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ENGINE SYSTEMS
8F - 1
ENGINE SYSTEMS
TABLE OF CONTENTS
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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BATTERY SYSTEM
TABLE OF CONTENTS
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BATTERY SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERYSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLSBATTERY SYSTEM SPECIAL TOOLS
. . . . . . . 7
BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 7
STANDARD PROCEDURESTANDARD PROCEDURE - BATTERY
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 11
BATTERY SYSTEM DESCRIPTION
A single 12-volt battery is standard factory-in- stalled equipment on gasoline engine equipped mod- els. Diesel engine equipped vehicles utilize two 12-volt batteries connected in parallel. All of the com- ponents of the battery system are located within the engine compartment of the vehicle. The battery sys- tem for this vehicle, covers the following related com- ponents, which are covered in further detail later in this section of the service manual:
STANDARD PROCEDURE - USING MICRO
420 BATTERY TESTER . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14BATTERY HOLDDOWN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14BATTERY CABLES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - BATTERYCABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17BATTERY TRAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18† Battery - The storage battery provides a reli- able means of storing a renewable source of electrical energy within the vehicle. † Battery Cables - The battery cables connect the battery terminal posts to the vehicle electrical system. † Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment. † Battery Tray - The battery tray provides a secure mounting location in the vehicle for the bat- tery and an anchor point for the battery holddown hardware.
BATTERY SYSTEM
8F - 2
BATTERY SYSTEM (Continued)For battery system maintenance schedules and jump starting procedures, see the owner’s manual in the vehicle glove box. Optionally, refer to the Lubri- cation and Maintenance section of this manual for the proper battery jump starting procedure. While battery charging can be considered a maintenance procedure, the battery charging procedure and related information are located later in this section of the service manual. This was done because the bat- tery must be fully-charged before any battery system diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and storing electrical energy. This electrical energy is required to operate the engine starting system, as well as to operate many of the other vehicle acces- sory systems for limited durations while the engine and/or the charging system are not operating. The battery system is also designed to provide a reserve of electrical energy to supplement the charging sys- tem for short durations while the engine is running and the electrical current demands of the vehicle exceed the output of the charging system. In addition to delivering, and storing electrical energy for the vehicle, the battery system serves as a capacitor and voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or transient voltages caused by the switching of any of the electrical components or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM The battery, starting, and charging systems in the vehicle operate with one another and must be tested as a complete system. In order for the engine to start and the battery to maintain its charge properly, all of the components that are used in these systems must perform within specifications. It is important that
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the battery, starting, and charging systems be thor- oughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal bat- tery discharge, overcharging or early battery failure must be diagnosed and corrected before a battery is replaced and before a vehicle is returned to service. The service information for these systems has been separated within this service manual to make it eas- ier to locate the specific information you are seeking. However, when attempting to diagnose any of these systems, it is important that you keep their interde- pendency in mind.
The diagnostic procedures used for the battery, starting, and charging systems include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, a volt/ohmme- ter, a battery charger, a carbon pile rheostat (load tester), a 12-volt test lamp and/or special service tools may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Always check the PCM for stored trouble codes before returning the vehicle to service. Refer to Charging System for the proper charging system test procedures. Refer to Starting System for the proper starting system test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester
is designed to help the dealership technician diagnose a defective battery. Follow the instruction manual sup- plied with the tester to properly diagnose a battery. If the instruction manual is not available, refer to the standard procedure in this section, which includes the directions for using the Micro 420 bat- tery tester.
DR BATTERY SYSTEM (Continued)
BATTERY SYSTEM 8F - 3
CONDITION
POSSIBLE CAUSES
CORRECTION
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS WEAK OR DEAD WHEN ATTEMPTING TO START THE ENGINE.
1. The electrical system ignition-off draw is excessive.
2. The charging system is faulty.
3. The battery is discharged.
4. The battery terminal connections are loose or corroded.
5. The battery has an incorrect size or rating for this vehicle. 6. The battery is faulty.
7. The starting system is faulty.
8. The battery is physically damaged.
1. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the excessive ignition-off draw, as required. 2. Determine if the charging system is performing to specifications. Refer to Charging System for additional charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 3. Determine the battery state-of-charge using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Charge the faulty battery, as required. 4. Refer to Battery Cables for the proper battery cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 5. Refer to Battery System Specifications for the proper size and rating. Replace an incorrect battery, as required. 6. Determine the battery cranking capacity using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Replace the faulty battery, as required. 7. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 8. Inspect the battery for loose terminal posts or a cracked and leaking case. Replace the damaged battery, as required.
BATTERY SYSTEM
8F - 4
BATTERY SYSTEM (Continued)DR
BATTERY SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
THE BATTERY STATE OF CHARGE CANNOT BE MAINTAINED.
