Battery System: Diagnosis Chrysler Pacifica CS

INSPECTION

The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this service 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 holddown hardware for damage. Replace any damaged parts.
3. Slide the thermowrap off of the battery case. 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 thermowrap 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 to «STANDARD PROCEDURE»(ref-245419-S01485558782006110200000) for the proper battery built-in indicator test procedures. Also refer to «STANDARD PROCEDURE»(ref-245419-S01485558782006110200000) for the proper battery charging procedures.

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 procedures, and Battery System Inspection for the proper battery inspection procedures. Refer to STANDARD PROCEDURE for the proper battery charging procedures.

STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage test will show the approximate state-of-charge of a battery. This test can be used if no other battery tester is available.

Before proceeding with this test, completely charge the battery. Refer to STANDARD PROCEDURE for the proper battery charging procedures.

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. (Scheme 4)

Scheme 4

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 tested to reveal its cranking capacity. Refer to STANDARD PROCEDURE for the proper Micro 420 battery test procedures.

STANDARD PROCEDURE - 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 forty-five milliamperes (0.005 to 0.045 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to forty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), radio, and other modules which may vary with the vehicle equipment.

A vehicle that has not been operated for approximately twenty-one days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty-one 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

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 forty-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 twenty minutes.
2. Disconnect the battery negative 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 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 «SYSTEM WIRING DIAGRAMS»(ref-172301) for complete Integrated Power Module fuse, circuit breaker, 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 and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to «CHARGING»(ref-245457) 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.
5. Allow twenty minutes for the IOD to stabilize and observe the multi-meter reading. The low-amperage IOD should not exceed forty-five milliamperes (0.045 ampere). If the current draw exceeds forty-five milliamperes, isolate each circuit using the fuse and circuit breaker 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.

DIAGNOSIS AND TESTING - BATTERY CABLE

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.

When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive 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

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 tested. Refer to «STANDARD PROCEDURE»(ref-245419-S01485558782006110200000) for the proper battery charging and test procedures.
2. Fully engage the parking brake.
3. Place the gearshift selector lever in the Park position.
4. Verify that all lamps and accessories are turned off.
5. To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is located in the Intelligent Power Module (IPM), in the engine compartment. See the fuse and relay layout label affixed to the underside of the IPM cover for ASD relay identification and location.

Scheme 5

Scheme 6

Scheme 7

1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. (Scheme 5) 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. 1 - Voltmeter 2 - Battery
2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. (Scheme 6) 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. 1 - Voltmeter 2 - Battery
3. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud. (Scheme 7) 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 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. 1 - Battery 2 - Voltmeter 3 - Starter Motor
4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block. (Scheme 8) 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 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 8