En GENERAL ‘SPECIFICATIONS ... EE2 SPECIAL TOOLS FES ‘TOUBLESHOOTING IGNITION SYSTEM ‘COMPONENT LOCATION EEG IGNTION CO. REMOVAL AND INSTALLATION ow BEB INSPECTION cE IGNITION SWITCH REMOVAL AND INSTALLATION EE-1 INSPECTION EE-12 SPARK PLUG INSPECTION. EE-14 ‘SPARK PLUG CABLE ‘COMPONENT LOCATION EE-16 INSPECTION, BEAT. CHARGING SYSTEM (GENERAL INFORMATION oo INSPECTION. EAB EE 19 ine Electrical System GENERATOR INSTALLATION. CIRCUMT DIAGRAM. (GENERAL INFORMATION... INSPECTION... STARTING SYSTEM ‘GENERAL INFORMATION. INSPECTION sn STARTER REMOVAL AND INSTALLATION. ‘COMPONENTS... INSPECTION. REASSEMBLY PREHEATING SYSTEM ‘SPECIFICATIONS INSPECTION.EE ENGINE ELECTRICAL SYSTEM GENERAL SPECIFICATIONS execs IGNITION COIL Gasoline Type ‘Mold dual coil Primary col resistance 0.870 = 10% Secondary col resistance 43.0KR = 15% ‘SPARK PLUG Gasoline Type Leaded NGK BKRSES: Champion RCIOTC Unleaded NGK BKRSESI Champion RCI0TC4 8 (0.028 ~ 0.032) Plug gap min) { a Unleaded 1.0 = 1.4 (0.089 - 0.043) STARTER Gasoline Diesel re Direct drive type Direct drive type Rated output 12V 0.9KW 12 1.7KW Rated time 30 sec. 30 sex. No-load characterstos Terminal votage 115V iV ‘Amperage 0A 908 Maximum speed 15,500 rpm 2,600 rpm 'No. cof pinion teeth Pinion gap mm(in) 8 015 ~ 2 (0.0197 ~ 0.079) a (05 ~ 2 (0.0197 - 0.078) GENERATOR Gasoline Diesel Type Battery voltago sensing Battery voltage sensing Rated output 13.5V, 908, 12, 808 Voltage regulator Electronic builtin type Electronic builtin type Regulator setting voltage 14.55 = 02 145 « 0.3V ‘Temperature compensation “10 = 8mvrC “10 + SmVPCGENERAL EE-3 BATTERY Type MF45AH MESSAH MFBOAH ‘Ampere hours (SHR) 364 448 ‘48H oid cranking fat -17.8°C (0°F)] 4108, 500A 550A, Reserve capacity 80 min. 85 min. ‘92 Specific gravity fat 25°C (77°F) 1,280 = 0.01 1,280 + 0.01 1,280 = 0.01 NOTE RESERVE CAPACITY RATING is the amount of time COLD CRANKING AMPERAGE is the amperage that the battery can delivery for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at a specified temperature. TIGHTENING TORQUE a battery can deliver 254 and maintain a minimum torminal voltage of 10.5 volts at 26.7°C (80°F). tems: kgem Weft ‘Generator terminal (B+) 5-7 50 ~ 70 36-51 Starter motor terminal (B+) 10 ~ 12 100 ~ 120 73-88 Battery terminal 4-6 40 ~ 60 29-43 ‘Spark plug 20 ~ 30 200 ~ 300 15 ~ 22 SPECIAL TOOL came ‘TOOL(Number and name) Use (09973-27000 ‘Removal and installation of the ‘Attornator pulley remover and installor alternator pulleyEE-4 IE ELECTRICAL SYSTEM TROUBLESHOOTING evcsa IGNITION SYSTEM ‘Trouble symptom Probable cause Remedy Engine will not start or is hard to start (Cranks OK) Ignition lock switch fauity Ignition coil fauty Power transistor faulty Repiace ignition lock switch Inspect ignition coil Inspect power transistor Spark plugs faulty Replace plugs {gnition wiring cisconnected or broken | Inspect wiring Spark plugs faulty Replace plugs Rough ide or stalls {gnition wiring fauty Inspect wiring lgnition coil faulty Roplace ignition coil Spark plug cable faulty Roplaco spark plug cable Engine hesitates/poor acceleration | Spark plugs fauly Replace plugs Ignition wiring faulty Inspect ignition coil and wires Poor mileage Spark plugs fauty Replace plugs CHARGING SYSTEM ‘Trouble symptom Probable cause Remedy ‘Charging waming indicator does | Fuse blown Check fuses ‘ot light with ignition switch *ON* | Light burned out Replace fight and engine off Wiring connection loose Tighten loose connections Electronic voltage regulator fauty __| Replace voltage regulator Charging warning indicator does not__| Drive belt loose or worn ‘Adjust tension or replace drive belt go out with engine running Battery cables loose, corroded —_| Repair or replace cables (Gattery requires frequent recharging) | or worn Fuse blown ‘Check fuses Fusible ink blown piace fusible link Electronic voltage regulator or Test goneraior ‘generator faulty Wiring fauty Repair wiring Engine hesitates/poor acceleration Overcharge Drive belt loose or worn Wiring connection loose or ‘Adjust tension or replace drive belt Tighten loose connection or open circuit repair wiring ' Fusible