1. The battery has an incorrect size or rating for this vehicle.
1. Refer to Battery System Specifications for the proper specifications. Replace an incorrect battery, as required.
2. The battery terminal connections are loose or corroded.
3. The electrical system ignition-off draw is excessive.
4. The battery is faulty.
5. The starting system is faulty.
6. The charging system is faulty.
7. Electrical loads exceed the output of the charging system. 8. Slow driving or prolonged idling with high-amperage draw systems in use.
1. The battery is faulty.
2. Refer to Battery Cable for the proper cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 3. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the faulty electrical system, as required. 4. Test the battery using the Micro 420 battery tester. Refer to Standard Procedures for additional test procedures. Replace the faulty battery, as required. 5. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 6. Determine if the charging system is performing to specifications. Refer to Charging System for additional charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 7. Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads. 8. Advise the vehicle operator, as required.
1. Test the battery using the Micro 420 battery tester. Charge or replace the faulty battery, as required.
THE BATTERY WILL NOT ACCEPT A CHARGE.
ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging:
1. A faulty or incorrect charging system compo- nent. Refer to Charging System for additional charg- ing system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420 bat- tery tester and refer to Battery System for additional battery diagnosis and testing procedures.
3. A faulty circuit or component causing excessive
ignition-off draw.
4. Electrical loads that exceed the output of the charging system. This can be due to equipment
installed after manufacture, or repeated short trip use.
5. A faulty or incorrect starting system component. Refer to Starting System for the proper starting sys- tem diagnosis and testing procedures.
6. Corroded or loose battery posts and/or terminal
clamps.
7. Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw systems in use.
CLEANING
The following information details the recommended cleaning procedures for the battery and related com-
BATTERY SYSTEM 8F - 5
DR BATTERY SYSTEM (Continued)
ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all corrosion. Remove any corrosion using a wire brush or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 1).
Fig.2CleanBattery-Typical
1 - CLEANING BRUSH 2 - WARM WATER AND BAKING SODA SOLUTION 3 - BATTERY
(5) Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3).
Fig.1CleanBatteryCableTerminalClamp-Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE
(2) Clean the battery tray and battery holddown hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution. Paint any exposed bare metal.
(3) If the removed battery is to be reinstalled, clean the outside of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film (Fig. 2). Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, refer to Battery System Specifications for the factory-installed battery specifications. Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle.
(4) Clean the battery thermal guard with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film.
Fig.3CleanBatteryTerminalPost-Typical
1 - TERMINAL BRUSH 2 - BATTERY CABLE 3 - BATTERY
BATTERY SYSTEM
8F - 6
BATTERY SYSTEM (Continued) INSPECTIONThe following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance sched- ules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related compo- nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a dam- aged or deformed terminal clamp.
(2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case (if equipped). Inspect the battery case for cracks or other damage that could result in electrolyte leaks. Also, check the battery terminal posts for looseness. Batteries with damaged cases or loose terminal posts must be replaced.
(4) Inspect the battery thermal guard (if equipped) for tears, cracks, deformation or other damage. Replace any battery thermal guard that has been damaged.
(5) Inspect the battery built-in test indicator sight glass (if equipped) for an indication of the battery condition. If the battery is discharged, charge as required. Refer the proper battery built-in indicator test procedures. Also refer to Standard Procedures for the proper battery charging procedures.
to Standard Procedures for
SPECIFICATIONS
The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be
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found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below. † Group Size - The outside dimensions and ter- minal placement of the battery conform to standards established by the Battery Council International (BCI). Each battery is assigned a BCI Group Size number to help identify a correctly-sized replace- ment.† Cold Cranking Amperage - The Cold Crank- ing Amperage (CCA) rating specifies how much cur- rent (in amperes) the battery can deliver for thirty seconds at -18° C (0° F). Terminal voltage must not fall below 7.2 volts during or after the thirty second discharge period. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. † Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for bat- tery terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the battery fully-charged at 26.7° C (80° F). This rat- ing estimates how long the battery might last after a charging system failure, under minimum electrical load.† Ampere-Hours - The Ampere-Hours (AH) rat- ing specifies the current (in amperes) that a battery can deliver steadily for twenty hours, with the volt- age in the battery not falling below 10.5 volts. This rating is also sometimes identified as the twenty- hour discharge rating.
