Chrysler 2004 Pacifica, Service Manual, Page: 1992 / 3603

A clamping type female battery terminal made of
stamped metal is attached to one end of the battery
cable wire. A pinch-bolt and hex nut are installed at
the open end of the female battery terminal clamp.
Large eyelet type terminals are crimped onto the
opposite end of the battery cable wire and then sol-
der-dipped. The battery positive cable wires have a
red insulating jacket to provide visual identification
and feature a larger female battery terminal clamp
to allow connection to the larger battery positive ter-
minal post. The battery negative cable wires have a
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.
CS
BATTERY SYSTEM 8F - 13
BATTERY CABLES (Continued)