loose orcorroded.3. The generator drive belt is

loose or worn.4. The electrical system isfaulty.5. The battery is faulty.

6. The starting system isfaulty.7. The charging system isfaulty.

8. Electrical loads exceed theoutput of the charging

system.9. Slow driving or prolonged

idling with high-amperagedraw systems in use.

1. See Specifications in this group. Replace theincorrect battery with the correct battery, ifrequired.

2. See the Voltage Drop Test in this group. Clean

and tighten the battery terminal connections, ifrequired.3. Refer to Group 7 - Cooling Systems for more

information. Replace or adjust the generator drivebelt, 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 determinethe battery condition. Replace the battery, ifrequired.6. Check whether the starting system is

performing to specifictions. 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, ifrequired.8. Inspect the vehicle for aftermarket electricalequipment which might cause excessive electricalloads.

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.

XJ BATTERY 8 A - 5



6/16


7/16

26.6 C - -12.2 C = 38.8 C (80 F -

10 F = 70 F)

(2) Divide the result from Step 1 by 5.5 (10):

38.8 C 5.5 = 7 (70 F 10 = 7)

(3) Multiply the result from Step 2 by the temper-

ature correction factor (0.004):

7 X 0.004 = 0.028

(4) Th e t e m p er a t u r e a t t e st in g w a s below 26.7 C

(80 F); th erefore, t he tempera ture correction factor

is su bt r a ct ed :

1.240 - 0.028 = 1.212

The corrected specific gravity of the battery in this

example is 1.212.

If the specific gravity of all cells is above 1.235, but

t h e va r ia t io n be t w e e n ce lls is m o r e t h a n f i f t y p o in t s

(0.050), the battery should be replaced. If the specific

gravit y of one or more cells is less tha n 1.235, char ge

t h e ba t t e r y a t a r a t e o f a p p r o x im a t e ly f ive a m p e r e s.

Continue charging the battery until three consecu-

t ive sp e cif ic g r a vit y t e st s , t a k e n a t on e -h ou r in t er -

v a ls , a r e con st a n t . I f t h e cell s pecif ic g ra v it y

variat ion is more than fifty points (0.050) at the endof the charge period, replace the battery.

When the specific gravity of all cells is above 1.235,

and the cell variat ion is less than fifty points (0.050),

t h e b a t ter y m a y b e loa d t es t ed t o d et er min e it s

cr a n k in g ca p a cit y. Se e t h e L oa d Te st p r oced u r e in

this group for more information.

OPEN-CIRCUIT VOLTAGE TEST

A ba t t e r y op en -cir cu it volt a g e (n o loa d ) t e st w il l

show t he sta te-of-charge of a bat tery. This t est ca n be

used in place of the hydrometer test when a hydrom-

eter is not available, or for maintenance-free batter-

ies with non-removable cell caps.


ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORCHARGE. THE BATTERY MAY ARC INTERNALLY








Before proceeding with this test , completely charge

t h e ba t t e r y a s d e scr ibed in t h e B a t t e r y Ch a r g in g p r o-

cedure in this group.

(1) B efore measuring the open-circuit voltage, the

s u rf a ce ch a r g e m u s t b e r em ov ed f r om t h e b a t t e ry.Tu r n on t h e h ea d l a m ps f or f if t ee n s econ d s , t h e n

a l l ow u p t o f iv e m i n u t es f or t h e b a t t e ry v ol t a g e t o

stabilize.

(2) Disconnect an d isolate both ba ttery cables, neg-

a t ive ca ble f ir st .

(3) U s in g a v ol t m et e r con n ect e d t o t h e b a t t e ry

p os t s (r ef er t o t h e i n st r u ct i on s p rov id ed w i t h t h e

voltmeter), measure the open-circuit voltage (Fig. 5).

Fig. 4 Hydrometer - Typical

BULB SURFACE COHESIONSPECIFIC GRAVITYREADINGTEMPERATURE READINGHYDROMETERBARRELFLOAT

Fig. 5 Testing Open-Circuit Voltage - Typical

XJ BATTERY 8 A - 7



8/16

Se e t h e O pe n -Cir cu it Volt a g e ch a r t . Th is volt a g e

reading will indicate the battery state-of-charge, but

w il l n o t r e ve a l i t s cr a n k in g ca p a cit y . I f a ba t t e r y h a s

a n op en -ci r cu it v ol t a g e r ea d i n g of 12. 4 v ol t s or

g r e a t e r , i t m a y be lo a d t e st e d t o r e ve a l i t s cr a n k in g

capacity. S ee the Load Test procedure in this group

for more information.