Part Number
56029449AB 56029451AB 56028450AA 56028452AA 56028452AB 56029396AA 56029382AA
BATTERY CLASSIFICATIONS & RATINGS
BCI Group Size
Classification
Cold Cranking
Amperage
65
65
65
65
65
65
65600
750
600
750
700
700
700Reserve Capacity
120 Minutes 150 Minutes 120 Minutes 150 Minutes 130 Minutes 130 Minutes 130 Minutes
Ampere -
Hours
Load Test Amperage
66
75
66
75
70
70
70300
375
300
375
350
350
350DR BATTERY SYSTEM (Continued) SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
Micro420BatteryTester
BATTERY DESCRIPTION
BATTERY SYSTEM 8F - 7
A large capacity, low-maintenance storage battery (Fig. 4) is standard factory-installed equipment on this model. Models equipped with a diesel engine must utilize two 12-volt batteries connected in paral- lel. Male post type terminals made of a soft lead material protrude from the top of the molded plastic battery case to provide the means for connecting the battery to the vehicle electrical system. The battery positive terminal post is physically larger in diameter than the negative terminal post to ensure proper bat- tery connection. The letters POS and NEG are also molded into the top of the battery case adjacent to their respective positive and negative terminal posts for to Battery Cables for more information on the battery cables that connect the battery to the vehicle electrical sys- tem.
identification confirmation. Refer
The battery is made up of six individual cells that are connected in series. Each cell contains positively charged plate groups that are connected with lead straps to the positive terminal post, and negatively charged plate groups that are connected with lead straps to the negative terminal post. Each plate con- sists of a stiff mesh framework or grid coated with lead dioxide (positive plate) or sponge lead (negative plate). Insulators or plate separators made of a non- conductive material are inserted between the positive and negative plates to prevent them from contacting or shorting against one another. These dissimilar metal plates are submerged in a sulfuric acid and water solution called an electrolyte.
The factory-installed battery has a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condi- tion. Refer to Standard Procedures for the proper built-in indicator test procedures. The factory-in- stalled low-maintenance battery has non-re- movable battery cell caps. Water cannot be added to this battery. The battery is not sealed and has vent holes in the cell caps. The chemical composition of the metal coated plates within the low-mainte- nance battery reduces battery gassing and water loss, at normal charge and discharge rates. There- fore, the battery should not require additional water in normal service. Rapid loss of electrolyte can be caused by an overcharging condition.
Fig.4Low-MaintenanceBattery-Typical
1 - POSITIVE POST 2 - VENT 3 - CELL CAP 4 - TEST INDICATOR (IF EQUIPPED) 5 - CELL CAP 6 - VENT 7 - NEGATIVE POST 8 - GREEN BALL 9 - ELECTROLYTE LEVEL 10 - PLATE GROUPS 11 - LOW-MAINTENANCE BATTERY
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed. Refer to Battery System Cleaning for the proper cleaning pro- cedures, and Battery System Inspection for the proper battery inspection procedures. Refer to Stan- dard Procedures for the proper battery charging pro- cedures.
8F - 8
BATTERY SYSTEM BATTERY (Continued) MICRO 420 BATTERY TESTERThe Micro 420 automotive battery tester
is designed to help the dealership technician diagnose the cause of a defective battery. Follow the instruc- tion manual supplied with the tester to properly diagnose a battery. If the instruction manual is not available, refer to the standard procedure in this sec- tion, which includes the directions for using the Micro 420 battery tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BAT- TERY. PERSONAL INJURY AND/OR VEHICLE DAM- AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.
A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is faulty and must be replaced. Always test battery using the Micro 420 battery tester before attempting to replace a battery under the manufactures war- ranty provisions.
NOTE: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedures for the proper battery charging proce- dures.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY CHARGING
Battery charging can be performed fast or slow, in terms of time. Slow battery charging is the best means of restoring a battery to full potential. Fast battery charging should only be performed when
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battery charging.
absolutely necessary due to time restraints. A battery is fully-charged when: † All of the battery cells are gassing freely during † A green color is visible in the sight glass of the † Three hydrometer tests, taken at one-hour inter- indicate no increase in the temperature-cor- † Open-circuit voltage of the battery is 12.65 volts
vals, rected specific gravity of the battery electrolyte.
battery built-in test indicator.
or above.
WARNING: NEVER EXCEED TWENTY AMPERES WHEN CHARGING A COLD (-1° C [30° F] OR LOWER) BATTERY. THE BATTERY MAY ARC INTER- NALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat- tery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system compo- nents may result.
CAUTION: Battery electrolyte will bubble inside the battery case during normal battery charging. Elec- trolyte boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery may result from overcharging.
CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continu- ing the charging operation. Damage to the battery may result.
NOTE: Models equipped with the diesel engine are equipped with two 12-volt batteries, connected in parallel (positive-to-positive and negative-to-nega- tive). In order to ensure proper charging of each battery, these batteries MUST be disconnected from each other, as well as from the vehicle electrical system while being charged.
Some battery chargers are equipped with polarity- sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of- charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by
DR BATTERY (Continued)
BATTERY SYSTEM 8F - 9
the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.
After the battery has been charged to 12.4 volts or greater, perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is faulty and must be replaced.
Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Bat- tery System Inspection for the proper battery system inspection procedures.
CHARGING A COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge a completely discharged battery. Unless this proce- dure is properly followed, a good battery may be needlessly replaced.
