Dodge Durango (DN). Manual — part 264

(1) Determine the number of degrees above or

below 26.7° C (80° F): 26.6° C - -12.2° C = 38.8° C
(80° F - 10° F = 70° F)

(2) Divide the result from Step 1 by 5.5° C (10° F):

38.8° C

4 5.5° C = 7 (70° F 4 10° F = 7)

(3) Multiply the result from Step 2 by the temper-

ature correction factor (0.004): 7 X 0.004 = 0.028

(4) The temperature at testing was below 26.7° C

(80° F); therefore, the temperature correction factor
is subtracted: 1.240 - 0.028 = 1.212

(5) The corrected specific gravity of the battery cell

in this example is 1.212.

Test the specific gravity of the electrolyte in each

battery cell. If the specific gravity of all cells is above
1.235, but the variation between cells is more than
fifty points (0.050), the battery should be replaced. If
the specific gravity of one or more cells is less than
1.235, charge the battery at a rate of approximately
five amperes. Continue charging the battery until
three consecutive specific gravity tests, taken at one-
hour intervals, are constant. If the cell specific grav-
ity variation is more than fifty points (0.050) at the
end of the charge period, replace the battery.

When the specific gravity of all cells is above 1.235,

and the cell variation is less than fifty points (0.050),
the battery may be load tested to determine its
cranking capacity. Refer to Load Test in this section
for the proper battery load testing procedures.

OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will

show the state-of-charge of a battery. This test can be
used in place of the hydrometer test when a hydrom-
eter is not available, or for maintenance-free batter-
ies with non-removable cell caps.

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.

Before proceeding with this test, completely charge

the battery. Refer to Battery Charging in the index
of this service manual for the location of 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. 8).

See the Open-Circuit Voltage chart. 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 Load Test in this section for the
proper battery load testing procedures.

LOAD TEST

A battery load test will verify the battery cranking

capacity. This test is based on the Cold Cranking

Fig. 8 Testing Open-Circuit Voltage - Typical

Open Circuit Voltage

Open Circuit Volts

Charge Percentage

11.7 volts or less

0%

12.0 volts

25%

12.2 volts

50%

12.4 volts

75%

12.6 volts or more

100%

DN

BATTERY

8A - 11

DIAGNOSIS AND TESTING (Continued)

Amperage (CCA) rating of the battery. See the label
affixed to the battery case, or refer to Battery in the
index of this service manual for the location of the
proper

factory-installed

battery

specifications

to

determine the battery CCA rating.

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.

Before proceeding with this test, completely charge

the battery. Refer to Battery Charging in the index
of this service manual for the location of the proper
battery charging procedures.

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

ative cable first. The battery top and posts should be
clean.

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

(Fig. 9) to the battery posts (Fig. 10). See the instruc-
tions provided by the manufacturer of the tester you
are using. Check the open-circuit voltage (no load) of
the battery. Refer to Open-Circuit Voltage Test in
this section for the proper battery open-circuit volt-
age testing procedures. The battery open-circuit volt-
age 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. 11). 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.
12). After fifteen seconds, record the loaded voltage

reading, then return the load control knob to the Off
position.

Fig. 9 Volt-Ammeter-Load Tester - Typical

Fig. 10 Volt-Ammeter-Load Tester Connections -

Typical

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

Fig. 11 Remove Surface Charge from Battery -

Typical

8A - 12

BATTERY

DN

DIAGNOSIS AND TESTING (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 chart
for the proper loaded voltage reading.

(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.

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 twenty-five milliamperes (0.005 to 0.025 ampere)
with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working
order. The twenty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other electronic 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
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Junction Block (JB). This will reduce bat-
tery 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 twenty-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)

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

Central Timer Module

(CTM)

No

4.75

milliamperes

N/A

Fig. 12 Load 50% CCA Rating - Note Voltage -

Typical

Load Test Temperature

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°

DN

BATTERY

8A - 13

DIAGNOSIS AND TESTING (Continued)

ELECTRONIC MODULE IGNITION-OFF DRAW (IOD)

MODULE

TIME OUT?

(IF YES, INTERVAL AND WAKE-UP INPUT)

IOD

IOD AFTER

TIME OUT

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 under-hood 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), the
Junction Block (JB) and the relay and fuse block one
at a time (refer to Power Distribution Center,
Junction Block and Fuse/Fuse Block in the index
of this service manual for the location of complete
PDC, JB and relay and fuse block fuse and circuit
breaker identification contained in the wiring dia-
grams) until the amperage reading becomes very low,
or nonexistent. This will isolate each circuit and
identify the circuit that is the source of the high-am-
perage IOD. If the amperage reading remains high
after removing and replacing each fuse and circuit
breaker, disconnect the wire harness from the gener-
ator. If the amperage reading now becomes very low
or nonexistent, refer to Charging System in the
index of this service manual for the location of the
proper charging system diagnosis and testing proce-
dures. After the high-amperage IOD has been cor-

rected, 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-am-

perage IOD should not exceed twenty-five milliam-
peres (0.025 ampere). If the current draw exceeds
twenty-five milliamperes, isolate each circuit using
the fuse and circuit breaker remove-and-replace pro-
cess 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.

BATTERY CABLES

DIAGNOSIS

A voltage drop test will determine if there is exces-

sive resistance in the battery cable terminal connec-
tions or the battery cables. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion

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 impor-

tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached. EXAM-
PLE: When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive 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,

8A - 14

BATTERY

DN

DIAGNOSIS AND TESTING (Continued)