LOAD TEST

A ba t t e r y loa d t e st w il l ver i fy t h e ba t t e r y cr a n k in gca p a ci t y. Th e t e st i s b a s ed on t h e C ol d C r a n k in g

Am p e r a g e (CCA) r a t in g o f t h e ba t t e r y . Re f e r t o t h e

b a t t e r y l a b e l, or s ee t h e B a t t e ry C l a s s if ica t i on s a n d

R a t i n g s c h a r t i n S p eci fi ca t i on s a t t h e b a ck of t h i s

group for the CCA rating of the factory-installed bat-

tery.

WARNING:

IF THE BATTERY SHOWS SIGNS OF FREEZ-



AROUND THE BATTERY. DO NOT SMOKE, USEFLAME, OR CREATE SPARKS NEAR THE BATTERY.

PERSONAL INJURY AND/OR VEHICLE DAMAGEMAY 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 WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN.

IF THE BATTERY IS EQUIPPED WITH REMOV-ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-SONAL INJURY AND/OR VEHICLE DAMAGE MAY

RESULT FROM LOOSE OR MISSING CELL CAPS.

Before proceeding with this test , completely charge

t h e ba t t e r y a s d e scr ibed in t h e B a t t e r y Ch a r g in g p ro-

cedure in this group.

(1) Disconnect an d isolate both ba ttery cables, neg-

ative cable first . The battery top and posts should be

clean.

(2) Con n e ct a su it a ble volt -a m m e t e r -loa d t e st er

(F i g. 6) t o t h e b a t t e r y p os t s (F i g. 7). R ef er t o t h e

operating instructions provided with the tester being

used. Check the open-circuit voltage (no load) of theba t t e r y. O pe n -cir cu it volt a g e m u st be 12.4 volt s or

greater.

(3) Rotate the load control knob (carbon pile rheo-

s t a t ) t o a p p l y a 3 0 0 a m p e r e l o a d t o t h e b a t t e r y f o r

f i f t e e n se co n d s, t h e n r e t u r n t h e co n t r o l k n o b t o t h eO ff p osit ion (F ig . 8). Th is w il l r e m ove t h e su r f a ce

ch a r g e f r o m t h e ba t t e r y .

(4) Allow t h e ba t t e r y t o st a bil iz e t o op en -cir cu it

v o l t a g e . I t m a y t a k e u p t o f i v e m i n u t e s f o r t h e b a t -

tery voltage to stabilize.

(5) Rotate the load control knob to maintain a load

e q u a l t o 50% of t h e CCA r a t in g o f t h e ba t t e r y (F ig .

9). Af t e r f if t e en se con d s, r e cor d t h e loa d e d volt a g e

reading, then return the load control knob to the Off

position.

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

INDUCTIONAMMETERCLAMP NEGATIVECLAMPPOSITIVECLAMP

8 A - 8 BATTERY XJ



9/16

(6) Th e v ol t a g e d r op w i ll v a r y w i t h t h e b a t t e r y

t e m pe r a t u r e a t t h e t im e o f t h e lo a d t e st . Th e ba t t e r y

t e m p e r a t u r e ca n be e st im a t e d by u sin g t h e a m bie n t

t e m pe ra t u r e d u r in g t h e p a s t s ev er a l h ou r s. I f t h e

ba t t e r y h a s bee n ch a r g e d , boost e d , o r loa d e d a f ew

m i n ut e s p r i or t o t h e t e st , t h e b a t t e ry w i ll b e s om e-

w h a t w a r m e r. Se e t h e L oa d Te st Te m pe r a t u r e ch a r t

for the proper loaded voltage reading.

(7) If t he voltmeter rea ding falls below 9.6 volts, a t

a minimum battery temperature of 21 C (70 F), the

ba t t e r y is f a u lt y a n d m u st be r e p la ce d .

IGNITION- OFF DRAW TEST

I g n it i on -O ff D r a w (I O D ) r ef er s t o p ow e r b ei n g

d r a in e d f r o m t h e ba t t e r y w it h t h e ig n it io n sw it ch inthe Off posit ion. A normal vehicle electrical system

w i ll d ra w f rom f iv e t o t w en t y -f iv e m il li a m per es

(0.005 t o 0.025 a m p er e ) w it h t h e ig n it ion sw it ch in

the Off posit ion, a nd all non-ignit ion controlled cir-

cuits in proper working order. The twenty-five milli-

a m p e r es a r e n e ed e d t o e n a ble t h e m e m or y f u n ct ion s

f or t h e P o w e rt r a i n C on t r ol M od u le (P C M ), d ig it a l

clock, electronically tuned ra dio, an d other m odules

w h ich m a y va r y w it h t h e ve h icle e q u ip m e n t .