(1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 5). If the reading is below ten volts, the battery charging cur- rent will be low. It could take some time before the battery accepts a current greater than a few milliam- peres. Such low current may not be detectable on the ammeters built into many battery chargers.
Fig.5Voltmeter-Typical
(2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some bat- tery chargers are equipped with polarity-sensing cir- cuitry. This circuitry protects the battery charger and the battery from being damaged if they are improp- erly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging cur- rent. See the instructions provided by the manufac-
turer of the battery charger for details on how to bypass the polarity-sensing circuitry.
they provide. The amount of
(3) Battery chargers vary in the amount of voltage and current time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not mea- surable at the end of the charging time, the battery is faulty and must be replaced. If the charging cur- rent is measurable during the charging time, the bat- tery may be good and the charging should be completed in the normal manner.
CHARGE RATE TABLE
Voltage
16.0 volts maximum
14.0 to 15.9 volts 13.9 volts or less
Hours
up to 4 hours up to 8 hours up to 16 hours
CHARGING TIME REQUIRED
depending upon the following factors:
The time required to charge a battery will vary, † Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. † Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). † Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies twenty amperes or more will require a shorter charg- ing time. † State-Of-Charge - A completely discharged bat- tery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the bat- tery charges, the specific gravity of the electrolyte will gradually rise.
The Battery Charging Time Table gives an indica- tion of the time required to charge a typical battery at room temperature based upon the battery state-of- charge and the charger capacity.
BATTERY SYSTEM
8F - 10
BATTERY (Continued)BATTERY CHARGING TIME TABLE
Charging Amperage Open Circuit
Voltage
5 Amps
10
Amps
20 Amps
Hours Charging @ 21° C
12.25 to 12.49
6 hours
(70° F) 3 hours
12.00 to 12.24
10 hours
5 hours
10.00 to 11.99
14 hours
7 hours
Below 10.00
18 hours
9 hours
1.5
hours 2.5
hours 3.5
hours 4.5
hoursSTANDARD PROCEDURE - BUILT-IN INDICATOR TEST
If equipped, an indicator (hydrometer) built into the top of the battery case provides visual informa- tion for battery testing (Fig. 6). Like a hydrometer, the built-in indicator measures the specific gravity of the battery electrolyte. The specific gravity of the electrolyte reveals the battery state-of-charge; how- ever, it will not reveal the cranking capacity of the battery. A load test must be performed to determine the battery cranking capacity. Refer to Standard Pro- cedures for the proper battery load test procedures.
Fig.6Built-InIndicator
1 - SIGHT GLASS 2 - BATTERY TOP 3 - GREEN BALL 4 - PLASTIC ROD
Before testing, visually inspect the battery for any damage (a cracked case or cover, loose posts, etc.) that would cause the battery to be faulty. In order to obtain correct indications from the built-in indicator, it is important that the battery be level and have a clean sight glass. Additional light may be required to view the indicator. Do not use open flame as a source of additional light.
To read the built-in indicator, look into the sight glass and note the color of the indication (Fig. 7). The
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indicates
each color
battery condition that described in the following list:
is † Green - Indicates 75% to 100% battery state-of- charge. The battery is adequately charged for further testing or return to service. If the starter will not crank for a minimum of fifteen seconds with a fully- charged battery, the battery must be load tested. Refer to Standard Procedures for the proper battery load test procedures. † Black or Dark - Indicates 0% to 75% battery state-of-charge. The battery is inadequately charged and must be charged until a green indication is visi- ble in the sight glass (12.4 volts or more), before the battery is tested further or returned to service. Refer to Standard Procedures for the proper battery charg- ing procedures. Also refer to Diagnosis and Testing for more information on the possible causes of the discharged battery condition. † Clear or Bright - Indicates a low battery elec- trolyte level. The electrolyte level in the battery is below the built-in indicator. A maintenance-free bat- tery with non-removable cell caps must be replaced if the electrolyte level is low. Water must be added to a low-maintenance battery with removable cell caps before it is charged. Refer to Standard Procedures for the proper battery filling procedures. A low electro- lyte level may be caused by an overcharging condi- tion. Refer to Charging System for the proper charging system diagnosis and testing procedures.
Fig.7Built-InIndicatorSightGlassChart STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST
A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. This test can be used in place of the hydrometer test when a hydrometer is not available, or for mainte- nance-free batteries with non-removable cell caps.
Before proceeding with this test, completely charge the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuring the open-circuit voltage, the surface charge must be removed from the battery.
DR BATTERY (Continued)
Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.
(2) Disconnect and isolate both battery cables, neg-
ative cable first.
(3) Using a voltmeter connected to the battery posts (see the instructions provided by the manufac- turer of the voltmeter), measure the open-circuit volt- age (Fig. 8).
