Battery Cables Description; Operation; Diagnosis And Testing - Battery Cables - Chrysler PT Cruiser Service & Repair Manual

8F - 18 BATTERY SYSTEM
BATTERY CABLES
DESCRIPTION
The battery cables are large gauge, stranded cop-
per wires sheathed within a heavy plastic or syn-
thetic rubber insulating jacket. The wire used in the
battery cables combines excellent flexibility and reli-
ability with high electrical current carrying capacity.
The battery cables feature a clamping type female
battery terminal made of stamped sheet metal that is
die cast onto one end of the battery cable wire. A
pinch-bolt and 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 soldered. 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 terminal post. The battery
negative cable wires have a black insulating jacket
and a 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.

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 for restor-
ing the voltage potential of the battery. The female
battery 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 terminal 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 pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
One wire has an eyelet terminal that connects the
battery positive cable to the B(+) terminal stud of the
Power Distribution Center (PDC), and the other wire
has an eyelet terminal that connects the battery pos-
itive cable to the B(+) terminal stud of the engine
starter motor solenoid. The battery negative cable
terminal clamp has one wire as an eyelet terminal
that connects the battery negative cable to the vehi-
cle powertrain through a ground connection, typically
on the engine cylinder block.

DIAGNOSIS AND TESTING - BATTERY CABLES

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
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 load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures.
• Fully engage the parking brake.
• If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed 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 Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC 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. 17). 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.
material, then reassembled.
PT