Dodge Dakota (R1). Manual - part 298

Before proceeding with this test, completely charge

the battery. Refer to Standard Procedures for the
proper battery charging procedures.

(1) Before measuring the open-circuit voltage, the

surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize.

(2) Disconnect and isolate both battery cables, neg-

ative cable first.

(3) Using a voltmeter connected to the battery

posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 11).

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 Procedures for the proper
battery load test procedures.

OPEN CIRCUIT VOLTAGE TABLE

Open Circuit Voltage

Charge Percentage

11.7 volts or less

12.0 volts

25%

12.2 volts

50%

12.4 volts

75%

12.6 volts or more

100%

STANDARD PROCEDURE - LOAD TEST

A battery load test will verify the battery cranking

capacity. The test is based on the Cold Cranking
Amperage (CCA) rating of the battery. To determine
the battery CCA rating, see the label affixed to the
battery case or refer to Battery Specifications for the
proper factory-installed specifications.

WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.

WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.

WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.

WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.

Before proceeding with this test, completely charge

the battery. Refer to Standard Procedures for the
proper battery charging procedures.

(1) Disconnect and isolate both battery cables, neg-

ative cable first. The battery top and posts should be
clean. Refer to Battery System Cleaning for the
proper cleaning procedures.

(2) Connect a suitable volt-ammeter-load tester

(Fig. 12) to the battery posts (Fig. 13). See the
instructions provided by the manufacturer of the
tester you are using. Check the open-circuit voltage
(no load) of the battery. Refer to Standard Procedures
for the proper battery open-circuit voltage test proce-
dures. The battery open-circuit voltage must be 12.4
volts or greater.

(3) Rotate the load control knob (carbon pile rheo-

stat) to apply a 300 ampere load to the battery for
fifteen seconds, then return the control knob to the
Off position (Fig. 14). This will remove the surface
charge from the battery.

(4) Allow the battery to stabilize to open-circuit

voltage. It may take up to five minutes for the bat-
tery voltage to stabilize.

(5) Rotate the load control knob to maintain a load

equal to 50% of the CCA rating of the battery (Fig.
15). After fifteen seconds, record the loaded voltage
reading, then return the load control knob to the Off
position.

Fig. 11 Testing Open-Circuit Voltage - Typical

8F - 14

BATTERY SYSTEM

BATTERY (Continued)

(6) The voltage drop will vary with the battery

temperature at the time of the load test. The battery
temperature can be estimated by using the ambient
temperature during the past several hours. If the
battery has been charged, boosted, or loaded a few

minutes prior to the test, the battery will be some-
what warmer. See the Load Test Temperature Table
for the proper loaded voltage reading.

LOAD TEST TEMPERATURE TABLE

Minimum Voltage

Temperature

°F

°C

9.6 volts

70° and above

21° and above

9.5 volts

60°

16°

9.4 volts

50°

10°

9.3 volts

40°

4°

9.1 volts

30°

-1°

8.9 volts

20°

-7°

8.7 volts

10°

-12°

8.5 volts

0°

-18°

(7) If the voltmeter reading falls below 9.6 volts, at

a minimum battery temperature of 21° C (70° F), the
battery is faulty and must be replaced.

STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST

The term Ignition-Off Draw (IOD) identifies a nor-

mal 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 Con-
trol 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 approxi-

mately twenty days, may discharge the battery to an

Fig. 12 Volt-Ammeter-Load Tester - Typical

Fig. 13 Volt-Ammeter-Load

1 - INDUCTION AMMETER CLAMP
2 - NEGATIVE CLAMP
3 - POSITIVE CLAMP

Fig. 14 Remove Surface Charge from Battery

Fig. 15 Load 50% CCA Rating - Note Voltage -

Typical

BATTERY SYSTEM

8F - 15

BATTERY (Continued)

inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Power Distribution Center (PDC). This will
reduce battery discharging.

Excessive IOD can be caused by:
• Electrical items left on.

• Faulty or improperly adjusted switches.

• Faulty or shorted electronic modules and compo-

nents.

• An internally shorted generator.

• Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the

problem must be found and corrected before replac-

ing 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 illumi-
nated 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 Igni-
tion-Off Draw Table for more information.

ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE

Module

Time Out?

