Battery System Chrysler PT Cruiser I

DESCRIPTION

A single 12-volt battery is standard factory-installed equipment on this model. All of the components of the battery system are located within the engine compartment of the vehicle, except on vehicles equipped with a diesel engine. Vehicles equipped with a diesel engine have the battery mounted under the passenger front seat. The battery system for this vehicle covers the following related components, which are covered in further detail later in this article

1. Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle.
2. Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to the vehicle electrical system.
3. Battery Holddown - The battery holddown hardware secures the battery in the battery tray.
4. Battery Thermal Guard - The battery thermal guard insulates the battery to protect it from engine compartment temperature extremes.
5. Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery holddown hardware (some models) and battery temperature sensor (if equipped).
6. Battery Tray Support Bracket - The battery tray support bracket provides additional support for the battery and battery tray.

For battery system maintenance schedules and jump starting procedures, see the owner's manual in the vehicle glove box. Optionally, refer to LUBRICATION & MAINTENANCE for the recommended battery maintenance schedules and 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 article. This was done because the battery 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 accessory 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 system for short durations while the engine is running and the electrical current demands of the vehicle that 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.

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 the battery, starting, and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal battery 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 information to make it easier to locate the specific information you are seeking. However, when attempting to diagnose any of these systems, it is important that you keep their interdependency 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/ohmmeter, a battery charger, a carbon pile rheostat (load tester) and a 12-volt test lamp 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. Refer to CHARGING for the proper charging system on-board diagnostic test procedures.

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this article, which includes the directions for using the Micro 420 battery tester.

ABNORMAL BATTERY DISCHARGING

Any of the following conditions can result in abnormal battery discharging

1. A faulty or incorrect charging system component. Refer to «CHARGING»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#charging-system) for additional charging system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420 tester and refer to «BATTERY SYSTEM»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#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»(/chrysler/pt-cruiser/i-2000-2010/remont/starter/#starting-system) for the proper starting system 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 loads in use.

CLEANING

The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in LUBRICATION & MAINTENANCE 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.

Scheme 1

Scheme 2

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. (Scheme 1) 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. (Scheme 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»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#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. 1 - CLEANING BRUSH 2 - WARM WATER AND BAKING SODA SOLUTION 3 - BATTERY
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.
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. (Scheme 3)

Scheme 3

INSPECTION

The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in LUBRICATION & MAINTENANCE 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 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 for tears, cracks, deformation or other damage (if equipped). 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 «CHARGING»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#charging-system) Standard Procedures for detailed instructions.

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 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.

Note. Vehicles equipped with a diesel engine utilize a unique battery. The specifications for this battery may differ from the standards shown here. Refer to the battery manufacturer for detailed specifications.

1. Group Size - The outside dimensions and terminal 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 replacement.
2. Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (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.
3. Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery 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 rating estimates how long the battery might last after a charging system failure, under minimum electrical load.
4. Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can deliver steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating is also sometimes identified as the twenty-hour discharge rating.

Scheme 4

There are two different batteries available on this model. Vehicles equipped with a diesel engine utilize a spiral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery. This additional power is required by a diesel engine during cold cranking. Vehicles equipped with a gasoline engine utilize a conventional battery. Refer to the following information for detailed differences and descriptions of these two batteries.

SPIRAL PLATE BATTERY - DIESEL ENGINE

Spiral plate technology takes the elements of traditional batteries - lead and sulfuric acid - to the next level. By tightly winding layers of spiral grids and acid-permeated vitreous separators into cells, the manufacturer has developed a battery with more power and service life than conventional batteries the same size. The spiral plate battery is completely, permanently sealed. Through gas recombination, hydrogen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte, eliminating the need to add distilled water. Therefore, these batteries have non-removable battery vent caps. Water cannot be added to this battery. (Scheme 5)

Scheme 5

The acid inside an spiral plate battery is bound within the vitreous separators, ending the threat of acid leaks. This feature allows the battery to be installed in any position anywhere in the vehicle.

Spiral plate technology is the process by which the plates holding the active material in the battery are wound tightly in coils instead of hanging flat, like conventional batteries. This design has a lower internal resistance and also increases the active material surface area.

Due to the maintanance-free design, distilled water cannot be added to this battery. Therefore, if more than 14.4 volts are used during the spiral plate battery charging process, water vapor can be exhausted through the pressure-sensitive battery vents and lost for good. This can permanently damage the spiral plate battery. Never exceed 14.4 volts when charging a spiral plate battery. Personal injury and/or battery damage may result.

CONVENTIONAL BATTERY - GASOLINE ENGINE

Low-maintenance conventional batteries are used on vehicles equipped with a gasoline engine, these batteries have non-removable battery cell caps. Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates.