Fig.8TestingOpen-CircuitVoltage-Typical
See the Open-Circuit Voltage Table. This voltage reading will indicate the battery state-of-charge, but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking capacity (Refer to 8 - ELECTRICAL/BATTERY SYS- TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage
Charge Percentage
11.7 volts or less
12.0 volts 12.2 volts 12.4 volts
12.6 volts or more
0% 25% 50% 75% 100%
BATTERY SYSTEM 8F - 11
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor- mal condition where power is being drained from the battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Con- trol Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment.
A vehicle that has not been operated for approxi- mately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Integrated Power Module (IPM). This will reduce battery discharging. Excessive IOD can be caused by: † Electrical items left on. † Faulty or improperly adjusted switches. † Faulty or shorted electronic modules and compo- nents.† An internally shorted generator. † Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replac- ing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected.
(1) Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illumi- nated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Igni- tion-Off Draw Table for more information.
Module
Radio
Audio Power
Amplifier
Powertrain Control
Module (PCM)
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Time Out?
(If Yes, Interval And Wake-Up Input)
No
No
No
IOD
1 to 3
milliamperes
up to 1
milliampere
0.95 milliampere
IOD After Time
Out
N/A
N/A
N/A
BATTERY SYSTEM
8F - 12
BATTERY (Continued)Module
ElectroMechanical Instrument Cluster
(EMIC)
Combination Flasher
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Time Out?
(If Yes, Interval And Wake-Up Input)
IOD
No
No
0.44 milliampere
0.08 milliampere
DR
IOD After Time
Out
N/A
N/A
(2) Determine that the underhood lamp is operat- ing properly, then disconnect the lamp wire harness connector or remove the lamp bulb.
(3) Disconnect the battery negative cable. (4) Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable ter- minal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi- meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the bat- tery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated.
(5) After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Integrated Power Module (IPM), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information in this service manual for complete Inte- grated Power Module fuse, circuit breaker, and cir- cuit identification. This will isolate each circuit and identify the circuit that is the source of the high-am- perage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the gener- ator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing proce- dures. After the high-amperage IOD has been cor- rected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD.
CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged.
(6) Observe the multi-meter reading. The low-am- perage IOD should not exceed thirty-five milliam- peres (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault.
STANDARD PROCEDURE - USING MICRO 420
BATTERY TESTERFig.9MICRO420BATTERYTESTER
Always use the Micro 420 Instruction Manual that was supplied with the tester as a reference. If the Instruction Manual is not available the following pro- cedure can be used:
DR BATTERY (Continued)
WARNING: ALWAYS WEAR APPROPRIATE EYE PROTECTION AND USE EXTREME CAUTION WHEN WORKING WITH BATTERIES.
BATTERY TESTING
(1) If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before test- ing. If the battery is equipped with side post termi- nals, install and tighten the supplied lead terminal stud adapters. Do not use steel bolts. Failure to prop- erly install the stud adapters, or using stud adapters that are dirty or worn-out may result in false test readings.
(2) If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF, including the ignition. The preferred test position is at the battery terminal. If the battery is not accessible, you may test using both the positive and negative jumper posts. Select TESTING AT JUMPER POST when connecting to that location.
(3) Connect the tester (Fig. 9) to the battery or jumper posts, the red clamp to positive (+) and the black clamp to negative (–).
NOTE: Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test. Failure to disconnect may result in false battery test readings.
(4) Using the ARROW key select in or out of vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate bat- tery rating for your area (see menu). The tester will then run its self programmed test of the battery and display the results. Refer to the test result table noted below.
CAUTION: If REPLACE BATTERY is the result of the test, this may mean a poor connection between the vehicle’s cables and battery exists. After discon- necting the vehicle’s battery cables from the bat- tery, retest the battery using the OUT-OF-VEHICLE test before replacing.
(6) While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit. Then press the ENTER button to view the SERVICE CODE. Pressing the CODE button a second time will return you to the test results.
BATTERY SYSTEM 8F - 13
BATTERY TEST RESULTS
GOOD BATTERY
Return to service
GOOD - RECHARGE
Fully charge battery and
return to service
CHARGE & RETEST
Fully charge battery and
REPLACE BATTERY
BAD-CELL REPLACE
retest battery
Replace the battery and retest complete system Replace the battery and retest complete system
NOTE: The SERVICE CODE is required on every warranty claim submitted for battery replacement.
REMOVAL
(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Fig. 10).
Fig.10RemovingBatteryCableTerminalClamp
1 - BATTERY 2 - BATTERY TERMINAL PULLER
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If nec- essary, use a battery terminal puller to remove the terminal clamp from the battery post (Fig. 10).
(6) Remove the battery hold down retaining bolt.
WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BAT- TERY IS CRACKED OR LEAKING, THE ELECTRO- LYTE CAN BURN THE SKIN AND EYES.
BATTERY SYSTEM
8F - 14
BATTERY (Continued)(7) Remove the battery from the battery tray.