A ve h icle t h a t h a s n o t be e n o p e r a t e d f o r a p p r o x i-

m a t e ly t w e n t y d a y s , m a y d is ch a r g e t h e b a t t e r y t o a n

inadequate level. When a vehicle will not be used for

t w e n t y d a y s or m or e (st or e d ), r e m ove t h e I O D f u sefrom the Power Distribution Center (PDC). This will

reduce battery discharging.

Ex ce ssive I O D ca n be ca u se d by :

Electrical items left on

Faulty or improperly adjusted switches

Fa ulty or shorted electronic modules a nd compo-

n e n t s

An internally shorted generator

I n t e r m it t e n t sh o r t s in t h e w ir in g .

I f t h e I O D i s ov er t w e n t y -f iv e m i ll ia m p er es , t h e

problem must be found a nd corrected before replac-

i ng a b a t ter y. I n m os t ca s es , t h e b a t t er y ca n b e

ch a r g e d a n d r e t u r n e d t o se r vice a f t e r t h e e x ce ssiveIOD condition has been corrected.

DIAGNOSIS

(1) Ve r if y t h a t a l l e le ct r ica l a cce ssor ies a r e of f .

Turn off a ll la mps, remove the ignit ion key, and close

a l l d oor s . I f t h e v eh i cl e i s e q ui pp ed w i t h a i ll um i -

n a t e d e nt r y s y s t em or e le ct r on i ca l l y t u n ed r a d i o,

allow the electronic t imer function of these systems

t o a u t o m a t ica l ly sh u t of f ( t im e o u t ). Th is m a y t a k e

u p t o t h r e e m in u t e s.

(2) D e t e r m in e t h a t t h e u n d e r h o o d la m p is o p e r a t -

ing properly, then unplug the lamp wire harness con-

nector or remove the lamp bulb.(3) Disconnect the battery negative cable.

(4) S et a n e le ct r on i c d i gi t a l m u lt i -m et e r t o i t s

h i gh es t a m p er a g e s ca l e. C on n ect t h e m u lt i -m et e r

b et w e en t h e d is con n ect e d b a t t e r y n eg a t i ve ca b l e

cla m p a n d t h e ba t t e r y n e g a t ive t e r m in a l p o st . Ma k e

su r e t h a t t h e d o o r s r e m a in clo se d so t h a t t h e i l lu m i-

nated entry system is not activated. The multi-meter

a m p e r a g e r e a d i n g m a y r e m a i n h i g h f o r u p t o t h r e e

m in u t es, o r m a y n ot g ive a n y r e a d in g a t a l l w h ile se t

in t h e h ig h est a m p e r a g e sca le, d e pe n d in g u p on t h e

electrical equipment on the vehicle. The multi-meter

Fig. 8 Remove Surface Charge from Battery -Typical

Fig. 9 Load 50% CCA Rating - Note Voltage - Typical

Load Test Temperature

Minimum Volt-

age

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

XJ BATTERY 8 A - 9



10/16

le a d s m u st be se cu r e ly cla m p e d t o t h e ba t t e r y n e g a -

t i v e c a b l e c l a m p a n d t h e b a t t e r y n e g a t i v e t e r m i n a l

p o st . I f co n t in u it y be t w e e n t h e ba t t e r y n e g a t ive t e r -

m in a l p o st a n d t h e n e g a t ive ca ble cla m p is lo st d u r -

i n g a n y p a r t of t h e I O D t e st , t h e el ect r on i c t i m er

f u nct i on w i ll b e a c t i va t e d a n d a l l of t h e t e s t s w i ll

h a ve t o be r e pe a t e d .(5) Aft e r a bo u t t h r e e m in u t e s, t h e h ig h -a m p e r a g e

