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Battery System: Removal & Installation Dodge Caravan IV

Charging System 3 illustrations ~676 words

REMOVAL - BATTERY

WARNINGA SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES AND SAFETY GLASSES SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY.
WARNINGREMOVE METALLIC JEWELRY TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT.

Scheme 9

Scheme 9
Scheme 9
  1. Verify that the ignition switch and all accessories are OFF.
  2. Disconnect the battery cables from the battery posts, negative first. (Scheme 9)
  3. Remove the battery hold down retaining nut. 1 - BATTERY THERMOWRAP (IF EQUIPPED) 2 - INTEGRATED POWER MODULE 3 - FRONT CONTROL MODULE
  4. Remove the battery hold down bracket.
  5. Remove the battery from the vehicle.

INSTALLATION

  1. Position the battery in the battery tray.
  2. Install the battery hold down bracket and retaining nut. Torque the nut to 20 N.m (180 in. lbs.).
  3. Connect the battery cables to the battery posts, positive cable first. Torque terminal fasteners to 5 N.m (40 in. lbs.).

REMOVAL

All of the battery hold down hardware can be serviced without removal of the battery or the battery tray and support unit.

  1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
  2. Disconnect and isolate the battery negative cable.
  3. Remove the nut with washer that secures the battery hold down bracket to the battery tray and support unit.
  4. Remove the battery hold down bracket from the battery tray and support unit.
  1. Install the battery hold down bracket in the battery tray and support unit.
  2. Install the nut with washer that secures the battery hold down bracket to the battery tray and support unit. Torque to 20 N.m (180 in. lbs.).
  3. Connect the battery negative cable.

The battery cables on this vehicle may include portions of wiring circuits for the generator and other components on the vehicle. If battery cable replacement is required, it will be necessary to extract the cables out of the engine wire harness assembly. Use care not to damage the other wires and circuits which are also packaged into the engine wire harness assembly.

  1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
  2. Disconnect and isolate the battery negative cable.
  3. Remove the battery thermowrap (if equipped) from the battery tray.
  4. Remove the tape from the engine wire harness assembly, to access the desired battery cable.
  5. One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle.
  6. Feed the battery cable out of the vehicle.
  1. Position the battery cable in the vehicle.
  2. One at a time, trace and install the battery cable retaining fasteners and routing clips until the desired cable is properly installed in the engine wire harness assembly.
  3. Install the tape on the engine wire harness assembly.
  4. Install the battery thermowrap (if equipped) on the battery tray.
  5. Connect the battery negative cable.

Scheme 10

Scheme 10: DESCRIPTION
Scheme 10: DESCRIPTION
1 - ENGINE VACUUM RESERVOIR
2 - BATTERY TRAY ASSEMBLY
3 - DRAINAGE HOSE

The battery is mounted in a molded plastic battery tray and support unit located in the left front corner of the engine compartment. The battery tray and support unit is secured with two nuts, one is located directly under the battery and the other is located on the right side of the tray which also serves as a coolant bottle neck retaining bolt. An additional bolt is located directly under the battery.

The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit. (Scheme 10) And a drainage hose, located in the front of the unit. (Scheme 10)

Scheme 11

Scheme 11: REMOVAL
Scheme 11: REMOVAL
  1. Disconnect and isolate the battery negative cable.
  2. Disconnect and isolate the battery positive cable.
  3. Remove the battery from the vehicle. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(ref-248889-S29572206352007022700000).
  4. Remove the battery tray retaining fasteners. (Scheme 11) 1 - BATTERY TRAY RETAINING FASTENERS
  5. Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted, vacuum reservoir.
  6. Remove the battery tray from the vehicle.
  1. Position the battery tray in the vehicle.
  2. Connect the engine vacuum harness hose on the battery tray mounted vacuum reservoir.
  3. Position drainage hose and install the battery tray retaining fasteners. see scheme 20 1 - BATTERY TRAY RETAINING FASTENERS
  4. Install the battery in the vehicle. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(ref-248889-S17951773902007022700000).
  5. Connect the battery positive cable.
  6. Connect the battery negative cable.

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