Battery System: Diagnosis Chrysler Crossfire I

INSPECTION

The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this information and the owner's manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service.

1. Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or deformed terminal clamp.
2. Inspect the battery tray and battery hold-down hardware for damage. Replace any damaged parts.
3. 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.

BATTERY TESTING

1. If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before testing. If the battery is equipped with side post terminals, install and tighten the supplied lead terminal stud adapters. Do not use steel bolts. Failure to properly 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 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 vehicle testing and press ENTER to make a selection.
5. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery 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 «BATTERY TEST RESULTS»(ref-250654-S35014268612007031500000) table. 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 disconnecting the vehicle's battery cables from the battery, 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 TEST RESULTS

Note. The SERVICE CODE is required on every warranty claim submitted for battery replacement.

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 maintenance-free batteries with non-removable cell caps.

Before proceeding with this test, completely charge the battery. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE) .

1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. 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, negative cable first.
3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage.

OPEN CIRCUIT VOLTAGE

IGNITION-OFF DRAW TEST

The term Ignition-Off Draw (IOD) identifies a normal 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 Control Module (PCM), and other modules which may vary with the vehicle equipment.

A vehicle that has not been operated for approximately 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 negative battery cable from the battery. This will reduce battery discharging.

Excessive IOD can be caused by

1. Electrical items left on.
2. Faulty or improperly adjusted switches.
3. Faulty or shorted electronic modules and components.
4. An internally shorted generator.
5. Intermittent shorts in the wiring.

If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing 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 illuminated 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 Ignition-Off Draw Table for more information. ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) Module Time Out? (If Yes, Interval And Wake-Up Input) IOD IOD After Time Out Controller Antilock Brake (CAB) No - N/A Body Control Module (BCM) No - N/A Powertrain Control Module (PCM) No - N/A Transmission Control Module (TCM) No - N/A Instrument Cluster No - N/A Shift Lever Assembly No - N/A Garage Door Opener/Tire Pressure Monitor No - N/A A/C Heater Control Module No - N/A Occupant Restraint Control Module No - N/A Pneumatic System Equipment (PSE) Control Module No - N/A RKE Module No - N/A
2. Disconnect the negative battery cable.
3. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal 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 battery 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.
4. 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 each fuse in the Underhood Accessory Fuse Block, one at a time until the amperage reading becomes very low, or nonexistent. If the amperage reading is still high, remove each fuse one at a time in the Illumination Control Module until the amperage reading becomes very low or nonexistent. If the amperage reading is still high, remove each fuse one at a time in the Relay Control Module until the amperage reading becomes very low or nonexistent. Refer to the appropriate wiring information for complete Underhood Accessory Fuse, Illumination Control Module Fuse, Relay Control Module Fuse and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, «(Refer to ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING)»(ref-250642-S17483632802007031500000) for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, 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.
5. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 amperes). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse remove-and-replace process in step 4 . 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.

VOLTAGE DROP TEST

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

1. The battery is fully-charged and load tested. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE)»(ref-250654-S01097150932007031500000) for the proper battery charging and load test procedures.
2. Fully engage the parking brake.
3. 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 manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position.
4. Verify that all lamps and accessories are turned off.
5. To prevent the engine from starting, remove the ignition coil fuse. The ignition coil fuse is located in the Underhood Accessory Fuse Block, in the engine compartment. See the fuse layout label affixed to the underside of the fuse block cover for ignition coil fuse identification and location.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post.
2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post.
3. Connect the voltmeter (2) to measure between the battery (1) positive cable terminal clamp and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter (2). If the reading is above 0.2 volt, clean and tighten the battery (1) positive cable eyelet terminal connection 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.
4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter (1). If the reading is above 0.2 volt, clean and tighten the battery (2) negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.

Scheme 13

The battery is mounted in a battery tray (1) located in the right rear corner of the engine compartment. The battery tray and support unit is secured at the front with a bolt (2) on the front wheelhouse inner panel, and at the rear with a bolt (2) on a bracket from the bulkhead.

Scheme 14

The battery is mounted in a battery tray (1) located in the left rear corner of the engine compartment. The battery tray and support unit is secured at the front with a bolt (2) on the front wheelhouse inner panel, and at the rear with a bolt (2) on a bracket from the bulkhead.