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Dodge Caliber. Manual - part 276

SPECIAL TOOLS

BATTERY SYSTEM SPECIAL TOOLS

BATTERY SYSTEM

8F - 9

BATTERY

DESCRIPTION

There are two different batteries available for this vehicle. Vehicles equipped with a diesel engine utilize a spiral cell
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 differ-
ences and descriptions of these two batteries.

SPIRAL CELL BATTERY - DIESEL ENGINE

WARNING: Never exceed 14.4 volts when charging
a spiral cell battery. Personal injury and/or battery
damage may result.

By tightly winding layers of spiral grids and acid-per-
meated vitreous separators into cells, the battery has
more power and service life than conventional batter-
ies of the same size. The spiral cell battery is com-
pletely,

permanently

sealed.

Through

gas

recombination, hydrogen and oxygen within the bat-
tery 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.

The acid inside a spiral cell 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 cell technology is the process by which the cells
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 cell battery charging process, water vapor can be exhausted through the pressure-
sensitive battery vents and lost for good. This can permanently damage the spiral cell battery.

CONVENTIONAL BATTERY - GASOLINE ENGINE

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

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

The battery is used to store electrical energy potential in a chemical form. When an electrical load is applied to the
battery terminals, an electrochemical reaction occurs within the battery. This reaction causes the battery to dis-
charge electrical current.

8F - 10

BATTERY SYSTEM

OPERATION

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 sul-
fate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, caus-
ing 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 elec-
tron 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 dis-
charged. 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 diag-
nostic procedures are performed. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - CLEANING) for the proper bat-
tery cleaning procedures. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - INSPECTION) for the proper battery
inspection procedures. Refer to Standard Procedures for the proper battery charging procedures.

MICRO 420 BATTERY TESTER (GASOLINE ENGINES)

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

OTC ONE STEP BATTERY ANALYZER AND CHARGER (DIESEL ENGINES)

The OTC One Step Battery Analyzer and Charger is designed to help diagnose the cause of a defective battery.
Follow the instruction manual supplied with the tester to properly diagnose a vehicle.

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 battery. Personal injury and/or vehicle damage 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: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery dam-
age may result.

BATTERY SYSTEM

8F - 11

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 fails the OTC One Step
Battery Analyzer and Charger or other load test, is faulty and must be replaced.

NOTE: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Pro-
cedures for the proper battery charging procedures.

STANDARD PROCEDURE

SPIRAL CELL BATTERY CHARGING

WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery dam-
age may result.

Vehicles equipped with a diesel engine utilize a unique spiral cell 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 cell 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:

•

OTC One Step Battery Analyzer and Charger special tool number OT-3641 or equivalent tester indicates bat-
tery is OK.

•

Open-circuit voltage of the battery is 12.65 volts or above.

•

Battery passes Load Test multiple times.

WARNING: If the battery shows signs of freezing, leaking, loose posts or low electrolyte level, 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 battery. Personal injury and/or vehicle damage may result.

CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Charge the
battery directly at the battery terminals. Do not exceed 14.4 volts while charging a battery.

CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing the charging operation. Damage to the battery may result.

After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking
capacity. If the battery passes a load test, return the battery to service. If the battery fails 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 8 - ELECTRICAL/BATTERY SYSTEM - CLEANING) for the proper battery system cleaning procedures. (Refer to
8 - ELECTRICAL/BATTERY SYSTEM - INSPECTION) for the proper battery system inspection procedures.

CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL CELL BATTERY

WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery dam-
age may result.

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

8F - 12

BATTERY SYSTEM

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