Battery System: Other Dodge Dakota III

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery system tester is designed to help diagnose the cause of a defective battery. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER) for directions on using the Micro 420 battery tester.

CLEANING

The following information details the recommended cleaning procedures for the battery and related components. In addition to the MAINTENANCE SCHEDULES , it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service.

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1. Clean the battery cable terminal clamps (2) of all corrosion. Remove any corrosion using a wire brush or a post and terminal cleaning tool (1), and a sodium bicarbonate (baking soda) and warm water cleaning solution.
2. Clean the battery tray and battery hold down hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution (2). Paint any exposed bare metal.
3. If the removed battery is to be reinstalled, clean the outside of the battery case (3) and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution (2) using a stiff bristle parts cleaning brush (1) to remove any acid film. 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, 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 (2) using a stiff bristle parts cleaning brush (1) to remove any acid film.
5. Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner (1) and a sodium bicarbonate (baking soda) and warm water cleaning solution.

The Micro 420 automotive battery tester is designed to help diagnose the cause of an inoperative battery. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER) for instructions on the use of the Micro 420 battery tester.

A battery that will not accept a charge is inoperative, 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 inoperative and must be replaced.

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

BATTERY CHARGING

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 electrical system tester indicates battery is OK.
2. All of the battery cells are gassing freely during battery charging.
3. Open-circuit voltage of the battery is 12.4 volts or above.

After the battery has been charged to 12.4 volts or greater, perform a load test to determine the battery cranking capacity, (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER) 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 inoperative and must be replaced.

Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. (Refer to ELECTRICAL/BATTERY SYSTEM - CLEANING) and (Refer to ELECTRICAL/BATTERY SYSTEM - INSPECTION) for the proper battery system cleaning and inspection procedures.

CHARGING A COMPLETELY DISCHARGED 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.

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. 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 inoperative 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 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 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.

BATTERY CABLES

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. 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.

NEGATIVE

1. Position the battery negative cable (4) in the vehicle and into the engine harness conduit.
2. One at a time, install the battery cable retaining push pins (5), fasteners and routing clips until the cable is secure in the vehicle.
3. Install the bolt (2) securing the negative cable eyelet (3) to the left front fender.
4. Raise the vehicle on a hoist.
5. Install the bolt (3) securing the negative cable (1) to the engine block (2).
6. Lower the vehicle.
7. Connect the battery negative cable terminal clamp (4).
8. Check the vehicle for normal operation.

POSITIVE

1. Position the battery positive cable (4 and 8) in the vehicle.
2. Install the nut (5) securing the cable to the Integrated Power Module (IPM) (7) stud (6).
3. Install the nut (3) securing the cable (4) to the alternator.
4. Install the cable (5) push pin into the left frame rail (4).
5. Connect the starter solenoid wire harness connector (1).
6. Raise the vehicle on a hoist.
7. Install the nut (2) securing the cable (1) to the starter solenoid (3).
8. Connect the battery cable retaining push pin (6) securing the cable to the engine block.
9. Lower the vehicle.
10. Connect the battery positive cable terminal clamp (8).
11. Position the resonator (4) into the vehicle. Install the bolts (3) into the air intake resonator (4) and tighten the band clamp (2) on the air inlet tube (1).
12. Connect the battery negative cable terminal clamp.
13. Check the vehicle for normal operation.

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The molded plastic battery tray (3) is located in the left front corner of the engine compartment. On this vehicle, the battery tray also provides an anchor point for the anti-lock brake controller (4), battery temperature sensor (2) and the Integrated Power Module (IPM) (1). The battery hold down hardware is contained within the battery tray. A hole in the bottom of the battery tray is fitted with a battery temperature sensor. (Refer to ELECTRICAL/CHARGING/BATTERY TEMPERATURE SENSOR - DESCRIPTION) for additional information on the battery temperature sensor.

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1. Disconnect and isolate the battery negative cable.
2. Remove the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(ref-247603-S11923746172007020100000) .
3. Remove the battery temperature sensor (2) from the battery tray (3) «(Refer to ELECTRICAL/CHARGING/BATTERY TEMPERATURE SENSOR - REMOVAL)»(ref-247626-S08969395562007020100000) .
4. Remove the Integrated Power Module (IPM) (1) «(Refer to ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL)»(ref-247631-S01391528722007020100000) .
5. Remove the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) (3) bolts (2) from the battery tray (1).
6. Remove the battery negative cable retaining push pins (5) from the battery tray.
7. Remove the engine compartment wire harness retaining push pins (3) from the battery tray (2).
8. Remove the left headlamp assembly, «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - REMOVAL)»(ref-247634-S22829171922007020100000) .
9. Remove the battery tray bolts.
10. Remove the six upper battery tray bolts.
11. Raise the vehicle on a hoist.
12. Remove the left front fender liner. Refer to «LINER-FRONT FENDER»(ref-247640-S31411477702007020100000) . NOTE: The middle bolt hole is to remain open for a front fender liner fastener (1).
13. Remove the lower battery tray mounting bolts (2).
14. Lower the vehicle.
15. Remove the battery tray (2) from the vehicle.

Scheme 27

1. Clean and inspect the battery tray «(Refer to ELECTRICAL/BATTERY SYSTEM - CLEANING)»(ref-247603-S12699602272007020100000) .
2. Position the battery tray into the vehicle.
3. Install the six upper battery tray bolts hand tight.
4. Install the two front battery tray bolts hand tight.
5. Raise the vehicle on a hoist. NOTE: The middle bolt hole is to remain open for a front fender liner fastener (1).
6. Install the two lower battery tray bolts (2). Tighten the bolts to 10.2 N.m (90 in. lbs.).
7. Install the left front fender liner. Refer to «LINER-FRONT FENDER»(ref-247640-S31411477702007020100000) .
8. Lower the vehicle.
9. Tighten the upper battery tray bolts to 10.2 N.m (90 in. lbs.).
10. Tighten the two front battery tray bolts to 8.5 N.m (75 in. lbs.).
11. Install the engine compartment wire harness retaining push pins (3) to the battery tray (2).
12. Install the battery negative cable retaining push pins (5) to the battery tray.
13. Install the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) (3) bolts (2) into the battery tray (1). Tighten the bolts to 18 N.m (160 in. lbs.).
14. Install the battery temperature sensor (2) into the battery tray (3).
15. Install the Integrated Power Module (IPM) (1) «(Refer to ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - INSTALLATION)»(ref-247631-S35411468202007020100000) .
16. Install the battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(ref-247603-S36016915822007020100000) .
17. Verify proper vehicle operation.