Dodge Durango (DN). Manual — part 261

INSPECTION

Hold cap at eye level, right side up. The vent valve

(Fig. 29) at bottom of cap should open. If rubber gas-
ket has swollen and prevents vent valve from open-
ing, replace cap.

Hold cap at eye level, upside down. If any light can

be seen between vent valve and rubber gasket,
replace cap. Do not use a replacement cap that
has a spring to hold vent shut. A replacement cap
must be the type designed for a coolant reserve/over-
flow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.

RADIATOR

CLEANING

Clean radiator fins With the engine cold, apply cold

water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.

INSPECTION

The radiator cooling fins should be checked for

damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.

Inspect the radiator neck for damage or distortion.

WATER PUMP

CLEANING

Clean the gasket mating surface. Use caution not

to damage the gasket sealing surface.

INSPECTION

Inspect the water pump assembly for cracks in the

housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.

FAN BLADE

CLEANING

Clean the fan blades using a mild soap and water.

Do not use an abrasive to clean the blades.

INSPECTION

WARNING: DO

NOT

ATTEMPT

TO

BEND

OR

STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.

CAUTION: If

fan

blade

assembly

is

replaced

because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.

(1) Remove fan blade assembly from viscous fan

drive unit (four bolts).

(2) Lay fan on a flat surface with leading edge fac-

ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.

(3) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan if any damage is
found.

SPECIFICATIONS

COOLING SYSTEM CAPACITIES

ENGINE

CAPACITY

5.2L/5.9L

*13.5L (14.3 Qts.)

4.7L

*12.3L ( 13.0 Qts.)

* Nominal refill capacities are shown. A variation
may be observed from

vehicle due to manufacturing tolerances and refill
procedures.

* Capacities shown include vehicles with air
conditioning and/or heavy

duty cooling systems.

DN

COOLING SYSTEM

7 - 43

CLEANING AND INSPECTION (Continued)

COOLING SYSTEM

SPECIAL TOOLS

COOLING

DESCRIPTION

N·m

Ft.

In.

Lbs.

Lbs.

Automatic Belt Tensioner to
Mounting

Bracket—Bolts(5.2L/5.9L)

67

50

—

Automatic Belt Tensioner to
Block—Bolts

(4.7L)

41

30

—

Automatic Belt Tensioner
Pulley—Bolt

61

45

—

Block Heater—Bolt

2

—

17

Generator/Compressor
Mounting

Bracket—Bolts

# 1 and 2

54

40

—

# 3

40

30

—

Fan Shroud Mounting—Bolts

6

—

50

Fan Blade to Fan Drive—
Bolts

23

17

—

Idler Pulley—Bolt

54

40

—

Radiator to Support—Bolts

23

—

200

Thermostat Housing—Bolts

23

—

200

Transmission Auxiliary Oil
Cooler—Bolts

10

—

90

Upper Radiator Closure
Panel—Bolts

10

—

90

Water Pump—Bolts

40

30

—

Pliers Constant Pressure Hose Clamp—6094

Cooling System Pressure Tester—7700A

3/8” Disconnect Tool—6935

7 - 44

COOLING SYSTEM

DN

SPECIFICATIONS (Continued)

BATTERY

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . . 4
BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSIS AND TESTING

BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE PROCEDURES

BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . 16

REMOVAL AND INSTALLATION

BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . 18
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . 20

CLEANING AND INSPECTION

BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SPECIFICATIONS

BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DESCRIPTION AND OPERATION

BATTERY

DESCRIPTION

A large capacity, maintenance-free storage battery

(Fig. 1) is standard factory-installed equipment on
this model. 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 connect-
ing the battery to the vehicle electrical system. The
battery positive terminal post is visibly larger in
diameter than the negative terminal post, for easy
identification. 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 additional identification confirmation. Refer to
Battery Cables in the index of this service manual
for the location of more information on the battery
cables that connect the battery to the vehicle electri-
cal system.

This battery is designed to provide a safe, efficient

and reliable means of storing electrical energy in a
chemical form. This means of energy storage allows
the battery to produce the electrical energy 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 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). Insu-
lators or plate separators made of a non-conductive
material are inserted between the positive and nega-
tive plates to prevent them from contacting or short-
ing against one another. These dissimilar metal

Fig. 1 Maintenance-Free Battery - Typical

1 – POSITIVE POST
2 – VENT CAPS
3 – NEGATIVE POST
4 – GREEN BALL
5 – ELECTROLYTE LEVEL
6 – MAINTENANCE-FREE BATTERY
7 – PLATE GROUPS
8 – TEST INDICATOR
9 – VENTS

DN

BATTERY

8A - 1

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 condi-
tion. For more information on the use of the built-in
test indicator, refer to Battery in the index of this
service manual for the location of the proper battery
diagnosis and testing procedures. The factory-in-
stalled maintenance-free battery has non-re-
movable battery vent caps. Water cannot be added
to this battery. The chemical composition of the metal
coated plates within the maintenance-free battery
reduces battery gassing and water loss, at normal
charge and discharge rates. Therefore, the battery
should not require additional water in normal ser-
vice. If the electrolyte level in this battery does
become low, the battery must be replaced. However,
rapid loss of electrolyte can be caused by an over-
charging condition. Be certain to diagnose the charg-
ing system after replacing the battery for a low
electrolyte condition and before returning the vehicle
to service. Refer to Charging System in the index of
this service manual for the location of the proper
charging system diagnosis and testing procedures.

For battery maintenance schedules and jump start-

ing procedures, see the owner’s manual in the vehicle
glove box. Optionally, refer to Maintenance Sched-
ules and Jump Starting, Towing and Hoisting in
the index of this service manual for the location of
the recommended battery maintenance schedules and
the proper battery jump starting procedures. While
battery charging can be considered a maintenance
procedure, the battery charging procedures and infor-
mation are located in the service procedures section
of this service manual. This was done because the
battery must be fully-charged before any battery
diagnosis or testing procedures can be performed.
Refer to Battery Charging in the index of this ser-
vice manual for the location of the proper battery
charging procedures.

BATTERY SIZE AND RATINGS

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 correct
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. Refer to
Battery in the index of this service manual for the
location of the proper factory-installed battery speci-
fications. Battery sizes and ratings are discussed in
more detail below.

• 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.

• 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.

• 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.

• 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 fall-
ing below 10.5 volts. This rating is also sometimes
identified as the twenty-hour discharge rating.

OPERATION

When an electrical load is applied to the terminals

of the battery, an electrochemical reaction occurs.
This reaction causes the battery to discharge electri-
cal current from its terminals. As the battery dis-
charges, 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 sulfate. At the same
time, oxygen from the positive plate material com-
bines with hydrogen from the sulfuric acid, causing
the electrolyte to become mainly water. The chemical
changes within the battery are caused by the move-
ment of excess or free electrons between the positive
and negative plate groups. This movement of elec-
trons produces a flow of electrical current through
the load device attached to the battery terminals.

As the plate materials become more similar chem-

ically, and the electrolyte becomes less acid, the volt-
age 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 electron

8A - 2

BATTERY

DN

DESCRIPTION AND OPERATION (Continued)