Dodge Neon / Neon SRT-4. Manual — part 79

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
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 eight minutes.

(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
eight 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 eight 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-
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

WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.

(1) Make sure ignition switch is in OFF position

and all accessories are OFF.

(2) Open hood.
(3) Disconnect and isolate the battery negative

cable then the positive cable (Fig. 8).

(4) Remove thermal guard from battery.
(5) Loosen bolt and retainer that holds the battery

down to the tray.

(6) Lift battery out of battery tray and remove

from vehicle.

8F - 12

BATTERY SYSTEM

PL/SRT-4

BATTERY (Continued)

INSTALLATION

When replacing battery, the thermal guard MUST

be transferred to the new battery. Refer to Battery
Thermal Guard Removal and Installation in this sec-
tion.

(1) Install battery in vehicle making sure that the

thermal guard is present and battery is properly
positioned on battery tray.

(2) Install battery hold down clamp, making sure

that it is properly positioned on battery.

(3) Connect battery cable clamps to battery posts

and making sure top of clamp is flush or below with
top of post (Fig. 8). Install battery positive cable first.

(4) Tighten clamp nuts securely.

BATTERY HOLDDOWN

DESCRIPTION

The battery holddown includes one bolt and a hold-

down bracket. The battery holddown bracket consists
of a formed steel bracket with one hole.

When installing a battery into the battery tray, it

is important 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 down for the proper installation proce-

dure, including the proper hold down fastener torque
specifications.

OPERATION

The battery holddown secures the battery in the

battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removal and lubrica-
tion of the battery holddown hardware is recom-
mended to prevent hardware seizure at a later date.

CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the single battery hold down retaining

bolt.

(3) Remove the battery hold down from the vehi-

cle.

INSTALLATION

(1) Install the battery hold down in the vehicle.
(2) Install the single battery hold down retaining

bolt.

(3) Connect the negative battery cable.

BATTERY CABLES

DESCRIPTION

The battery cables are large gauge, stranded cop-

per wires sheathed within a heavy plastic or syn-
thetic rubber insulating jacket. The wire used in the
battery cables combines excellent flexibility and reli-
ability with high electrical current carrying capacity.
The battery cables feature a clamping type female
battery terminal made of soft lead that is die cast
onto one end of the battery cable wire. A square
headed pinch-bolt and hex nut are installed at the
open end of the female battery terminal 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 insulat-
ing jacket to provide visual identification and feature
a larger female battery terminal clamp to allow con-
nection to the larger battery positive terminal post.
The battery negative cable wires have a black insu-
lating jacket and a smaller female battery terminal
clamp.

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

Fig. 8 Disconnect and Isolate the Battery Negative

Cable

1 - NEGATIVE CABLE
2 - NEGATIVE BATTERY POST

PL/SRT-4

BATTERY SYSTEM

8F - 13

BATTERY (Continued)

service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer to the appropriate wiring
information in this service manual for the location of
the proper battery cable wire harness diagrams. The
wiring information also includes proper wire and con-
nector repair procedures, further details on wire har-
ness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.

OPERATION

The battery cables connect the battery terminal

posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage 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 terminal 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 opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.

The battery positive cable terminal clamp is die

cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the Power Distribution
Center (PDC), and the other wire has an eyelet ter-
minal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
also die cast 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 stud
on the right side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
near the battery.

DIAGNOSIS AND TESTING - BATTERY CABLES

A voltage drop test will determine if there is exces-

sive resistance in the battery cable terminal connec-
tions or the battery cable. 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,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.

VOLTAGE DROP TEST

The following operation will require a voltmeter

accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:

• The battery is fully-charged and load tested.

Refer to Standard Procedures for the proper battery
charging and load test procedures.

• Fully engage the parking brake.

• If the vehicle is equipped with an automatic

transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.

• Verify that all lamps and accessories are turned

off.

• To prevent the engine from starting, remove the

Automatic Shut Down (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC cover
for ASD relay identification and location.

(1) Connect the positive lead of the voltmeter to

the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 9). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.

(2) Connect the positive lead of the voltmeter to

the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 10). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If
voltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post.

(3) Connect the voltmeter to measure between the

battery positive cable terminal clamp and the starter

8F - 14

BATTERY SYSTEM

PL/SRT-4

BATTERY CABLES (Continued)

solenoid B(+) terminal stud (Fig. 11). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 12). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.

REMOVAL

(1) Turn the ignition switch to the Off position. Be

certain that all electrical accessories are turned off.

(2) Disconnect and isolate the remote battery neg-

ative cable terminal.

(3) Remove the battery from the vehicle. Refer to

the procedure in this group.

(4) One at a time, trace the battery cable retaining

pushpins, fasteners and routing clips until the cables
are free from the vehicle.

(5) Remove the battery cables from the engine

compartment.

INSTALLATION

(1) Position the battery cables in the engine com-

partment.

Fig. 9 Test Battery Negative Connection Resistance

- Typical

1 - VOLTMETER
2 - BATTERY

Fig. 10 Test Battery Positive Connection Resistance

- Typical

1 - VOLTMETER
2 - BATTERY

Fig. 11 Test Battery Positive Cable Resistance -

Typical

1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR

Fig. 12 Test Ground Circuit Resistance - Typical

1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND

PL/SRT-4

BATTERY SYSTEM

8F - 15

BATTERY CABLES (Continued)