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why is the positive battery cable hot on a 1997 f150

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1999 Chrysler LHS V6-3.5L VIN G Battery Replacement Manual

Battery Replacement Notes WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . REMOVAL 1. Turn the steering wheel all the way to the right. 2. Verify that the ignition switch and all accessories are OFF. 3. Disconnect and isolate the negative battery cable remote terminal from the remote battery post. 4. Remove air cleaner housing. 5. Remove battery splash shield. 6. Remove two short bolts to battery hold down. 7. Slide battery rearward to disconnect the negative and positive battery terminals from battery. 8. Slide battery toward rear of vehicle and lift out through wheel well opening. 9. Remove battery from vehicle. 1. Tighten clamp nuts to 8.5 N.m (75 in. lbs.) torque.INSTALLATION For installation, reverse the above procedures. Inspect and clean battery and attaching components before installation. WARNING: DO NOT OVER TIGHTEN BATTERY CABLE CLAMPS, DAMAGE TO CLAMPS CAN RESULT .


POWERTRAIN CONTROL MODULE (PCM) Removal & Installation 1. The PCM is located between driver’s side front fender and power distribution center, near battery. See Fig. 1 . Disconnect negative battery cable and then positive battery cable from battery. 2. Remove bolts on side of power distribution center that secure power distribution center to mounting bracket. Remove heat shield from outside of battery. Remove battery. 3. Rotate power distribution center toward the engine to disengage power distribution center from rear mounting bracket. Pull power distribution center toward rear of vehicle to disengage power distribution center from front mounting bracket. 4. Allow power distribution center to lay aside for access to PCM. Remove electrical connectors from PCM. Electrical connectors may be removed by squeezing tabs on electrical connector together and pulling electrical connector from PCM. Remove bolts and PCM. To install, reverse removal procedure. Vehicles equipped with engine or transmission computers may require a relearn procedure after the vehicle battery is disconnected. Vehicle computers memorize and store vehicle operation patterns for optimum driveability and performance. When the vehicle battery is disconnected, this memory is lost. Default data is used until new data from each key start is stored. As the computer restores its memory from each new key start, driveability is restored. Driveability problems may occur during the relearn stage. Depending on the vehicle and how it is equipped, the following driveability problems may exist: z Rough or unstable idle. z Hesitation or stumble. z Rich or lean running. z Poor fuel mileage. z Harsh or poor transmission shift quality. To accelerate relearn process after battery removal and installation, vehicle should be road tested in the following manner: z Vehicle at normal operating temperature (cooling fan cycles). z Accelerate at normal throttle position (20-50%). z Cruise at light to medium throttle. z Decelerate to a stop, downshifting and using brakes normally. Manufacturers identify specific relearn procedures. See RELEARN PROCEDURES. Always complete the procedure before returning the vehicle to the owner. RELEARN PROCEDURES Theft Alarm Relearn Procedure 1. Theft alarm relearn is necessary whenever battery is disconnected or dead battery is boosted. If battery is connected or boosted without conducting relearn procedure, alarm system will enter power-up mode and vehicle will not start. 2. Before reconnecting battery or connecting booster, insert door key into driver side door lock


1. Disconnect negative battery cable from jumper terminal. Raise and support vehicle. Remove right front wheel. Remove accessory drive belt splash shield from right wheelwell. 2. Remove accessory drive belts. Remove right engine support assembly vertical bolts from bottom side of frame rail (timing belt end of engine). 3. Lower vehicle. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove 3 bolts attaching engine support assembly to engine block bracket. 4. Move the A/C drier aside with hoses attached. Remove coolant reservoir tank. Remove right engine support assembly. Remove 3 bolts attaching engine support bracket to engine block, and remove bracket. 5. Remove crankshaft vibration damper. Remove power steering pump (hoses attached) and bracket from engine block. Remove timing belt covers. 6. Rotate crankshaft to align camshaft and crankshaft timing marks. 7. If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt automatic tensioner bolts. Remove timing belt. Remove automatic tensioner. Installation 2.5L VIN H (Cirrus, Sebring Convertible & Stratus) 1. Place automatic tensioner into vise, and SLOWLY compress plunger. When plunger is compressed into tensioner body, install locking pin through body and plunger holes to retain plunger until tensioner is installed. See Fig. 13 . 2. Index tensioner in vise the same direction as installed. This will ensure proper pin orientation when tensioner is installed in engine.