Scheme 6

Conventional batteries are made up of six individual cells that are connected in series. Each cell contains positive charged plate groups made of lead oxide, and negatively charged plate groups made of sponge lead. The plates are submerged in a sulfuric acid and water solution called electrolyte. (Scheme 6)

Both batteries are used to store electrical energy potential in a chemical form. When an electrical load is applied to the battery terminals, an electrochemical reaction occurs within the battery. This reaction causes the battery to discharge electrical current.

The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals.

The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is exposed to flame or sparks, it may ignite. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level becomes low.

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 CHARGING Standard Procedures for the proper battery charging procedures.

The Micro 420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER article, which includes the directions for using the Micro 420 battery tester.

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 tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the Micro 420 or load test, is faulty and must be replaced.

Note. Completely discharged batteries may take several hours to accept a charge. Refer to CHARGING Standard Procedures for the proper battery charging procedures.

STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING

Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must not be exceeded in order to restore the battery to its full potential, failure to use the following spiral plate battery charging procedure could result in damage to the battery or personal injury.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when

1. Micro 420 battery tester indicates battery is OK.
2. Open-circuit voltage of the battery is 12.65 volts or above.
3. Battery passes Load Test multiple times.

After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. Refer to Battery DIAGNOSIS AND TESTING for the proper battery test procedures. If the battery will endure a load test, return the battery to service. If the battery will not pass 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 Battery System INSPECTION for the proper battery system inspection procedures.

CHARGING A COMPLETELY DISCHARGED BATTERY - SPIRAL PLATE BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

Scheme 7

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. (Scheme 7) Refer to Battery «REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__removal) and «INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__installation) for access instructions. If the reading is below ten volts, the battery charging current will be low. It could take several hours before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.
2. Disconnect and isolate the battery negative cable. Connect the battery charger leads. 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 the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.
3. Battery chargers vary in the amount of voltage and current they provide. The amount of 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 measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors

1. Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.
2. 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).
3. Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies eight amperes will require a shorter charging time.
4. State-Of-Charge - A completely discharged battery 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 battery charges, the specific gravity of the electrolyte will gradually rise.

The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING

Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the spiral plate battery charging procedure could result in damage to the battery or personal injury.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when

1. Micro 420 battery tester indicates battery is OK.
2. Open-circuit voltage of the battery is 12.65 volts or above.
3. Battery passes Load Test multiple times.

After the battery has been charged to an open-circuit voltage reading of 12.4 volts or greater, retest the battery with the Micro 420 tester or perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. Refer to Battery DIAGNOSIS AND TESTING . If the battery will pass a load test, return the battery to service. If the battery will not pass 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 Battery System INSPECTION for the proper battery system inspection procedures.

CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

Scheme 8

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. (Scheme 7) If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.
2. Disconnect and isolate the battery negative cable. Connect the battery charger leads. 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 the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.
3. Battery chargers vary in the amount of voltage and current they provide. The amount of 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 measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.

The time required to charge a battery will vary, depending upon the following factors

1. Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.
2. 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).
3. 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 charging time.
4. State-Of-Charge - A completely discharged battery 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 battery charges, the specific gravity of the electrolyte will gradually rise.

The Conventional Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

Scheme 9

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 procedure can be used

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 (-). (Scheme 9) 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. NOTE: When testing the battery in a PT Cruiser, always test at the battery terminals
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 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 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.

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

STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery.

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. (Scheme 10)

Scheme 10

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.

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 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), digital clock, electronically tuned radio, 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 IOD fuse from the Power Distribution Center (PDC). 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.
2. Determine that the underhood lamp is operating 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 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.
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 Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information in ELECTRICAL for complete PDC and JB 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»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#charging-system) 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.
6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (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.

REMOVAL - GASOLINE ENGINE

Scheme 11

Scheme 12

1. Make sure ignition switch is in OFF position and all accessories are OFF.
2. Open hood.
3. Remove the air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine.
4. Disconnect and isolate the battery negative cable then the positive cable.
5. Loosen bolt and retainer that holds the battery down to the tray. (Scheme 11)or (Scheme 12).
6. Lift battery out of battery tray and remove from vehicle. 1 - HOLD DOWN ROD 2 - HOLD DOWN RETAINER 3 - NON CORROSIVE SPACERS FOR SERVICE BATTERY 4 - BOLT
7. Remove thermal guard (if equipped) from battery.