link blown Replace fusible link oor grounding Repair Electronic voltage regulator or ‘Test generator, i faulty, repair generator faulty or replace Faulty battery Replace battery Electronic voltage regulator faulty _| Roplace voltage regulator Voltage sensing wire faulty Repair wireGENERAL EE STARTING SYSTEM ‘Trouble symptom Probable cause Remedy Engine will not crank Battery discharged ‘Charge or replace battery Battery cables loose, corroded Repair or replace cables (or worn out ‘Transaxle range switch faulty (Vehicle | Adjust or replace switch with automatic transaxle only) Fusible link blown Reptace fusibe link Starter motor faulty Repair starter motor Ignition switch fautty Replace ignition switch Ignition lock switch faulty Replace ignition lock switch Engine cranks slowly Battery discharged ‘Charge or replace battery Battory cables loose, corroded Repair or replace cables ‘or worn out Starter motor faulty Repair starter motor Starter keeps running Starter motor faulty Repair starter motor Ignition ewiteh faulty Replace ignition switch Starter spins but engine will not crank | Short in wiring Repair wiring Pinion gear teeth broken or Repair starter motor starter motor faulty Replace fiywheel ring gear or Ring gear teeth broken torque converter GLOW CONTROL SYSTEM (DIESEL) ‘Trouble symptom Brobable cause Remedy Engine will not start below 50°C __| Wiring connection loose or bad wiring | Repair or replace wiring ECT sensor maffunction Replace ECT sensor ‘Glow plug malfunction Repair or replace glow plug Glow plug control unit failed Replace glow contro! unit ‘After first combustion, engine stall | Wiring connection loose or bad wiring | Repair or replace wiring CF rough idle below 50°C Glow plug mattunction CChack the resistance of glow plug ‘Yellow glow lamp will not turn-ON Glow plug relay malfunction Glow plug control unit failed ‘Open lamp Wiring connection loose or bad wiring ‘Shorted wiring Glow plug control unit failed and replaco, of necessary Check the relay and replace, it necessary Check the contro unit and replace, it necessary Replce lamp Repair or replace wiring Repair or replace wiring Replace control unit, necessaryEES ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM IGNITION SYSTEM COMPONENT LOCATION eseocea [DOHC] herb sas [= NEA Osa a a: ah ‘ ws | SOKIGNITION SYSTEM. EE7 [sox] Spark plug cablesEES ENGINE ELECTRICAL SYSTEM IGNITION COIL REMOVAL AND INSTALLATION | eercouo 1. Remove the ignition fuse (Fusible link-F) 2. Disconnect the lead wire. ‘8. Remove the ignition coil mounting bolt and remove the ignition coll assembly, ‘4, Installation is the reverse order of removal.IGNITION SYSTEM INSPECTION teeume SPARK TEST Spark test Disconnect a high tension cord from the engine, position it about ~ 66 ~ 8mm away from the engine ground part, and then crank the engine. No spark occurs ‘Spark occurs: Measure the voltage at the (-)coll while the engine is being cranked. Voltage does not vary Voltage varies ‘Check the coll, wiring, power transistor and ECU. ‘Chest the coll wire and connectorEE -10 ENGINE ELECTRICAL SYSTEM CHECKING IGNITION COILS 4. Measure the primary coil resistance between tormi- nals 1 and 2. No. ana No, 2and 9 igniton cols ‘anion cols 2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, ‘and between the high-voltage terminals for the No.2 and No.3 cylinders. Standard value: 13.09 = 15% Q cauTion Be sure, when measuring the resistance of the secondary coil, to disconnect the connector of the ignition coll.IGNITION SYSTEM EE-11 IGNITION SWITCH 3, Remove the steering wheel lock nut. REMOVAL AND INSTALLATION ccxror 4. Disconnect the negative) battery terminal. 