Battery System Dodge Pickup R1500

DESCRIPTION

A single 12-volt battery is standard factory-installed equipment on gasoline engine equipped models. Diesel engine equipped vehicles utilize two 12-volt batteries connected in parallel. 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 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 battery terminal posts to the vehicle electrical system.
3. Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment.
4. 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.

For battery system maintenance Schedules and jump starting procedures, see the owner's manual in the vehicle glove box. 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 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 need 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 manual 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), a 12-volt test lamp and/or special service tools 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. Always check the PCM for stored trouble codes before returning the vehicle to service. Refer to GENERATORS & REGULATORS for the proper charging system test procedures. Refer to STARTERS for the properly starting system test procedures.

MICRO 420 BATTERY TESTER

The Micro 420 automotive battery tester is designed to help the dealership technician diagnose a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a battery. If the instruction manual is not available, refer to STANDARD PROCEDURE , which includes the directions for using the Micro 420 battery tester.

BATTERY SYSTEM DIAGNOSIS

ABNORMAL BATTERY DISCHARGING

Any of the following conditions can result in abnormal battery discharging

1. A faulty or incorrect charging system component. Refer to «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) for additional charging system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420 battery tester and refer to «BATTERY SYSTEM»(/dodge/pickup-r1500/1997-2012/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 «STARTERS»(/dodge/pickup-r1500/1997-2012/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 systems 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 this article 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 10

Scheme 11

Scheme 12

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 10)
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 11) 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»(/dodge/pickup-r1500/1997-2012/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.
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 12)

INSPECTION

The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this article 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 (if equipped) 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»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) for the proper battery built-in indicator test procedures. Also Refer to «STANDARD PROCEDURES»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) 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 corrected 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 13

Scheme 14

A large capacity, low-maintenance storage battery (Scheme 14) is standard factory-installed equipment on this model. Models equipped with a diesel engine must utilize two 12-volt batteries connected in parallel. Male post type terminals made of a soft lead material protrude from the top of the molded plastic battery case to provide the means for connecting the battery to the vehicle electrical system. The battery positive terminal post is physically larger in diameter than the negative terminal post to ensure proper battery connection. 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 identification confirmation. Refer to BATTERY CABLES for more information on the battery cables that connect the battery to the vehicle electrical system.

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.

The factory-installed battery has a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condition. Refer to STANDARD PROCEDURES for the proper built-in indicator test procedures. The factory-installed low-maintenance battery has non-removable battery cell caps. Water cannot be added to this battery. The battery is not sealed and has vent holes in the cell caps. The chemical composition of the metal coated plates within the low-maintenance battery reduces battery gassing and water loss, at normal charge and discharge rates. Therefore, the battery should not require additional water in normal service. Rapid loss of electrolyte can be caused by an overcharging condition.

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 CLEANING for the proper cleaning procedures, and INSPECTION for the proper battery inspection procedures. Refer to STANDARD PROCEDURES for the proper battery charging procedures.

The Micro 420 automotive battery tester is designed to help the dealership technician diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a battery. 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 load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is faulty and must be replaced. Always test battery using the Micro 420 battery tester before attempting to replace a battery under the manufactures warranty provisions.

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

STANDARD PROCEDURE - BATTERY CHARGING

Battery charging can be performed fast or slow, in terms of time. Slow battery charging is the best means of restoring a battery to full potential. Fast battery charging should only be performed when absolutely necessary due to time restraints. A battery is fully-charged when

1. All of the battery cells are gassing freely during battery charging.
2. A green color is visible in the sight glass of the battery built-in test indicator.
3. Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected specific gravity of the battery electrolyte.
4. Open-circuit voltage of the battery is 12.65 volts or above.

Note. Models equipped with the diesel engine are equipped with two 12-volt batteries, connected in parallel (positive-to-positive and negative-to-negative). In order to ensure proper charging of each battery, these batteries MUST be disconnected from each other, as well as from the vehicle electrical system while being charged.

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.

After the battery has been charged to 12.4 volts or greater, perform a load test to determine the battery cranking capacity. Refer to STANDARD PROCEDURES 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 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 Battery System Inspection for the proper battery system 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.

Scheme 15

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Scheme 15) 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»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) 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.

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 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 CHARGING TIME

STANDARD PROCEDURE - BUILT-IN INDICATOR TEST

If equipped, an indicator (hydrometer) built into the top of the battery case provides visual information for battery testing (Scheme 16) Like a hydrometer, the built-in indicator measures the specific gravity of the battery electrolyte. The specific gravity of the electrolyte reveals the battery state-of-charge; however, it will not reveal the cranking capacity of the battery. A load test must be performed to determine the battery cranking capacity. Refer to STANDARD PROCEDURES for the proper battery load test procedures.

