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PREPARATION
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PREPARATION
Special Service ToolINFOID:0000000001704343
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolINFOID:0000000001704344
Tool number
(Kent-Moore No.)
Tool nameDescription
—
(J-48087)
Battery Service CenterTests batteries.
For instructions, refer to Technical Service
Bulletin and Battery Service Center User
Guide.
—
(J-44373) Model 620
Starting/Charging System TesterTests starting and charging system.
For operating instructions, refer to Technical
Service Bulletin.
WKIA5280E
SEL403X
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E
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BATTERY
BATTERY
How to Handle BatteryINFOID:0000000001704345
CAUTION:
• If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.
• After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact.
• Never add distilled water through the hole used to check specific gravity.
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging
a battery.
• The battery surface (particularly its top) should always be kept
clean and dry.
• The terminal connections should be clean and tight.
• At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance” and
“maintenance-free”.
• When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal.
• Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep a
close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-
ing a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid con-
tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
MEL040F
MEL041F
MEL042F
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• Remove the cell plug using a suitable tool.
• Add distilled water up to the MAX level.
Sulfation
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulfation on the cell plates.
To determine if a battery has been sulfated, note its voltage and
current when charging it. Less current and higher voltage are
observed in the initial stage of charging sulfated batteries, as
shown.
A sulfated battery may sometimes be brought back into service
by means of a long, slow charge, 12 hours or more, followed by
a battery capacity test.
SPECIFIC GRAVITY CHECK
1. Read hydrometer and thermometer indications at eye level.
2. Use the following chart to correct your hydrometer reading
according to electrolyte temperature.
Hydrometer Temperature Correction
MEL043F
WKIA4166E
MEL042FA
Battery electrolyte temperature °C (°F) Add to specific gravity reading
71 (160) 0.032
66 (150) 0.028
60 (140) 0.024
54 (130) 0.020
49 (120) 0.016
43 (110) 0.012
38 (100) 0.008
32 (90) 0.004
27 (80) 0
21 (70)−0.004
16 (60)−0.008
10 (50)−0.012
4 (40)−0.016
−1 (30)−0.020
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BATTERY
CHARGING THE BATTERY
CAUTION:
• Do not “quick charge” a fully discharged battery.
• Keep the battery away from open flame while it is being charged.
• When connecting the charger, connect the leads first, then turn on the charger. Do not turn on the
charger first, as this may cause a spark.
• If battery electrolyte temperature rises above 55°C (131°F), stop charging. Always charge battery at a
temperature below 55°C (131°F).
Charging Rates
Do not charge at more than 50 ampere rate.
NOTE:
The ammeter reading on your battery charger will automatically decrease as the battery charges. This indi-
cates that the voltage of the battery is increasing normally as the state of charge improves. The charging amps
indicated above refer to initial charge rate.
• If, after charging, the specific gravity of any two cells varies more than 0.050, the battery should be replaced.
Trouble Diagnosis with Battery Service CenterINFOID:0000000001704346
For battery testing, use Battery Service Center (J-48087). For details and operating instructions, refer to Tech-
nical Service Bulletin and/or Battery Service Center User Guide.
Removal and InstallationINFOID:0000000001704347
REMOVAL
1. Loosen battery terminal nuts (A), and disconnect both battery
cables from battery terminal.
CAUTION:
When disconnecting, disconnect the battery cable from the
negative terminal first.
2. Remove battery frame nuts (B) and battery frame.
3. Remove battery shield.
4. Remove battery.
−7 (20)−0.024
−12 (10)−0.028
−18 (0)−0.032
Corrected specific gravity Approximate charge condition
1.260 - 1.280 Fully charged
1.230 - 1.250 3/4 charged
1.200 - 1.220 1/2 charged
1.170 - 1.190 1/4 charged
1.140 - 1.160 Almost discharged
1.110 - 1.130 Completely discharged Battery electrolyte temperature °C (°F) Add to specific gravity reading
Amps Time
50 1 hour
25 2 hours
10 5 hours
5 10 hours
PKIC0535E
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INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
When connecting, connect the battery cable to the positive terminal first.
Battery frame nut : 3.9 N·m (0.40 kg-m, 35 in-lb)
Battery terminal nut : 5.4 N·m (0.55 kg-m, 48 in-lb)
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STARTING SYSTEM
STARTING SYSTEM
System DescriptionINFOID:0000000001704348
M/T Models
Power is supplied at all times
• to starter motor terminal B, and
• through 40A fusible link (letter h , located in the fuse and fusible link box)
• to ignition switch terminal B.
With the ignition switch in the START position, power is supplied
• from ignition switch terminal ST
• to IPDM E/R terminal 21.
With the ignition switch in the ON or START position, power is supplied
• through 10A fuse (No. 49, located in the IPDM E/R)
• to the clutch interlock switch terminal 1.
With the clutch pedal depressed, power is supplied
• through the clutch interlock switch terminal 2
• to IPDM E/R terminal 35.
Ground is supplied at all times
• to IPDM E/R terminals 39 and 59
• through body grounds E15 and E24.
If the IPDM E/R receives a starter relay request ON signal from the BCM over the CAN communication lines,
the IPDM E/R grounds the starter relay and power is supplied
• through terminal 19 of the IPDM E/R
• to terminal S of the starter motor.
The starter motor magnetic switch energizes closing the circuit between the battery and the starter motor. The
starter motor is case ground through the cylinder block. With power and ground supplied, the starter motor
operates.
A/T Models
Power is supplied at all times
• to starter motor terminal B, and
• through 40A fusible link (letter h , located in the fuse and fusible link box)
• to ignition switch terminal B.
With the ignition switch in the START position, power is supplied
• from ignition switch terminal ST
• to IPDM E/R terminal 21.
With the ignition switch in the ON or START position, power is supplied
• through 10A fuse (No. 54, located in the IPDM E/R)
• to park/neutral position (PNP) switch terminal 1.
With the selector lever in the P or N position, power is supplied
• through PNP switch terminal 2
• to IPDM E/R terminal 35.
Ground is supplied at all times
• to IPDM E/R terminals 39 and 59
• through body grounds E15 and E24.
If the IPDM E/R receives a starter relay request ON signal from the BCM over the CAN communication lines,
the IPDM E/R grounds the starter relay and power is supplied
• through terminal 19 of the IPDM E/R
• to terminal S of the starter motor.
The starter motor magnetic switch energizes closing the circuit between the battery and the starter motor. The
starter motor is case ground through the cylinder block. With power and ground supplied, the starter motor
operates.
CVT Models
Power is supplied at all times
• to starter motor terminal B, and
• through 40A fusible link (letter h , located in the fuse and fusible link box)
• to ignition switch terminal B.
With the ignition switch in the START position, power is supplied
• from ignition switch terminal ST
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• to IPDM E/R terminal 21.
With the selector lever in the P or N position, power is supplied
• from the transmission control module (TCM) terminal 24
• to IPDM E/R terminal 35.
Ground is supplied at all times
• to IPDM E/R terminals 39 and 59
• through body grounds E15 and E24.
If the IPDM E/R receives a starter relay request ON signal from the BCM over the CAN network, the IPDM E/
R grounds the starter relay and power is supplied
• through terminal 19 of the IPDM E/R
• to terminal S of the starter motor.
The starter motor magnetic switch energizes closing the circuit between the battery and the starter motor. The
starter motor is case ground through the cylinder block. With power and ground supplied, the starter motor
operates.
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STARTING SYSTEM
Wiring Diagram - START -
INFOID:0000000001704349
M/T Models
WKWA4964E