Scheme 13

Scheme 14

Scheme 15

1. Make sure ignition switch is in OFF position and all accessories are OFF.
2. Open the passenger door.
3. Position passenger seat to the full rear location.
4. Remove the two screws from the seat front trim panel.
5. Lift trim panel to disengage the lower tabs from the lower mounting slots and set aside.
6. Disconnect and isolate the battery negative cable.
7. Disconnect the vent tube assembly by pulling the elbow straight forward from the battery vent port.
8. Unclip the vent tubing assembly from the battery hold down strap. Note the position of the clip for installation reference.
9. Loosen bolt that holds the battery down to the tray and slide battery forward enough to access the battery temperature sensor. (Scheme 13) Remove the battery temperature sensor from the battery case by pulling straight out. (Scheme 14) 1 - Bottom of Battery 2 - Battery Temperature Sensor 1 - Passenger Seat 2 - Spiral-Plate Battery
10. Lift the battery retaining strap and pull the battery forward, in front of the passenger seat. (Scheme 15)
11. Disconnect and isolate the battery positive cable. Note the position of the battery positive cable for installation reference.
12. Remove the battery from the vehicle.

INSTALLATION - GASOLINE ENGINE

When replacing battery, the thermal guard MUST be transferred to the new battery (if equipped).

1. Install battery in vehicle making sure that the thermal guard (if equipped) is present and battery is properly positioned on battery tray.
2. Install battery hold down clamp, making sure that it is properly positioned on battery. Torque clamp to 110 in. lbs. +/- 20 in. lbs. 1 - HOLD DOWN ROD 2 - HOLD DOWN RETAINER 3 - NON CORROSIVE SPACERS FOR SERVICE BATTERY 4 - BOLT CAUTION: Vehicles equipped with the turbocharged engine use a unique battery hold down. If the replacement battery is not identical, in size to the original, it may be necessary to use non-corrosive spacers on top of the hold down retainer to properly secure the battery in the battery tray. see scheme 16
3. Install battery cables on battery posts. Install battery positive cable first.
4. Torque clamp nuts to 110 in. lbs. +/- 20 in. lbs.
5. Install air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine.
6. Close hood.
7. Verify operation of vehicle and systems.

INSTALLATION - DIESEL ENGINE

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Position the battery in the vehicle.
2. Connect the battery positive cable. WARNING: THE POSITIVE BATTERY CABLE MUST BE CORRECTLY POSITIONED ON THE BATTERY POST. (Scheme 19) FAILURE TO INSTALL THE CABLE CORRECTLY COULD RESULT IN SERIOUS PERSONAL INJURY OR VEHICLE DAMAGE. 1 - Front Seat Cushion 2 - Positive Battery Cable 3 - Spiral-Plate Battery 4 - Battery Vent Hose
3. Lift the battery hold down strap and slide the battery in its tray far enough to install the battery temperature sensor. Install the battery temperature sensor. (Scheme 20)
4. Slide the battery all the way into its tray and install the bolt. Torque to 30 ft. lbs. +/-10 ft. lbs. Make certain the battery is securely held in place, you should not be able to move the battery in any direction using normal hand force.
5. Clip the vent tubing assembly on the battery hold down strap.
6. Connect the vent tube assembly or. (Scheme 18)and (Scheme 5). (Scheme 17). WARNING: BE CERTAIN TO PROPERLY CONNECT THE BATTERY VENT SYSTEM. FAILURE TO DO SO COULD RESULT IN EXPLOSIVE/CAUSTIC FUMES BEING RELEASED INSIDE THE VEHICLES PASSENGER COMPARTMENT. REPLACE ANY PART OF THE VENT SYSTEM IF IT SHOWS ANY SIGNS OF WEAR, CRACKING, COLLAPSING, PUNCTURE OR ANY OTHER FORM OF IMPERFECTION.
7. Connect the battery negative cable.
8. Install the seat front trim panel.
9. Install the two screws in the seat front trim panel.
10. Close the passenger door.
11. Verify operation of vehicle and systems.

The battery holddown includes a bolt and a holddown bracket/rod. On gasoline engine equipped vehicles, the battery holddown bracket bolts directly to the battery tray and when installed properly meshes with the battery case to form a secure and stable battery holddown assembly. On diesel engine equipped vehicles, the battery holddown and battery are located under the passenger front seat. see scheme 22

When installing a battery into the battery tray, it is important that the hold down hardware is properly installed and that the fasteners are tightened to the proper specifications. Improper hold down fastener tightness, whether too loose or too tight, can result in damage to the battery, the vehicle, or both.

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 lubrication of the battery holddown hardware is recommended to prevent hardware seizure at a later date.

REMOVAL

1. Disconnect and isolate the negative battery cable or remote negative battery post.
2. On gasoline engine vehicles, remove the air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine .
3. On diesel engine equipped vehicles, remove the front passengers seat.
4. Remove the battery hold down retaining bolt(s).
5. Remove the battery hold down from the vehicle.

INSTALLATION

1. Install the battery hold down in the vehicle.
2. On gasoline engine equipped vehicles, install the battery. Refer to the procedure in this article for detailed instructions.
3. On gasoline engine equipped vehicles, install the air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine .
4. On diesel engine equipped vehicles, install the passenger front seat.
5. On diesel engine equipped vehicles, install the battery. Refer to the procedure in this article for detailed instructions.
6. Connect the negative battery cable.