Scheme 16

Before testing, visually inspect the battery for any damage (a cracked case or cover, loose posts, etc.) that would cause the battery to be faulty. In order to obtain correct indications from the built-in indicator, it is important that the battery be level and have a clean sight glass. Additional light may be required to view the indicator. Do not use open flame as a source of additional light.

To read the built-in indicator, look into the sight glass and note the color of the indication (Scheme 17) The battery condition that each color indicates is described in the following list

Scheme 17

1. Green - Indicates 75% to 100% battery state-of-charge. The battery is adequately charged for further testing or return to service. If the starter will not crank for a minimum of fifteen seconds with a fully-charged battery, the battery must be load tested. Refer to «STANDARD PROCEDURES»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) for the proper battery load test procedures.
2. Black or Dark - Indicates 0% to 75% battery state-of-charge. The battery is inadequately charged and must be charged until a green indication is visible in the sight glass (12.4 volts or more), before the battery is tested further or returned to service. Refer to «STANDARD PROCEDURES»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) for the proper battery charging procedures. Also refer to Diagnosis and Testing for more information on the possible causes of the discharged battery condition.
3. Clear or Bright - Indicates a low battery electrolyte level. The electrolyte level in the battery is below the built-in indicator. A maintenance-free battery with non-removable cell caps must be replaced if the electrolyte level is low. Water must be added to a low-maintenance battery with removable cell caps before it is charged. Refer to «STANDARD PROCEDURES»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) for the proper battery filling procedures. A low electrolyte level may be caused by an overcharging condition. Refer to «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) for the proper charging system diagnosis and testing procedures.

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 in place of the hydrometer test when a hydrometer is not available, or for maintenance-free batteries with non-removable cell caps.

Before proceeding with this test, completely charge the battery (Refer to STANDARD PROCEDURE ).

Scheme 18

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 18)

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 ).

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 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 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 thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected.

1. Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the «ELECTRONIC MODULE IGNITION-OFF DRAW (IOD)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) Table for more information. ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE Module Time Out? (If Yes, Interval And Wake-Up Input) IOD IOD After Time Out Radio No 1 to 3 milliamperes N/A Audio Power Amplifier No up to 1 milliampere N/A Powertrain Control Module (PCM) No 0.95 milliampere N/A ElectroMechanical Instrument Cluster (EMIC) No 0.44 milliampere N/A Combination Flasher No 0.08 milliampere N/A
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 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.
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 Integrated Power Module (IPM), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate SYSTEM WIRING DIAGRAMS article 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 «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) 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.

STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER

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

Scheme 19

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 (Scheme 19) to the battery or jumper posts, the red clamp to positive (+) and the black clamp to negative (-). NOTE: Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test. Failure to disconnect may result in false battery test readings.
4. Using the ARROW key select in or out of vehicle testing and press ENTER to make a selection.
5. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery rating for your area (see menu). The tester will then run its self programmed test of the battery and display the results. Refer to «BATTERY TEST RESULTS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) table. CAUTION: If REPLACE BATTERY is the result of the test, this may mean a poor connection between the vehicle's cables and battery exists. After disconnecting the vehicle's battery cables from the battery, retest the battery using the OUT-OF-VEHICLE test before replacing.
6. While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit. Then press the ENTER button to view the SERVICE CODE. Pressing the CODE button a second time will return you to the test results.

BATTERY TEST RESULTS

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

Scheme 20

1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.
2. Loosen the battery negative cable terminal clamp pinch-bolt hex nut.
3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Scheme 20)
4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut.
5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Scheme 20)
6. Remove the battery hold down retaining bolt. WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.
7. Remove the battery from the battery tray.

INSTALLATION

1. Clean and inspect the battery.
2. Position the battery onto the battery tray. Ensure that the battery positive and negative terminal posts are correctly positioned. The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables.
3. Position the battery hold down and install the retaining bolt. CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery terminal posts. Reversed battery polarity may damage electrical components of the vehicle.
4. Clean the battery cable terminal clamps and the battery terminal posts.
5. Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N.m (35 in. lbs.).
6. Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N.m (35 in. lbs.).
7. Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.
8. Obtain a DRB III(R) scan tool and check the PCM for any stored battery disconnect trouble code, if required.

The battery hold down hardware includes a bolt and a molded plastic hold down bracket which meshes with the battery tray when properly installed. The battery tray and hold down hardware combine to form a very stable and secure battery hold down assembly.