IOD reading on the multi-meter should become very

low or n on e xist en t , d e pe n d in g u p on t h e e le ct r ica l

e q u ip m en t on t h e veh icle. I f t h e a m p e r a g e r e a d in g

r e m a in s h ig h , r e m ove e a ch f u se o r cir cuit br ea k e r

(refer to Group 8W - Wiring Diagrams for more infor-

m a t i on ) u n t il t h e a m p er a g e r ea d i n g b ecom es v er y

low, or nonexistent. This will isolate each circuit and

id en t i f y t h e so u r ce o f t h e h ig h -a m p e r a g e I O D . I f t h e

a m p e r a g e r e a d in g r e m a in s h ig h a f t e r d iscon n e ct in g

e a ch f u se a n d cir cu it br e a k e r , u n p lu g t h e w ir e h a r -

n e ss co n n e ct o r f r o m t h e g e n e r a t o r . I f t h e a m p e r a g e

reading now becomes very low or nonexistent, refert o G r ou p 8C - C h a r gin g S y st em t o d ia g nos e t h e

faulty charging system. After the high-amperage IOD

h a s bee n cor r e ct e d , sw it ch t h e m u lt i-m e t er t o p r o-

g r essive ly low e r a m p e r a g e sca le s a n d , i f n e ce ssa r y ,

r e pe a t t h e f u se a n d cir cu it br ea k e r r e m ova l p r ocess

to identify and correct the sources of excessive IOD.

I t is n o w sa f e t o se le ct t h e lo w e st m il l ia m p e r e sca le

of the multi-meter to check the low-amperage IOD.

CAUTION: Do not open any doors, or turn on anyelectrical accessories with the lowest milliamperescale selected, or the multi-meter may be damaged.

(6) Observe the multi-meter reading. The low-am-p er a g e I O D sh ou ld n ot e xcee d t w e n t y -f ive m il lia m -

peres (0.025 ampere). If the draw exceeds twenty-five

m illia m p er e s, iso la t e e a ch cir cu it by r e m ovin g t h e

circuit breakers a nd fuses. The mult i-meter rea ding

w i l l d r op t o w i t h in t h e a c ce pt a b l e l i mi t w h e n t h e

source of the excessive dra w is disconnected. Repair

t h is ci rcu it a s r eq u ir ed ; w h et h er a w i ri ng s h or t ,

incorrect switch adjustment, or a component fa ilure

i s a t f a u l t .

VOLTAGE DROP TEST

Th e v ol t a g e d r op t e st w i l l d et e rm i n e i f t h er e i s

e x ce ssive r e sist a n ce in t h e ba t t e r y t e r m in a l co n n e c-t ion s or t h e ba t t e r y ca ble s. Wh e n p er f or m in g t h e se

t e st s , i t i s i m p or t a n t t o r e m em b er t h a t t h e v o lt a g e

drop is giving an indication of the resistance between

t h e t w o poi nt s a t w h i ch t h e v ol tm et er pr ob es a r e

a t t a ch e d .

Example: W h e n t e st in g t h e r e sist a n ce o f t h e ba t -t e r y p o sit ive ca ble , t o u ch t h e vo lt m e t e r le a d s t o t h e

battery posit ive cable clamp and the cable connector

a t t h e st a r t e r so le n o id . I f y o u p r o be t h e ba t t e r y p o s-

i t iv e t e r m in a l p os t a n d t h e ca b l e c on n ect or a t t h e

st a r t e r so le n o id , y o u a r e r e a d in g t h e co m bin e d vo lt -

age drop in the bat tery posit ive cable clamp-to-termi-

nal post connection and the battery posit ive cable.










Th e f ol low in g op er a t io n w il l r e q u ir e a volt m e t er

accurate to 1/10 (0.10) volt . B efore performing the

tests, be certain the following procedures are accom-

plished:

B a t t e r y i s f ul ly -ch a r g ed a s d es cr i be d i n t h i sgroup.

F u lly e n g a g e t h e p a r k in g br a k e .

I f t h e v eh icl e i s eq u ipped w i t h a n a u t om a t i c

transmission, place the gearshift selector lever in the

P a r k p osit ion . I f t h e ve h icle is e q u ipp ed w it h a m a n -

ual transmission, place the gearshift selector lever in

t h e N eu t r a l p os it i on a n d f ul ly d ep res s t h e cl ut ch

pedal.

U n p lu g t h e Au t om a t ic Sh u t D ow n (ASD ) r e la y t o

p r even t t h e e n gin e f r om st a r t in g . Th e ASD r e la y is

l oca t e d i n t h e P o w er D i st r ib ut i on C en t er (P D C ).

Re f e r t o t h e PD C la be l f o r ASD r e la y id e n t i f ica t io n

and location.(1) Co n n ect t h e p osit ive lea d of t h e volt m e t er t o

t h e ba t t e r y n e ga t ive t e r m in a l p ost . Co n n ect t h e n e g -

a t i v e l ea d of t h e v ol t m et e r t o t h e b a t t e ry n eg a t i ve

ca ble cla m p (F ig . 10). Rot a t e a n d h old t h e ig n it ion

switch in the Start posit ion. Observe the voltmeter. I f

voltage is detected, correct the poor contact between

t h e ca ble cla m p a n d t h e t e r m in a l p o st .

