Engine Electrical Equipment

Power Cables

~2min read

Inspection

PROCEDURE

1. Periodically inspect the cables along their entire length. Damage, cracking or burning of the cable insulation, as well as corrosion, is not permitted. A loose battery connection may cause engine starting failures and reduced engine performance.
2. Check the condition of the terminal connections, the presence of corrosion, cracks and loose cable clamps. A white flaky deposit under the insulation at the terminal indicates corrosion of the cable conductors and the need to replace the cable. Check the terminals for corrosion and deformation and check the condition of the mounting bolts.
3. When removing the cables, always disconnect the battery ground cable first and connect it last, to avoid short-circuiting the battery terminals with the tool used to tighten the clamps. If only the positive cable needs to be replaced, disconnect the negative cable first.

Replacement

PROCEDURE

1. Disconnect the old cables from the battery. Note the routing of the cables along their length and locate their attachment points to the starter and to ground. Disconnect the cables from the starter solenoid and ground. Remember the route the cable takes so that the new cable can be routed in the same place as the old one.
2. If the cables are to be replaced with new ones, take the old cables with you when purchasing the new ones. It is extremely important that the new cables exactly match the old ones. The positive cable can easily be distinguished from the negative cable: the positive cable insulation is usually red, these cables have a larger cross-section, and the battery terminal has a larger diameter. The ground cable insulation is black, and its cross-section and terminal diameter are smaller than those of the positive battery cable.
3. Clean the threads of the battery cable attachments on the starter solenoid and on the body, and remove any traces of corrosion.

* To prevent corrosion, lubricate the threads with petroleum jelly or a special protective compound for battery terminals.

4. Connect the cable to the starter solenoid or to ground, and securely tighten the nuts and bolts.
5. Before connecting the new cable to the battery, make sure the cable is of sufficient length and will be installed without tension.
6. Connect the cable to the positive battery terminal first, then to the negative terminal.

Test yourself

A quick Toyota Corolla quiz: every answer comes with an explanation and a link to the manual page.