2001 CHRYSLER VOYAGER Service Manual

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Page 1857 of 4284

CHRYSLER VOYAGER 2001 Service Manual BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.1. The battery has an
incorrect size or rating for
this vehicle.1. Refe

Page 1858 of 4284

CHRYSLER VOYAGER 2001 Service Manual BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.1. The battery has an
incorrect size or rating for
this vehicle.1. Refer to Battery Speci

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.1. The battery has an
incorrect size or rating for
this vehicle.1. Refer to Battery Specifications for the proper
specifications. Replace an incorrect battery, as
required.
2. The battery terminal
connections are loose or
corroded.2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The generator drive belt is
slipping.3. Refer to Cooling System for the proper
accessory drive belt diagnosis and testing
procedures. Replace or adjust the faulty
generator drive belt, as required.
4. The electrical system
ignition-off draw is excessive.4. Refer to Standard Procedures for the proper
test procedures. Repair the faulty electrical
system, as required.
5. The battery is faulty. 5. Determine the battery cranking capacity. Refer
to Standard Procedures for the proper test
procedures. Replace the faulty battery, as
required.
6. The starting system is
faulty.6. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
7. The charging system is
faulty.7. Determine if the charging system is performing
to specifications. Refer to Charging System for
the proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
8. Electrical loads exceed the
output of the charging
system.8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Slow driving or prolonged
idling with high-amperage
draw systems in use.9. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.1. The battery is faulty. 1. Refer to Standard Procedures for the proper
battery charging procedures. Charge or replace
the faulty battery, as required.
ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging:
²Corroded or loose battery posts and terminal
clamps.
²A loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system. This can be due to equipment
installed after manufacture, or repeated short trip
use.²Slow driving speeds (heavy traffic conditions) or
prolonged idling, with high-amperage draw systems
in use.
²A faulty circuit or component causing excessive
ignition-off draw.
²A faulty or incorrect charging system compo-
nent. Refer to Charging System for the proper charg-
ing system diagnosis and testing procedures.
8F - 4 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

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CHRYSLER VOYAGER 2001 Service Manual ²A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures.
²A faulty or incorrect battery. Refer to Standard
Proced

²A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures.
²A faulty or incorrect battery. Refer to Standard
Procedures for the proper battery diagnosis and test-
ing procedures. Refer to Battery System Specifica-
tions for the proper specifications.
CLEANING
The following information details the recommended
cleaning procedures for the battery and related com-
ponents. In addition to the maintenance schedules
found in this service manual and the owner's man-
ual, it is recommended that these procedures be per-
formed any time the battery or related components
must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 1).
(2) Clean the battery tray and battery holddown
hardware of all corrosion. Remove any corrosion
using a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal.
(3) If the removed battery is to be reinstalled,
clean the outside of the battery case and the top
cover with a sodium bicarbonate (baking soda) and
warm water cleaning solution using a stiff bristleparts cleaning brush to remove any acid film (Fig. 2).
Rinse the battery with clean water. Ensure that the
cleaning solution does not enter the battery cells
through the vent holes. If the battery is being
replaced, refer to Battery Specifications for the facto-
ry-installed battery specifications. Confirm that the
replacement battery is the correct size and has the
correct ratings for the vehicle.
(4) Clean the battery thermal guard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.
(5) Clean any corrosion from the battery terminal
posts with a wire brush or a post and terminal
cleaner, and a sodium bicarbonate (baking soda) and
warm water cleaning solution (Fig. 3).
INSPECTION
The following information details the recommended
inspection procedures for the battery and related
components. In addition to the maintenance sched-
ules found in this service manual and the owner's
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp.
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
RSBATTERY SYSTEM8F-5
BATTERY SYSTEM (Continued)

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CHRYSLER VOYAGER 2001 Service Manual (2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case.
Inspect the battery case for cracks or other dama

Page 1861 of 4284

CHRYSLER VOYAGER 2001 Service Manual material protrude from the top of the molded plastic
battery case to provide the means for connecting the
battery to the vehicle electrical system. The battery
positive terminal post is visibly larger

material protrude from the top of the molded plastic
battery case to provide the means for connecting 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 lettersPOS
andNEGare also molded into the
top of the battery case adjacent to their respective
positive and negative terminal posts for additional
identification confirmation. Refer toBattery 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 electrical 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
plates are submerged in a sulfuric acid and water
solution called an electrolyte.
Some factory-installed batteries have 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 toStandard Procedures The
factory-installed low-maintenance battery has
removable battery cell caps.Distilled water can
be added to this battery. The battery is not sealed
and has vent holes in the cell caps. The chemical
composition of the metal coated plates within the
low-maintenance battery reduces battery gassing and
water loss, at normal charge and discharge rates.
Therefore, the battery should not require additional
water in normal service. If the electrolyte level in
this battery does become low, distilled water must be
added. However, rapid loss of electrolyte can be
caused by an overcharging condition. Be certain to
diagnose the charging system after replenishing the
water in the battery for a low electrolyte condition
and before returning the vehicle to service. Refer to
Charging Systemfor additional information.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 Specificationsin this group for the loca-
tion of the proper factory-installed battery specifica-
tions. Battery sizes and ratings are discussed in more
detail below.
Group Size
²The outside dimensions and terminal placement
of the battery conform to standards established by
the Battery Council International (BCI). Each bat-
tery is assigned a BCI Group Size number to help
identify a correctly-sized replacement.
Cold Cranking Amperage
²The Cold Cranking Amperage (CCA) rating spec-
ifies how much current (in amperes) the battery can
deliver for thirty seconds at -18É C (0É 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
²The Reserve Capacity (RC) rating specifies the
time (in minutes) it takes for battery terminal volt-
age to fall below 10.5 volts, at a discharge rate of 25
amperes. RC is determined with the battery fully-
charged at 26.7É C (80É F). This rating estimates how
long the battery might last after a charging system
failure, under minimum electrical load.
Ampere-Hours
²The Ampere-Hours (AH) rating specifies the cur-
rent (in amperes) that a battery can deliver steadily
for twenty hours, with the voltage in the battery not
falling below 10.5 volts. This rating is also sometimes
identified as the twenty-hour discharge rating.
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 reac-
tion occurs. This reaction causes the battery to dis-
charge electrical current from its terminals. As the
RSBATTERY SYSTEM8F-7
BATTERY (Continued)

