Battery System Dodge Grand Caravan IV

DESCRIPTION

A single 12-volt battery is standard factory-in-stalled equipment on this model. All of the components of the battery system are located within the engine compartment of the vehicle. The battery system for this vehicle covers the following related components, which are covered in further detail later

1. Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle.
2. Battery Cable - The battery cables connect the battery terminal posts to the vehicle electrical system.
3. Battery Hold down - The battery hold down hardware secures the battery in the battery tray in the engine compartment.
4. Battery Thermowrap - The battery thermowrap 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 hold down hardware.

For battery system maintenance schedules and jump starting procedure, see the owner's manual in the vehicle glove box. Optionally, refer to the LUBRICATION AND 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 in STANDARD PROCEDURE . 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 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 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 SYSTEM for the proper charging system onboard diagnostic test procedures.

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery system 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, which includes the directions for using the Micro 420 battery tester.

Scheme 7

Scheme 8

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 SYSTEM for additional charging system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420 tester and refer to «DIAGNOSIS AND TESTING - BATTERY SYSTEM»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#battery-system) .
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 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 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 9

Scheme 10

Scheme 11

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 9)
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. 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 10) 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 thermowrap with a sodium bicarbonate (baking soda) and warm water cleaning solution using a soft 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 11)

INSPECTION

The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules 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. 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 Procedures for the proper battery built-in indicator test procedures. Also refer to Standard Procedures for the proper battery charging procedures.

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.

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.

BATTERY CLASSIFICATIONS & RATINGS

Scheme 12

There are three 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 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 (Scheme 13) Water cannot be added to this battery.

Scheme 13

The acid inside a 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 batteries are used on export vehicles equipped with a gasoline engine, these batteries have removable battery cell caps (Scheme 14) Water can be added to this battery. Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates. However these batteries may require additional distilled water after years of service.

Scheme 14

Maintenance-free batteries are standard factory-installed equipment on all domestic versions of this model. Male post type terminals made of a soft lead material protrude from the top of the molded plastic battery case (Scheme 15) to provide the means for connecting the battery to the vehicle electrical system. The battery positive terminal post is visibly larger in diameter than the negative terminal post, for easy identification. 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 additional identification confirmation.

Scheme 15

This battery is designed to provide a safe, efficient and reliable means of storing electrical energy in a chemical form. This means of energy storage allows the battery to produce the electrical energy 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 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 consists 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.

Some factory-installed batteries have a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condition. For more information on the use of the built-in test indicator, refer to Standard Procedures. The chemical composition of the metal coated plates within the low-maintenance battery used in export models reduces battery gassing and water loss at normal charge and discharge rates. Therefore, the battery should not require additional water in normal service. If the electrolyte level in this battery does become low, distilled water must be added. However, rapid loss of electrolyte can be caused by an overcharging condition. Be certain to diagnose the charging system after replenishing the water in the battery for a low electrolyte condition and before returning the vehicle to service. Refer to Charging System for additional information.

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. Refer to SPECIFICATIONS for the location of the proper factory-installed battery specifications.

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 sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water. 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.

As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the battery discharging process is reversed. Charging the battery gradually changes the sulfated lead plates back into sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the difference in the electron charges deposited on the plates, and the voltage potential of the battery cells. For a battery to remain useful, it must be able to produce high-amperage current over an extended period. A battery must also be able to accept a charge, so that its voltage potential may be restored.

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 electrolyte level is low, the battery may arc internally and explode. 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 STANDARD PROCEDURE 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 STANDARD PROCEDURE , 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 STANDARD PROCEDURE 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 CLEANING for the proper battery system cleaning procedures, and 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 16

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Scheme 16) Refer to «REMOVAL - BATTERY»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#battery-system__removal-battery) and «INSTALLATION»(/dodge/grand-caravan/iv-2000-2007/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.

SPIRAL-PLATE BATTERY CHARGE RATE

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.

Scheme 17

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 PROCEDURE for the proper battery load test procedures. 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 CLEANING for the proper battery system cleaning procedures, and 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 18

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Scheme 18) 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.

CONVENTIONAL BATTERY CHARGE RATE

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 19

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 if no other battery tester is available.

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

Scheme 20

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 20)

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 STANDARD PROCEDURE for the proper battery load test procedures.

OPEN CIRCUIT VOLTAGE

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 fifteen to twenty-five milliamperes (0.015 to 0.025 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to twenty-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-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 twenty-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 multimeter 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 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 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.
5. Allow twenty minutes for the IOD to stabilize and observe the multi-meter reading. The low-amperage IOD should not exceed twenty-five milliamperes (0.025 ampere). If the current draw exceeds twenty-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.

STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL

The following procedure can be used to check the electrolyte level in a low-maintenance lead-acid battery.

Scheme 21

1. Unscrew and remove the battery cell caps with a flat-bladed screw driver (Scheme 21)
2. Wearing safety glasses, look through the battery cell cap holes to determine the level of the electrolyte in the battery. The electrolyte should be above the hooks inside the battery cells (Scheme 22)
3. Add only distilled water until the electrolyte is above the hooks inside the battery cells (Scheme 22)

REMOVAL - BATTERY

Scheme 22

1. Verify that the ignition switch and all accessories are OFF.
2. Disconnect the battery cables from the battery posts, negative first (Scheme 23)
3. Remove the battery hold down retaining nut.
4. Remove the battery hold down bracket.
5. Remove the battery from the vehicle.