REMOVAL
DR
INSTALLATION
(1) Clean and inspect the battery. (2) Position the battery onto the battery tray. Ensure that the battery positive and negative termi- nal posts are correctly positioned. The battery cable terminal clamps must reach the correct battery ter- minal post without stretching the cables.
(3) Position the battery hold down and install the
retaining bolt.
CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery termi- nal posts. Reversed battery polarity may damage electrical components of the vehicle.
(4) Clean the battery cable terminal clamps and
the battery terminal posts.
(5) Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N·m (35
in. lbs.).(6) Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N·m (35
in. lbs.).(7) Apply a thin coating of petroleum jelly or chas- sis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.
(8) Obtain a DRB IIIt scan tool and check the PCM for any stored battery disconnect trouble code, if required.
BATTERY HOLDDOWN DESCRIPTION
The battery hold down hardware includes a bolt and a molded plastic hold down bracket which meshes with the battery tray when properly installed. The battery tray and hold down hardware combine to form a very stable and secure battery hold down assembly.
OPERATION
The battery holddown secures the battery in the battery tray. This holddown is designed to prevent battery movement during the most extreme vehicle operation conditions. Periodic removal and lubrica- tion of the battery holddown hardware is recom- mended to prevent hardware seizure at a later date.
CAUTION: Never operate a vehicle without a battery holddown device properly installed. Damage to the vehicle, components and battery could result.
(1) Loosen and remove the battery hold down
(2) Remove the battery hold down bracket from
retaining bolt.
the battery case.
INSTALLATION
(1) Clean and inspect the battery hold down hard- ware (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - CLEANING).
(2) Position the battery hold down bracket in the battery tray. Be certain that the hold down bracket is properly positioned in the battery tray before tight- ening the hold down hardware.
(3) Install and tighten the battery hold down
retaining bolt.
BATTERY CABLES DESCRIPTION
The battery cables are large gauge, stranded cop- per wires sheathed within a heavy plastic or syn- thetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reli- ability with high electrical current carrying capacity. Refer to Wiring for the location of the proper battery cable wire gauge information.
The battery cables cannot be repaired and, if dam- aged or faulty they must be replaced. Both the bat- tery positive and negative cables are available for service replacement only as a unit with the battery positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other com- ponents on some models.
Most models feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber pro- tective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then sol- der-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive ter- minal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp.
OPERATION
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables
DR BATTERY CABLES (Continued)
also provide a return path for electrical current gen- erated by the charging system for restoring the volt- age potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The ter- minal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle elec- trical system.
DIAGNOSIS AND TESTING - BATTERY CABLES A voltage drop test will determine if there is exces- sive resistance in the battery cable terminal connec- tions or the battery cables. If excessive resistance is found in the battery cable connections, the connec- tion point should be disassembled, cleaned of all cor- rosion or then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.
foreign material,
When performing the voltage drop test, it is impor- tant to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAM- PLE: When testing the resistance of the battery pos- itive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery pos- itive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable.
VOLTAGE DROP TEST
WARNING: MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD) RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE FROM STARTING. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY.
The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished:
BATTERY SYSTEM 8F - 15
† The battery is fully-charged and tested (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE).
† Fully engage the parking brake. † If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a man- ual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. † Verify that all lamps and accessories are turned off.† To prevent a gasoline engine from starting, remove the Automatic ShutDown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location.
(1) Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the neg- ative lead of the voltmeter to the battery negative cable terminal clamp (Fig. 11). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor con- nection between the battery negative cable terminal clamp and the battery negative terminal post.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #1 must be performed twice, once for each battery.
Fig.11TestBatteryNegativeConnection
Resistance-Typical
1 - VOLTMETER 2 - BATTERY
(2) Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the nega- tive lead of the voltmeter to the battery positive cable terminal clamp (Fig. 12). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If connection voltage is detected,
the poor
correct
BATTERY SYSTEM
8F - 16
BATTERY CABLES (Continued)between the battery positive cable terminal clamp and the battery positive terminal post.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #2 must be performed twice, once for each battery.
DR
Fig.13TestBatteryPositiveCableResistance-
Typical
1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR
Fig.14TestGroundCircuit
1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND
REMOVAL
(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Disconnect and isolate the remote battery neg-
ative cable terminal.
(3) Remove the battery from the vehicle. Refer to
the procedure in this group.
(4) One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle.
(5) Remove the battery cable from the engine com-
partment.
Fig.12TestBatteryPositiveConnectionResistance
-Typical
1 - VOLTMETER 2 - BATTERY
(3) Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 13). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal con- nection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #3 must be performed twice, once for each battery.
(4) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 14). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable eyelet connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.terminal
NOTE: If the vehicle is equipped with two 12v bat- teries, step #4 must be performed twice, once for each battery.
DR BATTERY CABLES (Continued) INSTALLATION
(1) Position the battery cable in the engine com-
partment.