Page 1862 of 4284

CHRYSLER VOYAGER 2001 Service Manual battery discharges, a gradual chemical change takes
place within each cell. The sulfuric acid in the elec-
trolyte combines with the plate materials, causing
both plates to slowly change to lead sulfa

battery discharges, a gradual chemical change takes
place within each cell. The sulfuric acid in the elec-
trolyte combines with the plate materials, causing
both plates to slowly change to lead sulfate. 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 ter-
minals.
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
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.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
top, posts and terminal clamps should be properly
cleaned and inspected before diagnostic procedures
are performed. Refer to Battery System Cleaning for
the proper cleaning procedures, and Battery System
Inspection for the proper battery inspection proce-
dures. Refer to Standard Procedures for the proper
battery charging procedures.
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 BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE 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: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condition of a battery is determined by two cri-
teria:
²State-Of-Charge- This can be determined by
checking the specific gravity of the battery electrolyte
(built-in indicator test or hydrometer test), or by
checking the battery voltage (open-circuit voltage
test).
²Cranking 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, perform the built-in indicator
test to determine the state-of-charge. If the battery
has no built-in test indicator but does have remov-
able cell caps, perform the hydrometer test to deter-
mine the state-of-charge. If the battery cell caps are
not removable, or a hydrometer is not available, per-
form the open-circuit voltage test to determine the
state-of-charge. Refer to open-circuit voltage test in
the Standard Procedures section of this group.
Second, determine the battery cranking capacity by
performing a load test. The battery must be charged
before proceeding with a load test if:
²The battery built-in test indicator has a black or
dark color visible.
²The temperature corrected specific gravity of the
battery electrolyte is less than 1.235.
²The 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
8F - 8 BATTERY SYSTEMRS
BATTERY (Continued)

Page 1863 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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 ac

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 Standard
Procedures for the proper battery charging proce-
dures.
A battery is fully-charged when:
²All battery cells are gassing freely during charg-
ing.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three corrected specific gravity tests, taken at
one-hour intervals, indicate no increase in the spe-
cific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.4 volts
or greater.
STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The following procedure can be used to check the
electrolyte level in the battery.
(1) Remove the battery caps.
(2) Look through the battery cap holes to deter-
mine the level of the electrolyte in the battery. The
electrolyte should be approximately 1 centimeter
above the battery plates or until the hook inside the
battery cap holes is covered.
(3) Add only distilled water until the electrolyte
level is approx. one centimeter above the plates.
STANDARD PROCEDURE - BATTERY
CHARGING
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
²All of the battery cells are gassing freely during
battery charging.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.4 volts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1É C [30É F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOTTEST, 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 BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE 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: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
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 continu-
ing the charging operation. Damage to the battery
may result.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine the battery
cranking capacity. Refer to Standard Procedures for
the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
and must be replaced.
RSBATTERY SYSTEM8F-9
BATTERY (Continued)

Page 1864 of 4284

CHRYSLER VOYAGER 2001 Service Manual Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat

Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat-
tery System Inspection for the proper battery system
inspection procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce-
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure the voltage at the battery posts with a
voltmeter, accurate to 1/10 (0.10) volt (Fig. 6). If the
reading is below ten volts, the battery charging cur-
rent will be low. It could take some time before the
battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
(2) Disconnect and isolate the battery negative
cable. Connect the battery charger leads. Some bat-
tery chargers are equipped with polarity-sensing cir-
cuitry. This circuitry protects the battery charger and
the battery from being damaged if they are improp-
erly connected. If the battery state-of-charge is too
low for the polarity-sensing circuitry to detect, the
battery charger will not operate. This makes it
appear that the battery will not accept charging cur-
rent. See the instructions provided by the manufac-
turer of the battery charger for details on how to
bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltage
and current they provide. The amount of time
required for a battery to accept measurable charging
current at various voltages is shown in the Charge
Rate Table. If the charging current is still not mea-
surable at the end of the charging time, the battery
is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the bat-tery may be good and the charging should be
completed in the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The time required to charge a battery will vary,
depending upon the following factors:
²Battery Capacity- A completely discharged
heavy-duty battery requires twice the charging time
of a small capacity battery.
²Temperature- A longer time will be needed to
charge a battery at -18É C (0É F) than at 27É C (80É
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
²Charger Capacity- A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies
twenty amperes or more will require a shorter charg-
ing time.
²State-Of-Charge- A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
The Battery Charging Time Table gives an indica-
tion of the time required to charge a typical battery
at room temperature based upon the battery state-of-
charge and the charger capacity.
BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps10
Amps20 Amps
Open Circuit
VoltageHours Charging @ 21É C (70É
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
Fig. 6 Voltmeter - Typical
8F - 10 BATTERY SYSTEMRS
BATTERY (Continued)

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