Alternators and Starters 15 15–00 Safety Precautions 54 of the Cascadia Workshop Manual for ad- justment, repair, or replacement instructions. Safety Precautions in this section apply to all procedures within this group. 4.1 Clean and tighten the battery ground cable, terminal, and clamps. DANGER 4.2 Inspect the retainer assembly or battery hold-downs, and the battery box. Replace worn or damaged parts. Remove any cor- rosion with a wire brush, and wash with a weak solution of baking soda and water. Flush with clean water, and dry. Paint the retainer assembly if needed, to prevent rusting. When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Failure to follow these steps could result in serious personal injury or death. 4.3 Check that foreign objects, such as stones, bolts, and nuts, are removed from the battery box. 15–01 Alternator, Battery, and Starter Connections Check 4.4 After cleaning, connect the cables to the batteries and tighten them to the torque specifications listed on the battery, gener- ally 10 to 15 lbf·ft (14 to 20 N·m). WARNING 4.5 Coat the battery terminals with dielectric grease. Batteries generate explosive gas as a by-product of their chemical process.
Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment. Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables. 5. Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed. 6. Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning. Battery acid is extremely harmful if splashed in the eyes or on the skin.
Always wear a face shield and protective clothing when working around batteries. 1. Disconnect the batteries. 2. Check the tightness of the alternator bracket fas- teners; tighten the fasteners as needed. For torque values, see Group 15 of the Cascadia Workshop Manual . 3. Check that all electrical connections at the alter- nator and starter are clean. Clean and tighten all charging system electrical connections, including the connections at the starter B terminal and ground terminal, and where the alternator charg- ing cable terminates. 4. Inspect the battery cables for wear, and replace them if they are damaged. Clean the cable con- nector terminals with a wire brush.
See Group Cascadia Maintenance Manual, August 2015 15/1