(2) Co n n ect t h e p osit ive lea d of t h e volt m e t er t o

t h e ba t t e r y p osit ive t e r m in a l p ost . Co n n ect t h e n e ga -

tive lead of the voltmeter to the ba ttery posit ive cable

cla m p (F ig . 11). Ro t a t e a n d h o ld t h e ig n it io n sw it ch

8 A - 1 0 BATTERY XJ



11/16

in t h e St a r t p o sit io n . O bse r ve t h e vo lt m e t e r . I f vo lt -

age is detected, correct the poor contact between theca ble cla m p a n d t h e t e r m in a l p o st .

(3) Connect the voltmeter to measure between the

b a t t e r y p os it i ve t e rm i n a l p os t a n d t h e s t a r t e r s ol e-

n oid ba t t e r y t e r m in a l s t u d (F ig . 12). Ro t a t e a n d h old

t h e ig n it ion sw it ch in t h e S t a r t p osit ion . O bser ve t h e

volt m e t er. I f t h e r e a d in g is a bo ve 0.2 volt , c lea n a n d

t ig h t e n t h e ba t t e r y ca ble con n e ct ion a t t h e solen oid .

Re pe a t t h e t e st . I f t h e r e a d in g is s t i l l a bove 0.2 vo lt ,

replace the faulty battery posit ive cable.

(4) Connect the voltmeter to measure between the

b a t t er y n eg a t iv e t er m in a l pos t a n d a g ood cl ea n

ground on t he engine block (Fig. 13). R otate an d hold

the ignit ion switch in the Start posit ion. Observe the

volt m e t er. I f t h e r e a d in g is a bo ve 0.2 volt , c lea n a n d

t ig h t e n t h e ba t t e r y n e g a t ive ca ble a t t a ch m e n t o n t h ee n g in e blo ck . Re p e a t t h e t e st . I f t h e r e a d in g is s t i l l

a b ov e 0. 2 v ol t , r ep la c e t h e f a u lt y b a t t e r y n eg a t i v e

cable.

SERVICE PROCEDURES

BATTERY CHARGING

A battery is fully-charged when:

All cells are gassing freely during battery charg-

ing. A g r ee n color is visible in t h e sig h t g la ss of t h e

built-in test indicator.

Th r e e cor r e ct e d sp ecif ic g r a vit y t e st s , t a k en a t

on e -h ou r in t er va ls , in d ica t e n o in cr e a se in t h e sp e-

cific gravity.

Open-circuit voltage is 12.4 volts or above.

Fig. 10 Test Battery Negative Connection

Resistance - Typical

VOLTMETERBATTERY

Fig. 11 Test Battery Positive Connection Resistance- Typical

VOLTMETER BATTERY

Fig. 12 Test Battery Positive Cable Resistance -Typical

BATTERYVOLTMETERSTARTERMOTOR

Fig. 13 Test Ground Circuit Resistance - Typical

VOLTMETERENGINEGROUND BATTERY

XJ BATTER Y 8 A - 1 1



12/16



AND EXPLODE. PERSONAL INJURY AND/OR VEHI-

CLE DAMAGE MAY RESULT. EXPLOSIVE HYDROGEN GAS FORMS IN AND



WHICH IS POISONOUS AND CAUSTIC. AVOID CON-TACT WITH THE SKIN, EYES, OR CLOTHING. INTHE EVENT OF CONTACT, FLUSH WITH WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT

OF THE REACH OF CHILDREN. IF THE BATTERY IS EQUIPPED WITH REMOV-



CAUTION:

Always disconnect and isolate the battery neg-

ative cable before charging a battery. Do not exceedsixteen volts while charging a battery. Damage tothe vehicle electrical system components mayresult.

Battery electrolyte will bubble inside the bat-tery case during normal battery charging. Electro-lyte boiling or being discharged from the batteryvents indicates a battery overcharging condition.

Immediately reduce the charging rate or turn off thecharger to evaluate the battery condition. Damageto 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 thecharger and let the battery cool before continuingthe charging operation. Damage to the battery mayresult.

So m e ba t t e r y ch a r g e r s a r e e q u ip p e d w it h p o la r i t y -sensing circuitry. This circuitry protects the charger

a n d /or t h e b a t t e ry f r om b ei n g d a m a g ed i f t h ey a r e

improperly connected. If the bat tery sta te-of-charge

is too low for the polarity-sensing circuitry to detect ,

t h e ch a r g e r w ill n o t op er a t e . Th is m a k es i t a p p ea r

t h a t t h e b a t t e ry w i ll n ot a c ce pt ch a r g in g cu r r en t .

Re fe r t o t h e in st r u ct ion s p r ovide d w it h t h e ba t t e r y

charger to bypass the polarity-sensing circuitry.

After the battery has been charged to 12.4 volts or

g r ea t e r, p e r for m a loa d t e st t o d e t e r m in e t h e ba t t e r y

cr a n k in g ca p a c it y. I f t h e b a t t e ry w i ll e nd u r e a l oa d

t e st , r e t u r n t h e ba t t e r y t o u se . I f t h e ba t t e r y w il l n o t

e n d u r e a lo a d t e st , i t is f a u lt y a n d m u st be r e p la ce d .

Cle a n a n d in spe ct t h e ba t t e r y h o ld d ow n s, t r a y , t e r -

minals, posts, and top before completing service. See

t h e B a t t e r y Re m o va l a n d I n st a l la t io n p r o ce d u r e s in

this group for more information.

CHARGING A COMPLETELY DISCHARGED

BATTERY

The following procedure should be used to recharge

a com p le t ely d isch a r g e d ba t t e r y. U n le ss t h is p r oce-

d u r e i s p rop er l y f ol low e d , a g ood b a t t e r y m a y b e

needlessly replaced.

(1) Mea su r e t h e vo lt a g e a t t h e ba t t e r y p ost s w it h a

voltmeter, a ccura te to 1/10 (0.10) volt (Fig. 14). If th e

reading is below ten volts, the charge current will be

l ow . I t cou ld t a k e s om e t i me b ef or e t h e b a t t er y

a cce pt s a cu r r en t g r ea t e r t h a n a f ew m ill ia m p er e s.

S u ch l ow cu r ren t m a y n ot b e d e t ect a b le on t h e

a m m e t e r s bu il t in t o m a n y ch a r g e r s.

(2) D is con n ect a n d i sol a t e t h e b a t t e r y n eg a t i v e

ca ble . Co n n e ct t h e ba t t e r y ch a r g e r le a d s. So m e ba t -

tery chargers are equipped with polarity-sensing cir-

cuitry. This circuitry protects the charger an d/or t he

ba t t e r y f r o m be in g d a m a g e d i f t h e y a r e im p r o p e r ly

connected. If the battery state-of-charge is too low for

t h e p ola r i t y -sen sin g cir cuit r y t o d e t ect , t h e ch a r g e r

w il l n o t o p e r a t e . T h is m a k e s i t a p p e a r t h a t t h e ba t -t e r y w i ll n ot a c ce pt ch a r g in g cu r r en t . R ef er t o t h e

i n st r u ct i on s p rov id ed w i t h t h e b a t t e ry ch a r g er t o

bypass the polarity-sensing circuitry.

(3) B a t t e r y ch a r g e r s va r y in t h e a m o u n t o f vo lt a g e

a n d cu rr en t t h ey pr ov id e. Th e a m ou nt of t im e

r e q u ir e d f or a ba t t e r y t o a cce pt m e a su r a ble ch a r g er

c u r r e n t a t v a r i o u s v o l t a g e s i s s h o w n i n t h e C h a r g e

Ra t e ch a r t . I f t h e ch a r g e cu r r e n t is s t i l l n o t m e a su r -

a b l e a t t h e e n d o f t h e c h a r g i n g t i m e , t h e b a t t e r y i s

f a u lt y a n d m u st be r e p la ce d . I f t h e ch a r g e cu r r e n t is

m e a s ur a b l e d u r in g t h e ch a r g i ng t i m e, t h e b a t t e ry

Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -

Typical


SERVICE PROCEDURES (Continued)


13/16

ma y be good a nd t he charging sh ould be completed in

t h e n o r m a l m a n n e r .

CHARGING TIME REQUIRED

Th e t i m e r e q u ir ed t o ch a r g e a b a t t e r y w i ll v a r y,

depending upon the following factors:

Battery Capacity - A completely discha rgedh e a vy - d u t y ba t t e r y r e q u ir e s t w ice t h e ch a r g in g t im e

o f a sm a ll ca p a cit y ba t t e r y .