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. Loosen and remove the battery hold down retaining bolt.
2. Remove the battery hold down bracket from the battery case.

1. Clean and inspect the battery hold down hardware (Refer to «CLEANING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__cleaning) ).
2. Position the battery hold down bracket in the battery tray. Be certain that the hold down bracket is properly positioned in the battery tray before tightening the hold down hardware.
3. Install and tighten the battery hold down retaining bolt.

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 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 positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other components on some models.

Most models feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber protective cover for 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 connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path 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 ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system.

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 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.

VOLTAGE DROP TEST

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished

1. The battery is fully-charged and tested (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) ).
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 a gasoline engine from starting, remove the Automatic ShutDown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM 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. NOTE: If the vehicle is equipped with two 12v batteries, step #1 must be performed twice, once for each 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. NOTE: If the vehicle is equipped with two 12v batteries, step #2 must be performed twice, once for each 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. NOTE: If the vehicle is equipped with two 12v batteries, step #3 must be performed twice, once for each battery.
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.

Note. If the vehicle is equipped with two 12v batteries, step #4 must be performed twice, once for each battery.

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 «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__removal) .
4. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle.
5. Remove the battery cable from the engine compartment.

1. Position the battery cable in the engine compartment.
2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cable is installed exactly where it was in the vehicle.
3. Install the battery in the vehicle. Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system) .
4. Connect the battery negative cable terminal.

Scheme 25

The molded plastic tray battery tray is located in the left front corner of the engine compartment. On this model, the battery tray also provides an anchor point for the anti-lock brake controller, cruise control servo (if equipped) and the integrated power module (Scheme 25) 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 GENERATORS & REGULATORS for more information on the battery temperature sensor.

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 even the most extreme vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both.

LEFT SIDE

1. Remove the battery from the battery tray (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__removal) ).
2. Remove the integrated power module (Refer to «INTEGRATED POWER MODULE»(/dodge/pickup-r1500/1997-2012/remont/electrical-component-locations/#power-distribution) ).
3. Disconnect the wire harness retainers from the battery tray assembly.
4. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit.
5. Remove the left front wheelhouse splash shield (Refer to «FRONT WHEELHOUSE SPLASH SHIELD»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#exterior) ).
6. Mark the location of the cruise servo (if equipped) and remove the retaining screws. Position the servo out of the way.
7. Remove the battery temperature sensor from the battery tray (Refer to «BATTERY TEMPERATURE SENSOR»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
8. Disconnect the purge solenoid from its mounting bracket.
9. Disconnect the left front fender ground wire.
10. Remove the remaining battery tray retaining bolts (Scheme 26)
11. Remove the battery tray from the vehicle.

Scheme 26

Scheme 27

1. Remove the battery from the battery tray (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__removal) ).
2. Remove the right front wheelhouse splash shield.
3. Disconnect the right front fender ground wire.
4. Remove fasteners from grid heater relay bracket.
5. Remove air box.
6. Remove the remaining battery tray retaining bolts (Scheme 27)
7. Remove the battery tray from the vehicle.

1. Position the battery tray assembly and install the retaining bolts.
2. Connect the left front fender ground wire.
3. Install the purge solenoid on its mounting bracket.
4. Install the battery temperature sensor in the battery tray (Refer to «BATTERY TEMPERATURE SENSOR»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
5. Install the cruise servo (if equipped) and retaining screws.
6. Install the left front wheelhouse splash shield (Refer to «FRONT WHEELHOUSE SPLASH SHIELD»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#exterior) ).
7. Install the anti-lock brake controller (if equipped).
8. Connect the wire harness retainers on the battery tray assembly.
9. Install the integrated power module (Refer to «INTEGRATED POWER MODULE»(/dodge/pickup-r1500/1997-2012/remont/electrical-component-locations/#power-distribution) ).
10. Install the battery (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__installation) ).

RIGHT SIDE

1. Position the battery tray assembly and install the retaining bolts.
2. Connect the right front fender ground wire.
3. Install the air box.
4. Install the grid heater relay bracket.
5. Install the right front wheelhouse splash shield.
6. Install the battery (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#battery-system__installation) ).

See also:
• GENERATORS & REGULATORS
• STARTERS
• INTEGRATED POWER MODULE
• FRONT WHEELHOUSE SPLASH SHIELD
• STANDARD PROCEDURE
• STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
• SPECIFICATIONS
• CLEANING
• INSPECTION
• REMOVAL
• INSTALLATION