Battery Positive Cable Replacement 8.1L Engine

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable (1). Refer to Battery Negative Cable Disconnection and Connection .
2. Disconnect the positive battery cable (2).
3. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



4. Remove the ground wire bolt at the engine block.
5. Lower the vehicle.



6. Remove the secondary ground bolt.
7. Reposition the negative battery cable lead.



8. Remove the bolts from the positive battery cable clips.



9. Reposition the positive battery cable boot at the generator.
10. Remove the generator nut.
11. Remove the positive cable from the generator.
12. Raise the vehicle.



13. Remove the positive cable nut from the starter.
14. Remove the positive cable from the starter.
15. Lower the vehicle.
16. Remove the cable from the vehicle.

1. Install the cable to the vehicle.
2. Raise the vehicle.
3. Install the positive cable to the starter.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the positive cable nut to the starter.

Tighten
Tighten the positive cable nut to starter to 10 N·m (89 lb in).




5. Lower the vehicle.
6. Install the positive cable to the generator.
7. Install the generator nut.

Tighten
Tighten the generator nut to 8 N·m (71 lb in).

8. Position the positive battery cable boot at the generator.



9. Install the bolts at the positive battery cable clips.

Tighten
Tighten the positive battery cable clip bolts to 8 N·m (71 lb in).




10. Position the negative battery cable lead.
11. Install the secondary ground bolt.

Tighten
Tighten the secondary ground bolt to 4.5 N·m (40 lb in).




12. Raise the vehicle.
13. Install the ground wire bolt at the engine block.

Tighten
Tighten the ground wire bolt to 27 N·m (20 lb ft).




14. Lower the vehicle.
15. Connect the positive battery cable (2).

Tighten
Tighten the positive battery cable to 17 N·m (13 lb ft).

16. Connect the negative battery cable (1). Refer to Battery Negative Cable Disconnection and Connection .

Battery Positive Cable Replacement 6.5L Engine

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Disconnect the positive battery cable.
3. Remove the positive battery cable clip bolts.
4. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



5. Remove the positive battery cable nut from the starter.
6. Remove the positive battery cable from the starter.
7. Lower the vehicle.



8. Remove the positive battery cable clips from the fan shroud.
9. Remove the cable cover from the secondary battery positive cable.
10. Disconnect the positive battery cable from the secondary battery.



11. If equipped with a single generator, reposition the positive cable boot.
12. Remove the generator nut.
13. Remove the positive battery cable from the generator.



14. If equipped with a single generator, remove the fuse/relay center nut.
15. Remove the positive cable from the fuse/relay center stud.
16. Remove the positive cable clip from the fuse/relay center bracket.
17. Remove the positive battery cable.



18. If equipped with dual generators, remove the junction block cover.
19. Remove the junction block nut and washer.
20. Remove the junction block wire from the stud.
21. Remove the positive cables from the junction block stud.
22. Remove the positive cable clip from the fuse/relay center bracket.



23. If equipped with dual generators, reposition the positive cable boots.
24. Remove the generator nuts.
25. Remove the positive battery cables from the generators.
26. Remove the positive battery cable.

1. If equipped with dual generators, install the positive battery cable.
2. Install the positive battery cables to the generators.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the generator nuts.

Tighten
Tighten the generator nuts to 17 N·m (13 lb ft).

4. Position the positive cable boots.



5. If equipped with dual generators, install the positive cables to the junction block stud.
6. Install the junction block wire to the stud.
7. Install the junction block washer and nut.

Tighten
Tighten the junction block nut to 4 N·m (35 lb in).

8. Install the junction block cover.
9. Install the positive cable clip to the fuse/relay center bracket.



10. If equipped with a single generator, install the positive battery cable.
11. Install the positive cable to the fuse/relay center stud.
12. Install the fuse/relay center nut.

Tighten
Tighten the fuse/relay center nut to 9 N·m (80 lb in).

13. Install the positive cable clip to the fuse/relay center bracket.



14. If equipped with a single generator, install the positive battery cable to the generator.
15. Install the generator nut.

Tighten
Tighten the generator nut to 17 N·m (13 lb ft).

16. Position the positive cable boot.



17. Connect the positive battery cable to the secondary battery.

Tighten
Tighten the positive battery cable to 17 N·m (13 lb ft).

18. Install the cable cover to the secondary battery positive cable.
19. Install the positive battery cable clips from the fan shroud.



20. Raise the vehicle.
21. Install the positive battery cable to the starter.
22. Install the positive battery cable nut to the starter.

Tighten
Tighten the positive cable nut to starter to 14 N·m (10 lb ft).




23. Lower the vehicle.
24. Install the positive battery cable clip bolts.

Tighten
Tighten the positive battery cable clip bolts to 8 N·m (71 lb in).

25. Connect the positive battery cable.

Tighten
Tighten the positive battery cable to 17 N·m (13 lb ft).

26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .