Dodge Durango (DN). Manual — part 262

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 cur-
rent 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 when-
ever 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.

In addition to producing and storing electrical

energy, the battery serves as a capacitor and voltage
stabilizer for the electrical system of the vehicle. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
in the vehicle.

BATTERY CABLES

DESCRIPTION

The battery cables (Fig. 2) are large gauge,

stranded copper wires sheathed within a heavy plas-
tic or synthetic rubber insulating jacket. The wire
used in the battery cables combines excellent flexibil-
ity and reliability with high electrical current carry-

ing capacity. Refer to Wiring Diagrams in the index
of this service manual for the location of the proper
battery cable wire gauge information.

The battery cables cannot be repaired and, if dam-

aged or faulty they must be replaced. Both the bat-
tery 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 com-
ponents on some models. Refer to Wiring Diagrams
in the index of this service manual for the location of
more information on the various wiring circuits
included in the battery cable wire harnesses for the
vehicle being serviced.

The battery cables feature a stamped brass clamp-

ing type female battery terminal crimped onto one
end of the battery cable wire and then solder-dipped.
A square headed 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 termi-
nal 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 identi-
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
tive terminal post. The battery negative cable wires
have a black insulating jacket and a smaller female
battery terminal clamp.

OPERATION

The battery cables connect the battery terminal

posts to the vehicle electrical system. These cables
also provide a return path for electrical current gen-
erated by the charging system for restoring the volt-
age 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 ter-
minal 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 elec-
trical system.

The battery positive cable terminal clamp is

crimped onto the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Power Distri-
bution Center (PDC), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp

Fig. 2 Battery Cables

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

DN

BATTERY

8A - 3

DESCRIPTION AND OPERATION (Continued)

is also crimped onto the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a
ground screw or stud on the engine. The other wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle body through a weld stud
located near the front of the left front fender inner
shield, near the battery.

BATTERY HOLD DOWNS

DESCRIPTION

The battery hold down hardware (Fig. 3) includes

two bolts, two U-nuts and a hold down strap/battery
thermoguard unit. The molded plastic battery hold
down strap is integral to the battery thermoguard
unit, which encloses the sides of the battery case.

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 Downs in the index of this service
manual for the location of the proper battery hold
down installation procedures, including the proper
hold down fastener tightness specifications.

OPERATION

The battery hold down hardware secures the bat-

tery to the battery tray in the engine compartment.
This hardware is designed to prevent battery move-
ment during vehicle operation. Unrestrained battery
movement during vehicle operation can result in
damage to the vehicle, the battery or both. The bat-
tery thermoguard protects the battery from engine
compartment temperature extremes. The air trapped
between the thermoguard and the battery case cre-
ates a dead air space, which helps to insulate the
sides of the battery case from the surrounding engine
compartment air temperature.

The two hold down U-nuts are installed onto the

battery tray before the tray is installed in the engine
compartment. The U-nuts are installed over a hole in
a molded formation integral to each side of the bat-
tery tray. After the battery is properly positioned in
the battery tray, the hold down strap/battery thermo-
guard unit is installed over the top of the battery
case. A long hold down bolt is then installed through
a hole on each end of the battery hold down strap
and threaded into the U-nuts on the battery tray.
The hold down bolts are then tightened to securely
hold down the battery in the battery tray.

BATTERY TRAY

DESCRIPTION

The battery is mounted in a molded plastic tray

(Fig. 4) located in the left front corner of the engine
compartment. The battery tray is secured on the
inboard side with screws to a stamped steel battery
tray support located on the left side of the radiator,
on the outboard side with screws to the front exten-
sion of the left front wheelhouse inner panel and at
the front to the front closure panel on the left side of
the radiator yoke. The battery tray support is
secured at the front with screws to the left side of
the radiator yoke, and at the rear with a screw to the
front extension of the left front wheelhouse inner
panel.