(If Yes, Interval And Wake-Up Input)

IOD

IOD After Time

Out

Radio

1 to 3

milliamperes

N/A

Audio Power

Amplifier

up to 1

milliampere

N/A

Central Timer Module

(CTM)

4.75

milliamperes

(max.)

N/A

Powertrain Control

Module (PCM)

0.95 milliampere

N/A

ElectroMechanical

Instrument Cluster

(EMIC)

0.44 milliampere

N/A

Combination Flasher

0.08 milliampere

N/A

(2) Determine that the underhood lamp is operat-

ing 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 ter-
minal clamp and the battery negative terminal post.
Make sure that the doors remain closed so that the
illuminated entry system is not activated. The multi-
meter amperage reading may remain high for up to
three minutes, or may not give any reading at all
while set in the highest amperage scale, depending
upon the electrical equipment in the vehicle. The
multi-meter leads must be securely clamped to the
battery negative cable terminal clamp and the bat-
tery negative terminal post. If continuity between the
battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD
test, the electronic timer function will be activated
and all of the tests will have to be repeated.

(5) After about three minutes, the high-amperage

IOD reading on the multi-meter should become very
low or nonexistent, depending upon the electrical
equipment in the vehicle. If the amperage reading
remains high, remove and replace each fuse or circuit
breaker in the Power Distribution Center (PDC) and
then in the Junction Block (JB), one at a time until
the amperage reading becomes very low, or nonexist-
ent. Refer to the appropriate wiring information in
this service manual for complete PDC and JB fuse,
circuit breaker, and circuit identification. This will
isolate each circuit and identify the circuit that is the
source of the high-amperage IOD. If the amperage
reading remains high after removing and replacing
each fuse and circuit breaker, disconnect the wire
harness from the generator. If the amperage reading
now becomes very low or nonexistent, refer to Charg-
ing System for the proper charging system diagnosis
and testing procedures. After the high-amperage IOD
has been corrected, switch the multi-meter to pro-
gressively lower amperage scales and, if necessary,
repeat the fuse and circuit breaker remove-and-re-

8F - 16

BATTERY SYSTEM

BATTERY (Continued)

place process to identify and correct all sources of
excessive IOD. It is now safe to select the lowest mil-
liampere 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-am-

perage IOD should not exceed thirty-five milliam-
peres (0.035 ampere). If the current draw exceeds
thirty-five milliamperes, isolate each circuit using the
fuse and circuit breaker remove-and-replace process
in Step 5. The multi-meter reading will drop to
within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this
circuit as required; whether a wiring short, incorrect
switch adjustment, or a component failure is at fault.

REMOVAL

(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 (Fig. 16).

(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 nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.

(6) Remove the battery hold downs from the bat-

tery. Refer to Battery Hold Downs in this section
for the location of the proper battery hold down
removal procedures.

WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING

BATTERY

HAND.

SAFETY

GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.

(7) Remove the battery from the battery tray.

INSTALLATION

(1) Clean and inspect the battery. Refer to Bat-

tery System in this section for the location of the
proper battery cleaning and inspection procedures.

(2) Position the battery onto the battery tray.

Ensure that the battery positive and negative termi-
nal posts are correctly positioned. The battery cable
terminal clamps must reach the correct battery ter-
minal post without stretching the cables (Fig. 17).

(3) Reinstall the battery hold downs onto the bat-

tery. Refer to Battery Hold Downs in this section
for the location of the proper battery hold down
installation procedures.

CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reverse battery polarity may damage
electrical components of the vehicle.

(4) Clean the battery cable terminal clamps and

the battery terminal posts. Refer to Battery in this
section for the location of the proper battery cleaning
and inspection procedures.

(5) Reconnect the battery positive cable terminal

clamp to the battery positive terminal post. Tighten

Fig. 16 Remove Battery Cable Terminal Clamp -

Typical

1 - BATTERY
2 - BATTERY TERMINAL PULLER

Fig. 17 Battery Cables

1 - POWER DISTRIBUTION CENTER
2 - CLIP
3 - BATTERY
4 - TRAY
5 - NEGATIVE CABLE
6 - POSITIVE CABLE
7 - CLIP
8 - WHEELHOUSE INNER PANEL

BATTERY SYSTEM

8F - 17

BATTERY (Continued)

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