Temperature - A longer t ime w ill be needed toc h a r g e a b a t t e r y a t - 1 8 C ( 0 F ) t h a n a t 2 7 C ( 8 0

F ). Wh e n a f a st ch a r g e r is con n e ct e d t o a cold ba t -

tery, the current accepted by the battery will be veryl ow a t f ir s t . As t h e b a t t e r y w a r m s , i t w i ll a cce pt a

higher charging current rate (amperage).

Charger Capacity - A ch a r g e r t h a t su pp lieson l y f iv e a m p er es w i l l r eq u ir e a l on g er ch a r g in g

t i m e. A c ha r g er t h a t s u pp li es t w e n t y a m p er es or

m or e w ill r e q u ir e a sh or t e r ch a r g in g t im e .

State-Of-Charge - A com p le t ely d isch a r g e dba t t e r y r e q u ir e s m o r e ch a r g in g t im e t h a n a p a r t ia l ly

d isch a r g e d ba t t e r y . Ele ct r o ly t e is n e a r ly p u r e w a t e r

i n a com pl et el y d is ch a r ged b a t t er y. At f ir s t , t h e

charging current (amperage) will be low. As the bat-

t e r y ch a r g es, t h e sp ecif ic g r a vit y of t h e e le ct r o ly t e

w il l g r a d u a lly r ise.

WARNING: NEVER EXCEED TWENTY AMPERESWHEN CHARGING A COLD (-1 C/30 F) BATTERY.THE BATTERY MAY ARC INTERNALLY ANDEXPLODE. PERSONAL INJURY AND/OR VEHICLEDAMAGE MAY RESULT.

REMOVAL AND INSTALLATION

BATTERY

(1) Tu r n t h e ig n it ion sw it ch t o t h e O f f p o sit ion .Make sure all electrical accessories are turned off .

(2) L o o se n t h e ca ble t e r m in a l cla m p s a n d d isco n -

n e ct bo t h ba t t e r y ca ble s, n e g a t ive ca ble f ir st . I f n e c-

e ssa r y , u se a p u ller t o r e m ove t h e t e r m in a l cla m p s

from the battery posts (Fig. 15).

(3) Inspect the cable terminal clamps for corrosion

a n d d a m a g e. R em ov e a n y cor r os ion u si ng a w i re

b r us h or a p os t a n d t e rm i na l cl ea n i n g t o ol , a n d a

s od iu m b ica r b on a t e (b a k in g s od a ) a n d w a r m w a t e r

cle a n in g solu t ion (F ig . 16). Re pla ce a n y ca ble t h a t

h a s d a m a g e d o r d e f o r m e d t e r m in a l cla m p s.

WARNING: WEAR A SUITABLE PAIR OF RUBBERGLOVES (NOT THE HOUSEHOLD TYPE) WHEN

REMOVING A BATTERY BY HAND. SAFETYGLASSES 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 holddowns and remove the

battery from the vehicle (Fig. 17).

(5) Inspect the battery tray and holddowns for cor-

rosion or damage. Remove any corrosion using a wireb r us h a n d a s od iu m b ica r b on a t e (b a k in g s od a ) a n d

w a r m w a t er cl ea n i n g s ol ut i on . P a i n t a n y ex pos ed

b a r e m e t a l a n d r e pl a ce a n y d a m a g e d p a r t s .

(6) Sl id e t h e t h e r m o g u a r d o f f o f t h e ba t t e r y ca se .

I n sp e ct t h e ba t t e r y ca se f o r cr a ck s o r o t h e r d a m a g e

that could result in electrolyte leaks. Also, check the

ba t t e r y t e r m in a l p o st s f or loose n ess. B a t t e r ie s w it h

damaged cases or loose posts must be replaced.

(7) Check the electrolyte level in the ba ttery. Use a

p u t t y k n if e o r a n o t h e r su it a ble w id e f la t - bla d e d t o o l

to pry the cell caps off (Fig. 18). Do not use a screw-

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 Cir-

cuit Volt-

age

Hours Charging at 21C (70F)

12.25 to12.39

6 hours 3 hours 1.5 hours

12.00 to12.24

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 than10.00

See Charging Completely DischargedBattery

Fig. 15 Remove Battery Cable Terminal Clamp -Typical

BATTERY BATTERYTERMINALPULLER


SERVICE PROCEDURES (Continued)


14/16

d r ive r . Ad d d ist i l le d w a t e r t o e a ch ce l l u n t i l t h e l iq -

u id r ea c h es t h e b ot t om of t h e v en t w e ll . D O N OT

O V ERF I L L .