4, Remove the steering wheel with special tool (09561- 11002) Q caution 2, Remove the 2 bolts and disconnect the airbag con- Do not hammer on the steering wheel to remove rector and the horn connector, then remove the ‘irbag module. Doing somay damage the collapsible mechanism. caumon wont ‘Remove the horn pad only for vehicle without airbag.EE-12 ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM 6. Remove the screws holding the multi-function switch, INSPECTION. erciaeve then disconnect the wire connector. Remove the multi-function switch assembly, 1. Remove the drivers side crash pad lower panel 2. Disconnect the ignition switch connector and the door warning switch connector under the steering column, 8 lomove the key lock assembly from the steering col- umn shaft. (Refer to ST group) ‘9. Installation is the roverse of removal ‘ Ligation switch} [Door warning switch) ‘3. Check for continuity between the terminals.IGNITION SYSTEM 4, EE -13 continuity is not as specified, replace the switch TERMINAL IGNITION SWITCH ‘STEERING | DOORWARNING| POSITIONN, KEY REMOVAL Look Ace INSERT ON UNLock STARTEE-14 SPARK PLUG INSPECTION | escisce CHECKING SPARK PLUGS 1. Disconnect the spark plug cable from the spark plug. Qyore Pull on the spark plug cable boot when removing the ‘spark plug cable, not the cable, as it may be damaged. sone) [oowe} » 2) 2. Using a spark plug socket, remove all spark plugs 5) {rom the cylinder head. Q) caution 2 Take care not to allow contaminants to enter through the spark plug holes. ENGINE ELECTRICAL SYSTEM 8. Check the spark plugs for the following : Broken insulator Worn electrode Carbon deposits Damaged broken gasket Condition of the porcelain insulator at the tip of the spark plugIGNITION SYSTEM EE-~15 4, Check the spark plug gap using a wire gap gauge, SPARK PLUG TEST (WHEN ENGINE CAN BE and adjust if necessary. CRANKED) ‘Standard value = Connect the spark plug cable. Ground the outer electrode Unieaded : 1.0 ~ 1.1mm (0.039 - 0,043 in.) (main body), and crank the engine. In the atmosphere, only short sparks are produced because of the small dis- ccharge gap. M the spark plug is good, however, sparks will ‘occur in the discharge gap (between the electrodes). In 1 detective spark plug, no sparks will occur because of a leak through the insulation, 5. Re-insort the spark plug and tighten to the specitiod torque. It it is over torqued, damage to the thread portion of cylinder head might resut. Tightening torque = 20 ~ 30 Nm (200 ~ 300 kgiom, 15 ~ 21 lb) ANALYZING SPARK PLUGS Engine conditions can be analyzed by examining the tip deposits near electrode. Con- Gita | Dark deposits ‘White deposits De- | + Tooricha | + Tooleana fuel scrip» | fuel minture mixture tion | + Low alr * Advanced ignition [intake timing + Insufficient plug tighteningEE -16 ENGINE ELECTRICAL SYSTEM SPARK PLUG CABLE Therefore be careful to arrange the sparkplug cables prop- erly as shown in the illustration. COMPONENT LOCATION exscase Improper arrangement of spark plug cables will induce flash over between the cables, causing misfiring and surg- ing at acceleration in high-speed operations.IGNITION SYSTEM INSPECTION crus CHECKING SPARK PLUG CABLES 1. Check the cap and outer shell for cracks. 2. Measure the resistance. Spark plug cable ‘CYLIN- bern | Not LENGTH | 560 RESIS- TANCE | 251 ~ (ous | 3.76 a RESIS- TANCE | 5.60 ~ (RI6AIPS)| 11.76 2 Gnore Resistance should not be higher than 10,000 92 per foot of cable. if resistance is higher, replace the cable. [sone tooo} No2 Nos 360 1.81 ~ 2.42 3.60 ~ 7.56 sm) @ 310 1.39 ~ 3.10 ~ 651 EE~7EEA8 CHARGING SYSTEM GENERAL INFORMATION | cxsies0 GASOLINE ‘The charging system includes a battery, a generator with a builtin regulator, and the charging indicator light and wire. The generator has six builtin diodes (three positive ‘and three negative), each rectifying an AC current to DC current. Therefore, the DC current appears at generator “B" terminal, In addition, the charging voltage of the generator is regu- lated by the battery voltage detection system. The main ‘components of the generator are the rotor, stator, reti- fier, capacitor brushes, bearings and drive bet pulley. The brush holder contains a builtin electronic voltage regula tor. ENGINE ELECTRICAL SYSTEMCHARGING SYSTEM INSPECTION ror VOLTAGE DROP TEST OF GENERATOR OUTPUT ‘This test determines if the wiring between the generator "B® terminal and the battery (+) terminal is good by the voltage drop method. PREPARATION 1. Turn the ignition switch to "OFF*. To identity connection problems, be sure not to disturb ‘either ofthe two terminals or their connections during this test. 2. Connect a digital voltmeter between the generator “B* terminal and battery (+) terminal. Connect the (+) lead wire of the voltmeter to the “B* terminal and the (lead wire to the battery (+) terminal. CONDITIONS FOR TESTING With the engine running and headlamps, blower motor etc. (ON, check the reading on the votmeter. RESULT 1. The voltmeter should read a standard 0.3V. 2. Ifthe reading is above 0.3V, poor wiring should be suspected. (Chock wiring from generator ’B' terminal through the {sible link to the battery (+) terminal. ‘Check for loose wiring or color change from an over- heated harness. Correct and check again. 4. On completion of ho tst, sat the engine at io. Then tun ofthe headlamps, blower motor t., and iontlon EE -19 Fusble tne OUTPUT CURRENT TEST ‘This test determines if the generator gives an output cur- rent that is equivalent to the nominal output. PREPARATION 1. Prior tothe test, check the following items and correct ‘as necessary. a. Check if that the battery installed inthe vehicle is in good condition. For details, see "BATTERY". Gyno The battery that is used 10 test the output current should be one that has been partially discharged. With atully charged battary, the tast may not be con- ducted correctly due to an insufficient oad. b. Chock the tonsion of the generator drive belt. ‘Soe “COOLING. 2. Tum the ignition switch to "OFF*. 3. Disconnect the battery ground cable. ‘4, Disconnect the generator output wire from the gener- ator *B* terminal. 5. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Bo sure to connect the (-) lead wire of the ammeter to the disconnected output wire. Tighten each connection securely, as a heavy current will low. Do not rely on clips.EE -20 Connect a voltmeter (010 20V) between the *B"termi- ‘nal and ground, Connect the (+) lead wire to the gen- ‘erator “B" terminal and (-) lead wire to a good ground. ‘Attach an engine tachometer and connect the battery ‘ground cable. 8. Leave the engine hood open. Test 1. Check to 686 that the voltmeter reads the same value as the battery voltage. If the voltmeter reads OV, an ‘open circutin the wire between the generator “B* ter- ‘minal and battery (-) terminal, a blown fusible link or oor ground is suspected. 2. Start the engine and turn the headlights on, 3, Setthe heacights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm and read the maximum output current value indicated by the ammeter. Alter the engine starts, the charging current quickly ‘drops. Therefore, the above operation must be done quickly read the maximum current value correctly. ENGINE ELECTRICAL SYSTEM RESULT 1. The ammeter reading must be higher than the limit value. If itis lower but the generator output wire isin ‘good condition, remove the generator from the vehicle and test it. Limit value 634 min : 90A generator NOTE ‘The nominal output current value is shown on the ‘nameplate affixed to the generator body. 2. The output current value changes with the elec- trical load and the temperature of the generator felt Therefore, the nominal output current may not be ‘obtained. In such case, keep the headlights on to ‘discharge the battery, or use the lights of another vehicle to increase the electrical load. 2. Upon completion of the output current test, lower the ‘engine speed to idle and tur off the ignition switch, Disconnect the battery ground cable. 4, Remove the ammeter and voltmeter and the engine tachometer. 5. Connect the generator output wire to the generator “B* terminal. 6. Connect the battery ground cable. REGULATED VOLTAGE TEST ‘The purpose ofthis testis to check that the electronic volt age regulator controls the voltage correctly. PREPARATION 1. Priorto the test, check the following items and correct, it necessary. a. Check that the battery installed in the vehicle is fully charged. For battery checking method, see the "BATTERY" section. b. Check the generator drive belt tension. For belt tension check, see section, "COOLING" 2. Turn ignition switch to “OFF”. 