(2) One at a time, install the battery cable retain- ing pushpins, fasteners and routing clips until the cable is installed exactly where it was in the vehicle. Refer to Wiring for illustrations.
(3) Install the battery in the vehicle. Refer to the
procedure in this group.
(4) Connect the battery negative cable terminal.
BATTERY TRAY DESCRIPTION
BATTERY SYSTEM 8F - 17
OPERATION
The battery tray and the battery hold down hard- ware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during even the most extreme vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehi- cle, the battery, or both.
REMOVAL
LEFT SIDE
(1) Remove the battery from the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT- TERY - REMOVAL).
(2) Remove the integrated power module (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEL- LIGENT POWER MODULE - REMOVAL).
(3) Disconnect the wire harness retainers from the
battery tray assembly.
(4) Remove
the anti-lock brake
(if equipped) retaining bolts and support the brake con- troller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit.
controller
(5) Remove the left front wheelhouse splash shiel- to 23 - BODY/EXTERIOR/LF WHEEL-
d(Refer HOUSE SPLASH SHIELD - REMOVAL).
Fig.15DRBatteryTray
1 - BATTERY TRAY ASSEMBLY 2 - BATTERY TEMPERATURE SENSOR 3 - ANTI-LOCK BRAKE CONTROLLER MOUNTING LOCATION 4 - INTEGRATED POWER MODULE MOUNTING SANCTION
The molded plastic tray battery tray is located in the left front corner of the engine compartment. On this model, the battery tray also provides an anchor point for the anti-lock brake controller, cruise control servo (if equipped) and the integrated power module (Fig. 15). The battery hold down hardware is con- tained within the battery tray. A hole in the bottom of the battery tray is fitted with a battery tempera- ture sensor. Refer to Charging System for more infor- mation on the battery temperature sensor.
Fig.16LowerBatteryTrayRetainingBolts
1 - BATTERY TRAY ASSEMBLY 2 - BATTERY TRAY RETAINING BOLTS 3 - CRUISE CONTROL SERVO
BATTERY SYSTEM
8F - 18
BATTERY TRAY (Continued)DR
(6) Mark the location of
the cruise servo (if equipped) and remove the retaining screws. Position the servo out of the way.
(7) Remove the battery temperature sensor from the battery tray (Refer to 8 - ELECTRICAL/CHARG- ING/BATTERY REMOVAL).
TEMPERATURE
SENSOR
(8) Disconnect the purge solenoid from its mount-
(9) Disconnect the left front fender ground wire. (10) Remove the remaining battery tray retaining
(11) Remove the battery tray from the vehicle.
ing bracket.
bolts (Fig. 16).
RIGHT SIDE
(1) Remove the battery from the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT- TERY - REMOVAL).
(2) Remove the right
front wheelhouse splash
(3) Disconnect the right front fender ground wire. (4) Remove relay
from grid heater
fasteners
shield.
bracket.
Fig.17RIGHTSIDEBATTERYTRAY
(6) Install the left front wheelhouse splash shield (Refer to 23 - BODY/EXTERIOR/LF WHEELHOUSE SPLASH SHIELD - INSTALLATION).
(7) Install
the
anti-lock brake
controller
(if
equipped).
(8) Connect the wire harness retainers on the bat-
(9) Install the integrated power module (Refer to 8
- ELECTRICAL/POWER DISTRIBUTION/INTELLI- GENT POWER MODULE - INSTALLATION).(10) Install the battery (Refer to 8 - ELECTRI- INSTALLA-
CAL/BATTERY SYSTEM/BATTERY - TION).
(1) Position the battery tray assembly and install
(2) Connect the right front fender ground wire. (3) Install the air box. (4) Install the grid heater relay bracket. (5) Install
front wheelhouse splash
the right
shield.
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(5) Remove air box. (6) Remove the remaining battery tray retaining
tery tray assembly.
bolts (Fig. 17).
(7) Remove the battery tray from the vehicle.
INSTALLATION
LEFT SIDE
the retaining bolts.
(1) Position the battery tray assembly and install
RIGHT SIDE
(2) Connect the left front fender ground wire. (3) Install
the purge solenoid on its mounting
the retaining bolts.
bracket.
(4) Install the battery temperature sensor in the battery tray (Refer to 8 - ELECTRICAL/CHARGING/ BATTERY TEMPERATURE SENSOR - INSTALLA- TION).
(5) Install
the cruise servo (if equipped) and
retaining screws.