(8) Inspect the battery built-in test indicator sight

glass for an indication of the battery condition. If the

b a t t e ry i s d is ch a r g ed , ch a r g e a s r eq u ir ed . S e e t h e

B uilt-In Test Indicator a nd th e Ba ttery C ha rging pro-

cedures in this group for more information.

(9) If the battery is to be reinstalled, clean the out-

s id e o f t h e b a t t er y ca s e a n d t h e t o p c ov er w i t h a

s od i um b ica r b on a t e (b a k in g s od a ) a n d w a r m w a t er

cleaning solution t o remove any acid film (Fig. 19).

R i n s e t h e b a t t e r y w i t h c l e a n w a t e r . E n s u r e t h a t t h e

cl ea n i n g s ol ut i on d oe s n ot e nt e r t h e b a t t e r y ce ll s

t h rou gh t h e v en t h oles . I f t h e b a t ter y is b ei ngr e p la ce d , se e t h e B a t t e r y Ra t in g s a n d Cla ssi f ica t io n s

chart in Specifications at the back of this group. Con-

f ir m t h a t t h e r e p la ce m e n t ba t t e r y is t h e co r r e ct s iz e

a n d h a s t h e cor r e ct r a t in g s f or t h e ve h icle.

(10) Clean any corrosion from the battery terminal

pos t s w i th a w i re b ru sh or a pos t a n d t er mi na l

cleaner, and a sodium bicarbonate (baking soda) and

warm water cleaning solution (Fig. 20).

(11) Re in st a l l t h e ba t t e r y t h e r m o g u a r d by sl id in g

it o ve r t h e ba t t e r y ca se .

( 1 2 ) P o s i t i o n t h e b a t t e r y i n t h e t r a y . E n s u r e t h a t

the posit ive and negative terminal posts are correctly

posit ioned. The cable termina l clamps m ust reach t hecor r ect b a t t e ry p os t w i t h ou t s t r et c hi n g t h e ca b l es

(Fig. 21).

(13) L oos el y i n st a l l t h e b a t t e ry h ol dd ow n h a r d -

w a r e . En su r e t h a t t h e ba t t e r y ba se is co r r e ct ly p o si-

t ion e d in t h e t r a y , t h e n t ig h t e n t h e h old d ow n n u t s t o

2.2 Nm (20 in. lbs.). Tighten the holddown support

strap bolt to 9 Nm (77 in. lbs.).

CAUTION: Be certain that the battery cables areconnected to the correct battery terminals. Reversepolarity may damage electrical components.

Fig. 16 Clean Battery Cable Terminal Clamp -

Typical

TERMINALBRUSH BATTERYCABLETEST INDICA-TOR

Fig. 17 Battery Holddowns

BOLT NUTS HOLD DOWNTHERMOGUARDNUTSENSORPUSH-ONRETAIN ERT-BOLTWHEELHOUSE INNERPANELSTUDFWD TRAYRADIATORCROSS-MEMBERBATTERYSUPPORTSTRAP

Fig. 18 Removing Cell Caps - Typical


REMOVAL AND INSTALLATION (Continued)


15/16

(14) I n st a l l a n d t ig h t e n t h e ba t t e r y p o sit ive ca ble

t e r m in a l cla m p . T h e n in st a l l a n d t ig h t e n t h e ba t t e r y

n e g a t ive ca ble t e r m in a l cla m p . Tig h t en bot h ca bleterminal clamp bolts to 8.5 Nm (75 in. lbs.).

(15) Ap ply a t h in coa t in g of p et r o le u m je lly or

ch a ssis g r ea se t o t h e e x pose d su r f a ces of t h e ba t t e r y

ca b le t er min a l cla m ps a n d t h e b a tt er y t er min a l

posts.

SPECIFICATIONS

BATTERY

Fig. 19 Clean Battery - Typical

TEST INDICA-TORBATTERY CLEANINGBRUSHWA RM WAT ER AN DBAKING SODA SOLU-TION

Fig. 20 Clean Battery Terminal Post - Typical

BATTERY TEST INDI-CATOR TERMINAL BRUSHBATTERYCABLE

Fig. 21 Battery Cables

RADIATORCROSSMEMBER WHEELHOUSEINNER PANELNEGATIVECABLEPOSITIVECABLEFWDBATTERY

Battery Classifications and Ratings

Part NumberBCI Group Size

Classification

Cold Cranking

Amperage

Reserve Capac-

ityAmpere-Hours

Load Test

Amperage

56041105 58 500 85 Minutes 42 250


REMOVAL AND INSTALLATION (Continued)


16/16

EXJ_8A99 jeep xj service manual

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