3. Disconnect the battery ground cable.CHARGING SYSTEM 4. Connect a digital voltmeter betwoen the “S(L)" termi- nal of the generator and ground. Connect the (+) load of the voltmeter to the “S(L)" terminal of the generator. Connect the (-) lead to a ‘good ground or the battery (terminal. 5. Disconnect the generator output wire from the gener- ator *B* terminal. 6. Connect a DC ammeter (0 to 100A) in series between the "B* terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the di connected output wire. 7. Attach the engine tachometer and connect the battery ‘ground cable. Test 1. Tur on the ignition switch and check to see thatthe voltmeter indicates the following value. Voltage : Battery voltage Wit reads OV, there is an open circu in the wire be- {ween the generator “S(L)" terminal and the battery and the battery (+), oF the fusible link is blown. 2. Start the engine. Keep all lights and accessories off. ‘3. Run the engine at a speed of about 2,500 rpm and read the vollmeter when the generator output current drops to 10A or less. RESULT lt the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regu: lator is functioning correctly. It the reading is other than the standard value, the voltage regulator or the generator is faulty. REGULATING VOLTAGE TABLE Regulating voltage V 20 (-4) 20 (68) 60 (140) 80 (178) 2. Upon completion ofthe test, reduce the engine speed toile, and turn off the ignition switch. 3. Disconnect the battery ground cable. 4. Remove the voltmeter, ammeter, and the engine tachometer, 5. Connect the generator output wire to the generator *B* terminal. 6. Connect the battery ground cable.EE -22 ENGINE ELECTRICAL SYSTEM GENERATOR INSTALLATION | sxzoss: GASOLINE Bot Bracket 12-18 (120-160, 9-19) Generator mounting “Bt Generator ™ Bot Front case ‘Nut 20-25 (200-250, 14-18) TORQUE : Nm (kg-em, lb-ft)CHARGING SYSTEM. EE -23 CIRCUIT DIAGRAM conscce GASOLINE 1.5 pF Lc regulator i o . ° 00000, coum) LoadENGINE ELECTRICAL SYSTEM o>or, i o>or Pe 77. ALTERNATOR ASSY, WIREGULATOR REGULATOR ASSYCHARGING SYSTEM EE -25 REMOVAL AND INSTALLATION | esreor 4, Remove the belt by pushing the generator inward. GASOLINE 4. Disconnect the negative (-) terminal. 5. Remove the generator assembly. Y 2. ena be geet contactr dara he A "B+" torminal cable. tate is th reverse of meal Gore Peston the gener tne support bot 4. Loosen hebettnsen edusingbottendramae the «>on heganarstovartcet mounting bolt. 2. Push the generator forward and determine how ‘many spacers (thickness : 0.198 mm) should be inserted between the front leg of the generator and the front case. (space ‘AT inthe illustration) (There should be enough spacers so that they do ‘ot fall out when you let go of them.) 3. Insert the spacers (space “A” inthe istration), attach the nut, and complete the installation. |EE -26 ENGINE ELECTRICAL SYSTEM COMPONENTS | exrscu COMPONENTS: Brush holder boltsCHARGING SYSTEM EE .27 I SVS EEE 27 DIESELEE -28 ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM DISASSEMBLY crcrcoo 4, Remove the nut, pully and spacer. GASOLINE 1. Remove the generator cover using a screw driver '5. Loosen the 4 through bolts 2. Loosen the mounting bolts and disconnect the brush holder assembly. 7. Reassembly is the reverse of disassembly.CHARGING SYSTEM DIESEL 1. Remove the pulley cover. 2. Remove the pulley using the special tool. NOTE Use an air tool ‘3. After loosening the four vacuum pump mounting bots, Remove the vacuum pump. EE .29 5. After loosening the three rear cover mounting nuts ‘and one bolt, remove the rear cover. 6. Remove the two screws, then remove the brush holder cover and brush holder.EE -30 ENGINE ELECTRICAL SYSTEM 7. Remove the three screws, then remove the regulator. 10. After loosening the four screws, separate the motor from the stator assembly. 8. After loosening the four screws, remove the refer.CHARGING SYSTEM INSPECTION | ccoccrs ROTOR 1. Check the rotor coil for continuity. Check to make ure that there is continuity between the slip rings. If resistance is extremoly low, it means that there is a ‘short. If there is no continuity or i there is a short circuit, replace the rotor assembly. Resistance value : Approx. 