DR
CHARGING
8F - 19
CHARGING
TABLE OF CONTENTS
page
page
CHARGING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - CHARGINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS - TORQUE - GENERATOR/ CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 20
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27CHARGING DESCRIPTION The charging system consists of: † Generator † Electronic Voltage Regulator
(EVR)
circuitry within the Powertrain Control Module (PCM). Elec- tronic Control Module (ECM) for diesel engines. † Ignition switch † Battery (refer to 8, Battery for information) † Battery temperature sensor † Check Gauges Lamp (if equipped) † Voltmeter (refer to 8, Instrument Panel and † Wiring harness and connections (refer to 8, Wir-
Gauges for information)
ing Diagrams for information)
OPERATION
The charging system is turned on and off with the ignition switch. The system is on when the engine is running and the ASD relay is energized. When the ASD relay is on, voltage is supplied to the ASD relay sense circuit at the PCM (ECM Diesel). This voltage is connected through the PCM (ECM Diesel) and sup- plied to one of the generator field terminals (Gen. Source +) at the back of the generator.
The amount of direct current produced by the gen- erator is controlled by the EVR (field control) cir- cuitry contained within the PCM (ECM Diesel). This circuitry is connected in series with the second rotor field terminal and ground.
A battery temperature sensor, located in the bat- tery tray housing, is used to sense battery tempera- ture. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. This is
done by cycling the ground path to control the strength of the rotor magnetic field. The PCM then compensates and regulates generator current output accordingly.
All vehicles are equipped with On-Board Diagnos- tics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM (ECM Diesel). Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects.
The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant tempera- ture and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges. The sig- nal to activate the lamp is sent via the CCD bus cir- cuits. The lamp is located on the instrument panel. Refer to 8, Instrument Panel and Gauges for addi- tional information.
DIAGNOSIS AND TESTING - CHARGING SYSTEM
the charging system if:
nated with the engine running
The following procedures may be used to diagnose † the check gauges lamp (if equipped) is illumi- † the voltmeter (if equipped) does not register † an undercharged or overcharged battery condi-
properly
tion occurs.
running
caused by:
Remember that an undercharged battery is often † accessories being left on with the engine not
CHARGING
8F - 20
CHARGING (Continued) † a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test in 8, Battery for more information.INSPECTION
The PCM (Powertrain Control Module), or ECM (Diesel) monitors critical input and output circuits of the charging system, making sure they are opera- tional. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain Control Module; Electronic Control Modules for more DTC information. This will include a complete list of DTC’s including DTC’s for the charging system.
To perform a complete test of the charging system, refer to the appropriate Powertrain Diagnostic Proce- dures service manual and the DRBt scan tool. Per- form the following inspections before attaching the scan tool.
(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.
DR
(2) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required.
(3) Inspect all
fuses in both the fuseblock and Power Distribution Center (PDC) for tightness in receptacles. They should be properly installed and tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to the Gen- erator Removal/Installation section of this group for torque specifications.
(5) Inspect generator drive belt condition and ten- sion. Tighten or replace belt as required. Refer to Belt Tension Specifications in 7, Cooling System.
(6)
Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) Inspect generator electrical connections at gen- erator field, battery output, and ground terminal (if equipped). Also check generator ground wire connec- tion at engine (if equipped). They should all be clean and tight. Repair as required.
SPECIFICATIONS
GENERATOR RATINGS
TYPE DENSO DENSO BOSCH BOSCH DENSO DENSO BOSCH
PART NUMBER
RATED SAE AMPS
56029700AA 56029701AA 56041120AC 56028238AB 56028560AA 56028696AA 56028699AA
136
136
136
136
136
136
136ENGINES 3.7L / 4.7L 5.9L Gas 3.7L / 4.7L 5.9L Gas
8.0L
5.7L Gas/5.9L Diesel 5.7L Gas/5.9L Diesel
SPECIFICATIONS - TORQUE - GENERATOR / CHARGING SYSTEM
DESCRIPTION
Generator Mounting Bolts - 5.7L
Generator Support Bracket
Bolt/Nuts - 5.7L
Generator Mounting Bolts - 8.0L Generator Upper Mounting Bolt -
5.9L Diesel Engine
Generator Upper Mounting Bolt -
5.9L Gas Engine
N·m 41
41
41
41
41
Ft. Lbs.
In. Lbs.
30
30
30
30
30
CHARGING
8F - 21
Ft. Lbs.
In. Lbs.
30
40
40
55
108
DR CHARGING (Continued)
DESCRIPTION
Generator Lower Pivot Bolt / Nut -
5.9L Gas Engine
Generator Vertical Mounting Bolt -
3.7L / 4.7L Engines
Generator (long) Horizontal
Mounting Bolt - 3.7L / 4.7L Engines
Generator (short) Horizontal
Mounting Bolt - 3.7L / 4.7L Engines
Generator B+ Output Cable
Terminal Nut
N·m 41
55
55
74
12
BATTERY TEMPERATURE SENSOR DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper- ature and control battery charging rate. This temper- ature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures.
The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temper- ature increases, resistance in the sensor decreases and the detection voltage at the PCM increases.
The BTS is also used for OBD II diagnostics. Cer- tain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F.
REMOVAL
The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1).
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1).
(3) Disconnect sensor from engine wire harness
electrical connector.