INSTALLATION

1. Position the battery in the battery tray.
2. Install the battery hold down bracket and retaining nut. Torque the nut to 20 N.m (180 in. lbs.).
3. Connect the battery cables to the battery posts, positive cable first. Torque terminal fasteners to 5 N.m (40 in. lbs.).

The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of the battery tray and support unit, a molded steel hold down bracket and a single hex nut with a coned washer.

When installing a battery into the battery tray, be certain 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. Refer to BATTERY HOLD DOWN for the location of the proper battery hold down installation procedures, including the proper hold down fastener tightness specifications.

The battery hold down secures the battery in the battery tray. This hold down is designed to prevent battery movement during the most extreme vehicle operation conditions. Periodic removal and lubrication of the battery hold down hardware is recommended to prevent hardware seizure at a later date.

Note. Never operate a vehicle without a battery hold down device properly installed. Damage to the vehicle, components and battery could result.

REMOVAL

All of the battery hold down hardware can be serviced without removal of the battery or the battery tray and support unit.

1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
2. Remove the nut with washer that secures the battery hold down bracket to the battery tray and support unit.
3. Remove the battery hold down bracket from the battery tray and support unit.

1. Install the battery hold down bracket in the battery tray and support unit.
2. Install the nut with washer that secures the battery hold down bracket to the battery tray and support unit. Torque to 20 N.m (180 in. lbs.).

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. Refer to WIRING DIAGRAMS for the location of the proper battery cable wire gauge information.

A clamping type female battery terminal made of stamped metal is attached to one end of the battery cable wire. A square headed pinch-bolt and hex 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 solder-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 terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp.

The battery cables cannot be repaired and, if damaged or faulty they must be replaced. 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. Refer to WIRING DIAGRAMS for the location of more information on the various wiring circuits included in the battery wire harness for the vehicle being serviced.

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.

The battery positive cable terminal clamp is attached to the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Integrated Power Module (IPM), 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 is also attached to the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the left side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the left front fender inner shield, near the battery.

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

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. The battery is fully-charged and load tested. Refer to «STANDARD PROCEDURE»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#battery-system) 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 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. 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 24) 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. 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 25) 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. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Scheme 26) 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. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Scheme 27) 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.

The battery cables on this model may include portions of wiring circuits for the generator and other components on the vehicle. If battery cable replacement is required, it will be necessary to extract the cables out of the engine wire harness assembly. Use care not to damage the other wires and circuits which are also packaged into the engine wire harness assembly.

1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
2. Disconnect and isolate the negative battery cable terminal.
3. Remove the battery thermowrap (if equipped) from the battery tray.
4. Remove the tape from the engine wire harness assembly, to access the desired battery cable.
5. One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle.
6. Feed the battery cable out of the vehicle.

1. Position the battery cable in the vehicle.
2. One at a time, trace and install the battery cable retaining fasteners and routing clips until the desired cable is properly installed in the engine wire harness assembly.
3. Install the tape on the engine wire harness assembly.
4. Install the battery thermowrap (if equipped) on the battery tray.
5. Connect the negative battery cable terminal.

The battery is mounted in a molded plastic battery tray and support unit located in the left front corner of the engine compartment. The battery tray and support unit is secured with two nuts, one is located directly under the battery and the other is located on the right side of the tray which also serves as a coolant bottle neck retaining bolt. An additional bolt is located directly under the battery.

The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit (Scheme 28) And a drainage hose, located in the front of the unit (Scheme 28)

Scheme 27

The battery tray provides a secure mounting location and supports the battery. The battery tray also provides the anchor point for the battery hold down hardware. The battery tray and the battery hold-down hardware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both.

The battery tray used on this model also includes a engine vacuum reservoir and drainage hose. The vacuum reservoir provides a storage container for engine vacuum. Refer to ENGINE for more engine vacuum information. The drainage hose provides means for any liquid that might collect in the bottom of the battery tray to drain under the vehicle.

Scheme 28

1. Disconnect and isolate the negative battery cable.
2. Remove the battery from the vehicle.
3. Remove the battery tray retaining fasteners see scheme 23
4. Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted, vacuum reservoir.
5. Remove the battery tray from the vehicle.

1. Position the battery tray in the vehicle.
2. Connect the engine vacuum harness hose on the battery tray mounted vacuum reservoir.
3. Position drainage hose and install the battery tray retaining fasteners see scheme 23
4. Install the battery in the vehicle.
5. Connect the negative battery cable.

A one-piece slip-on thermowrap unit shields the battery case from engine compartment heat. The thermowrap slips over the battery case and due to its one piece design, the battery cables must be removed in order to install or remove the thermowrap.

The thermowrap protects the battery from engine compartment temperature extremes. The temperature of the battery can affect battery life. The air trapped in the padded material of the thermowrap 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. Disconnect and isolate the negative battery cable.
2. Disconnect the positive battery cable.
3. Lift the battery thermowrap straight up to remove from the battery.

1. Position the thermowrap on the battery.
2. Connect the negative and positive battery cables.

See also:
• STANDARD PROCEDURE
• SPECIFICATIONS
• CLEANING
• INSPECTION
• REMOVAL - BATTERY
• INSTALLATION