A hole in the bottom of the battery tray is fitted

with a battery temperature sensor. Refer to Battery
Temperature Sensor in the index of this service
manual for the location of more information on the
battery temperature sensor. The battery tray also
includes two stanchions that are molded into the rear

Fig. 3 Battery Hold Downs

1 – CLIPS
2 – BOLT
3 – TRAY
4 – BATTERY
5 – HOLD DOWN STRAP AND THERMOGUARD
6 – POSITIVE CABLE
7 – NEGATIVE CABLE

8A - 4

BATTERY

DN

DESCRIPTION AND OPERATION (Continued)

of the tray, which support the forward end of the
Power Distribution Center (PDC). Refer to Power
Distribution Center in the index of this service
manual for the location of more information on the
PDC mounting.

OPERATION

The battery tray provides a mounting location and

support for the vehicle battery. The battery tray also
provides anchor points 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. Unre-
strained battery movement during vehicle operation
can result in damage to the vehicle, the battery or
both.

DIAGNOSIS AND TESTING

BATTERY

DIAGNOSIS

The battery, starting system and charging system

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 charge properly, all of the
components that are used in these systems must per-
form within specifications. It is important that the
battery, starting system and charging system be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal dis-
charge, overcharging or early battery failure must be
diagnosed and corrected before a battery is replaced
and before a vehicle is returned to service. The ser-
vice information for these systems has been sepa-
rated within this service manual to make it easier to
locate the specific information you are seeking. How-
ever, when attempting to diagnose any of these sys-
tems,

it

is

important

that

you

keep

their

interdependency in mind.

The diagnostic procedures used for the battery,

starting system and charging system 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/ohmme-
ter, 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 Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System, On-Board Diagnostic Test in
the index of this service manual for the location of
the proper on-board diagnostic test procedures.

The battery must be completely charged and the

top, posts and terminal clamps should be properly
cleaned and inspected before any diagnostic proce-
dures are performed. Refer to Battery in the index
of this service manual for the location of the proper
battery cleaning and inspection procedures. Refer to
Battery Charging in the index of this service man-
ual for the location of the proper battery charging
procedures.

Fig. 4 Battery Tray

1 – SCREW
2 – SENSOR
3 – YOKE
4 – SCREW
5 – SUPPORT
6 – SCREW
7 – WHEELHOUSE INNER PANEL
8 – TRAY
9 – SCREW

DN

BATTERY

8A - 5

DESCRIPTION AND OPERATION (Continued)

WARNING:

•

IF THE BATTERY SHOWS SIGNS OF FREEZ-

ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.

•

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.

•

THE BATTERY CONTAINS SULFURIC ACID,

WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT 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.

•

IF THE BATTERY IS EQUIPPED WITH REMOV-

ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

The condition of a battery is determined by two cri-

teria:

1. State-Of-Charge

This can be determined by checking the specific grav-
ity of the battery electrolyte (built-in test indicator or
hydrometer test), or by checking the battery voltage
(open-circuit voltage test).

2. Cranking Capacity

This can be determined by performing a battery load
test, which measures the ability of the battery to
supply high-amperage current.

First, determine the battery state-of-charge. This

can be done in one of three ways. If the battery has a

built-in test indicator, view the test indicator to
determine the state-of-charge. If the battery has no
test indicator but does have removable cell caps, per-
form the hydrometer test to determine the state-of-
charge. If the battery cell caps are not removable or
a hydrometer is not available, perform the open-cir-
cuit voltage test to determine the state-of-charge.

The battery must be charged before proceeding

with a load test if:

• The battery built-in test indicator has a black or

dark color visible.

• The temperature corrected specific gravity of the

battery electrolyte is less than 1.235.

• The battery open-circuit voltage is less than 12.4

volts.

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.

NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Battery
Charging in the index of this service manual for the
location of the proper battery charging procedures.

A battery is fully-charged when:
• All battery cells are gassing freely during charg-

ing.

• A green color is visible in the sight glass of the

battery built-in test indicator.

• Three corrected specific gravity tests, taken at

one-hour intervals, indicate no increase in the spe-
cific gravity of the battery electrolyte.

• Open-circuit voltage of the battery is 12.4 volts

or greater.

8A - 6

BATTERY

DN

DIAGNOSIS AND TESTING (Continued)