The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then soldered. 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 terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp.

Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some models.

The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage 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 terminal 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 opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system.

One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Power Distribution Center (PDC), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block.

DIAGNOSIS AND TESTING - BATTERY CABLES

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 load tested. Refer to «CHARGING»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#charging-system) Standard Procedures 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 Automatic Shut Down (ASD) relay. The ASD relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay layout label affixed to the underside of the PDC cover for ASD relay identification and location.

Scheme 21

Scheme 22

Scheme 23

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 21) 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 22) 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 23) 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 24) 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 24

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 negative cable terminal.
3. Remove the battery from the vehicle. Refer to the procedure in this article.
4. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cables are free from the vehicle.
5. Remove the battery cables from the engine compartment.

1. Position the battery cables in the engine compartment.
2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cables are installed exactly where they were in the vehicle.
3. Install the battery in the vehicle. Refer to the procedure in this article.
4. Connect the remote battery negative cable terminal.

The battery is placed and secured in a plastic battery tray. On gasoline engine equipped vehicles, the battery tray is located in the left front side of the vehicle, next to the left strut tower. see scheme 27 On diesel engine equipped vehicles, the battery tray is located in the passenger compartment, under the passenger front seat. Refer to BATTERY HOLDDOWN down for more information on hold down hardware.

The battery tray provides a secure mounting location and supports the battery. On some vehicles, the battery tray also provides the anchor point/s for the battery holddown hardware. The battery tray and the battery holddown hardware combine to secure and stabilize the battery, which prevents battery movement during vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both.

1. Open the hood.
2. Remove the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__removal) .
3. Remove the bolts retaining the battery tray.
4. Lift the battery tray out of the engine compartment and remove from the vehicle.

REMOVAL - DIESEL ENGINE

1. Remove the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__removal) .
2. Remove the passengers front seat «(Refer to BODY/SEATS/SEAT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) .
3. Remove the battery tray retaining bolt.
4. Remove the battery tray from the vehicle.

1. Place battery tray into place in the engine compartment.
2. Install the bolts retaining the battery tray.
3. Install the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__installation) .
4. Close hood.

1. Place battery tray into place in the passenger compartment.
2. Install the battery tray retaining bolt.
3. Install the front passenger seat «(Refer to BODY/SEATS/SEAT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) .
4. Install the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__installation) .
5. Install and connect the vent tube assembly.

On gasoline engine equipped vehicles, a flexible thermal guard wraps around the battery case to enclose the sides of the battery. (Scheme 25) The thermal guard consists of a plastic cloth outer skin with a polyester based insulator fiber.

Scheme 25

The thermal guard protects the battery from engine compartment temperature extremes. The temperature of the battery can affect battery performance. The air trapped in the thermal guard creates a dead air space, which helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment.

1. Make sure ignition switch is in OFF position and all accessories are OFF.
2. Open hood.
3. Remove air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine .
4. Disconnect and isolate the battery negative cable.
5. Disconnect the battery positive cable.
6. Loosen bolt and retainer that holds the battery down to the tray.
7. Lift battery out of battery tray and remove from vehicle.
8. Carefully lift the thermal guard off over the battery taking care not to tear it.
9. Remove the thermal guard from battery.

When replacing battery, the thermal guard MUST be transferred to the new battery.

1. Slip the battery thermal guard over the battery being careful not to tear it.
2. Install battery in vehicle.
3. Install battery hold down clamp, making sure that it is properly positioned on battery.
4. Connect battery cable clamps to battery posts. Install battery positive cable first.
5. Tighten clamp nuts securely.
6. Install the air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) for 1.6L engine or «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for 2.4L engine .

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner housing.
3. Remove the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__removal) .
4. Remove the battery tray and battery temperature sensor.
5. Raise the vehicle on a hoist.
6. Working under the vehicle, remove two of the battery tray support bracket retaining bolts.
7. Lower the vehicle on the hoist.
8. Remove the remaining two battery tray support bracket retaining bolts and remove the bracket from the vehicle.

1. Position the battery tray support bracket and install the two battery tray support bracket retaining bolts.
2. Raise the vehicle on the hoist.
3. Working under the vehicle, install the two battery tray support bracket retaining bolts.
4. Lower the vehicle on a hoist.
5. Install the battery tray and battery temperature sensor (if equipped).
6. Install the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__installation) .
7. Install the air cleaner housing.
8. Connect the negative battery cable.

See also:
• LUBRICATION & MAINTENANCE
• CHARGING
• STARTING
• (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)
• (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)
• (Refer to BODY/SEATS/SEAT - REMOVAL)
• STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
• STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER
• SPECIFICATIONS
• CLEANING
• INSPECTION
• REMOVAL
• INSTALLATION