3.19 2. Check the rotor col for ground. Check to make sure that there is no continuity between the slip ring and the core, {It there is continuity, replace the rotor assembly. EE -31 STATOR Make a continuity chock on the stator coil. Check to ‘make sure that there is continuity between the coll leads. If there is no continuity, replace the stator assembly. Check the col for grounding. Check to make sure that ‘there is no continuity between the coll and the core. {f there is continuity, replace the stator assembly.EE -32 REPLACEMENT cass: BRUSH Replace the brushes if they are worn to the limit line, ees ‘Wear it ine 1. Unsolder the pigtail and remove the old brush and spring. 2. Install the brush spring and a new brush in the brush holder. ‘3. Insert the brush so that there is a space of 2 to 3 mm (0.079 100.118 in.) betwoen the limit line and the end of the brush holder. ‘4, Solder the pigtail to the brush holder. ENGINE ELECTRICAL SYSTEMCHARGING SYSTEM BATTERY GENERAL INFORMATION | «coca 1, Themaintenance-ree battery is, as the name implies, totally maintenance free and has no removable bat- tery cell caps. 2. Water never needs to be added to the maintenance- {ree battery. 3. The batteryis completely sealed, except for small vent holes in the cover. EE -33EE -34 ENGINE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM INSPECTION | cexcwre BATTERY VISUAL INSPECTION (1) ‘Check for obvious damage such as a cracked or broken ‘case or cover that could permit loss of electrolyte. Determine cause of damage and correct as needed. Clean off corrosion with a solution of baking soda and water. Not 0. Sea Replace battery ‘Check specitic gravity. Reter to "Specific gravity check chart” for electrolyte, ‘temperature compensation, and then select proper reading below. Bolow 1.100 4.100 - 1.220 ‘Above 1.220 ‘Slow charge Recharge Perform load test Slow charge battery at 5A forno | | Refer to charging guide and ‘more than 14 hrs.,then perform | | safety precautions load test. Load test battery Apply 200A load for 15 sec., then check battery . voltage and compare below ‘ ‘Above 9.6 volts 9.6-6.5 volts Below 6.5 volts Battery O.K/Reuse Fast charge battery and then per-| | Battery no good. {orm load test again. Replace NOTE : i battery is stil less than 9.6 volts after second fast charge and toad test, then it should be replaced,CHARGING SYSTEM. EE -35 BATTERY VISUAL INSPECTION (2) ‘Make sure ignition switch is in the Off position and all accessories are Off Disconnect the battery cables. (negative fist) Flemove the battery from the vehicle. Q caution Care should be taken in the event that the bat- tery case Is cracked or leaking, to protect your ‘skin from the electrolyte. A sultable pair of rub- ber gloves (not household type) should be worn when removing the battery. Inspect the battery carrier for damage caused by the loss of acid from the battery. If acid damage is present, it will be necessary to clean the area with a solution of clean, warm water and baking soda. ‘Scrub the area with a stif brush and wipe off with a ‘loth moistened with baking soda and water. Clean the top of the battery with the same solution as described in step 4. Inspect the battery case, and cover, for cracks. If ‘cracks are present, the battery must be replaced. 10. 1" 12, Clean the battery posts with a suitable battery post cleaner. Clean the inside surface of the terminal clamps with a suitable battery terminal cleaning tool. Replace dam- aged or frayed cables and broken terminal clamps. Install the battery in the vehicie. Connect the cable terminals to the battery post, mak- ing sure the top of the terminals are flush with the top of the post. ‘Tighten the terminal nut securely. Coat all connections with light mineral grease after tightening. & cauTion When batteries are being charged, an explosive 920 forms beneath the cover of each coll. Do ‘not smoke near batteries being charged or which have recently been charged. Do not break live clroults at the terminals of the batteries being charged. A spark will occur whore the clcult {a broken. Keep all lames away from an open