Battery Electrical Drain/ Parasitic Load Test Repair Manual

1. Disconnect the battery negative cable 2. Install the male end of the J 38758 to the negative battery terminal. 3. Turn OFF the test switch. 4. Install the negative battery cable to the female end of the test switch. 5. Install the Scan Tool (or equivalent) or wait for 20 minutes. 6. Turn ON the test switch. 7. Road test the vehicle while activating all accessories, including the radio and the air conditioning. 8. Lower the door glass, then exit the vehicle. Do not move the door handle after closing the door. 9. Open the hood. Important The power down timer will reset to 20 minutes if any wake up inputs are received by a Class 2 device (after the scan tool has put all Class 2 devices to sleep). 10. Put all of the Class 2 devices into the sleep mode. 11. Turn OFF the ignition switch. Remove the key. Important From this point on, electrical continuity must be maintained in the ground circuit of the battery through the Test Switch J 38758 in the ON position or through the ammeter J 39200 . 12. Components such as PCM, VCM, Automatic Air Conditioning, and the Truck Body Control Module have timers that draw several amps of current while they cycle down. This can give a false parasitic drain reading. Wait 20 minutes for these components to power down before continuing this test (or use the scan tool to put all Class 2 devices to sleep). 13. Connect a jumper wire with a 10 A fuse J 36169-A to the terminals of the test switch. 14. Turn the test switch to the OFF position. 15. Wait ten seconds. If the fuse does not blow, the current is less than 10 A. The ammeter can be used safely. 16. Before the fused jumper wire is removed, turn the test switch to the ON position. Important If an ammeter other than the J 39200 is used, ensure that the vehicle does not have a high current drain that would damage the ammeter when connected to the circuit. 17. Perform the following procedure in order to detect a high current drain: A. Set the ammeter J 39200 to the 10 A scale. B. Connect the ammeter to the test switch terminals. C. Turn OFF the test switch. This allows the current to flow through the ammeter. D. Wait one minute, then inspect the current reading. Ñ When there is a current reading of 2 A or less, turn ON the test switch, this maintains continuity in the electrical system. Ñ Then, switch the meter down to the 2 A scale, for a more accurate reading, when the test switch is reopened. E. Open the test switch. F. Take the reading in milliamps. G. Note the battery reserve capacity. Refer to Battery Usage . Ñ Divide this number by 4. Example: 90/4 = 22.5 Ñ Compare this to the ammeter reading. Ñ The current drain in milliamps should not exceed this number. Ñ Example: if a battery has a reserve capacity of 90 minutes, the current drain should not exceed 22 milliamps. H. When the current draw is too high, remove the electrical system fuses one at a time until the draw returns to a value less than or equal to specifications. Ñ Start with the fuses that are hot all the time. Ñ To remove the fuse, you must first open the door, which causes a high enough current flow to damage the ammeter. Ñ Protect the ammeter, without disturbing the electrical continuity, by turning ON the test tool before opening the door. Ñ Remove the courtesy lamp fuse. Ñ Note the ammeter reading. Ñ If the parasitic load is still excessive, start removing the remaining fuses one at a time. Ñ Keep the courtesy lamp fuse out during diagnosis, so the door can remain open. Ñ Perform Steps 11 through 13 each time a fuse is removed. I. Removing the PCM or VCM fuse should cause a drop of less than 10 milliamps. A drop greater than 10 milliamps indicates a possible short to ground. J. Check the orange wires along with the components connected to the orange wires. No drop in the milliampere reading indicates the PCM or VCM is not drawing current. K. Repeat the parasitic current drain test procedure after any repair has been completed. L. When the cause of the excessive current draw has been located and repaired, remove the ammeter and the parasitic draw test switch.


Removal 1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. Put a block of wood between cradle and engine torque strut at bottom front end of engine. See Fig. 2 . 2. Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. 3. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached). Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. 4. Remove support bracket between intake manifold and engine block. Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft, with flat side toward crankshaft gear (sprocket). Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. 5. Remove 4 bolts from front end of oil pan. Using RTV Cutter (SA9123E), cut RTV sealant between oil pan and front cover. Spray penetrating oil onto front cover dowel pins. Remove front cover bolts (one bolt is located above accessory drive belt pulley). Pry front cover from engine block. 6. To prevent pistons from hitting valves, turn crankshaft 90 degrees clockwise as viewed from front of engine until timing mark and keyway are aligned with split line of main bearing cap. Remove timing chain tensioner, guides and chain. While using a 7/8″ (21 mm) wrench to keep camshaft(s) from turning, remove camshaft sprocket bolt(s). Remove camshaft sprocket(s). Installation 1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head. Use a 7/8″ (21 mm) wrench to keep camshaft(s) from turning. 2. Install and tighten camshaft sprocket bolt(s) to specification. Rotate camshaft(s) until a 3/16″ (4.8 mm) drill bit can be inserted through timing pin hole(s) and into cylinder head. See Fig. 5 or Fig. 6 . 3. Rotate crankshaft counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with timing mark(s) on camshaft sprocket(s) and bottom tooth (or teeth) of crankshaft sprocket. See Fig. 5 or Fig. 6 . 4. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and pin ratchet