2001 DODGE TOWN AND COUNTRY battery

INSTALLATION
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
NOTE: If TCM is replaced and vehicle has less than
6,035 km (3750 miles), the Torque Converter Clutch
(TCC) Break-In Strategy reset procedure must also
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install TCM into position (Fig. 17). Install
three (3) screws and torque to 3 N´m (30 in. lbs.).(2) Install TCM harness 60±way connector (Fig.
18) and torque to 4 N´m (35 in. lbs.).
(3) Install splash shield into position with fasten-
ers.
(4) Install left front wheel/tire assembly.
(5) Lower vehicle.
(6) Connect battery negative cable.
(7) If TCM was replaced, reset Pinion Factor and
Quick Learn. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE).
(8) If TCM was replaced and vehicle has less than
6,035 km (3750 miles), perform TCC Break-In reset
procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 17 Transmission Control Module Removal/
Installation
1 - SCREW
2 - TRANSMISSION CONTROL MODULE (TCM)
3 - CLIP
4 - LEFT RAIL
Fig. 18 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
RSELECTRONIC CONTROL MODULES8E-29
TRANSMISSION CONTROL MODULE (Continued)
2001 RS Service Manual
Publication No. 81-370-1005
TSB 26-03-01 March, 2001
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ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 21STARTING............................... 27
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION............................2
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
BATTERY SYSTEM......................2
CLEANING...............................5
INSPECTION.............................5
BATTERY
DESCRIPTION............................6
OPERATION.............................7
DIAGNOSIS AND TESTING..................8
BATTERY..............................8
STANDARD PROCEDURE...................9
CHECKING BATTERY ELECTROLYTE
LEVEL................................9
BATTERY CHARGING....................9
BUILT- IN INDICATOR TEST...............11
HYDROMETER TEST....................11
OPEN-CIRCUIT VOLTAGE TEST...........12
LOAD TEST...........................13
IGNITION-OFF DRAW TEST...............14
REMOVAL..............................16INSTALLATION...........................16
BATTERY HOLDDOWN
DESCRIPTION...........................16
OPERATION.............................16
REMOVAL..............................16
INSTALLATION...........................16
BATTERY CABLES
DESCRIPTION...........................17
OPERATION.............................17
DIAGNOSIS AND TESTING.................17
BATTERY CABLE.......................17
BATTERY TRAY
DESCRIPTION...........................19
OPERATION.............................19
REMOVAL..............................19
INSTALLATION...........................19
THERMAL GUARD
DESCRIPTION...........................20
OPERATION.............................20
REMOVAL..............................20
INSTALLATION...........................20
RSENGINE SYSTEMS8F-1
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BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The service infor-
mation for the battery system in this vehicle covers
the following related components, which are covered
in further detail elsewhere in this service manual:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermoguard- The battery thermo-
guard insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintanance for the recommended battery main-
tenance schedules and for the proper battery jump
starting procedures. While battery charging can be
considered a maintenance procedure, the battery
charging procedures and related information are
located in the standard procedures section of this ser-
vice manual. This was done because the battery must
be fully-charged before any battery system diagnosis
or testing procedures can be performed. Refer to
Standard procedures for the proper battery charging
procedures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a single 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, and charging systems be thoroughly
tested and inspected any time a battery needs to be
charged or replaced. The cause of abnormal battery
discharge, overcharging or early battery failure must
be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems 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 for the proper charging system on-
board diagnostic test procedures.
8F - 2 BATTERY SYSTEMRS
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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. Refer to Battery Specifications for the proper
size and rating. Replace an incorrect battery, as
required.
2. The battery is physically
damaged.2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
3. The battery terminal
connections are loose or
corroded.3. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
4. The battery is discharged. 4. Determine the battery state-of-charge. Refer to
Standard Procedures for the proper test
procedures. Charge the faulty battery, as
required.
5. The electrical system
ignition-off draw is excessive.5. Refer to Standard Procedures for the proper
test procedures. Repair the faulty electrical
system, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity. Refer
to Standard Procedures for the test procedures.
Replace the faulty battery, as required.
7. The starting system is
faulty.7. 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.
8. The charging system is
faulty.8. 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.
RSBATTERY SYSTEM8F-3
BATTERY SYSTEM (Continued)
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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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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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(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 damage
that could result in electrolyte leaks. Also, check the
battery terminal posts for looseness. Batteries with
damaged cases or loose terminal posts must be
replaced.
(4) Inspect the battery thermal guard for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged.
(5) Inspect the electrolyte level in the battery. Use
a putty knife or another suitable wide flat-bladed tool
to pry the cell caps off (Fig. 4).DO NOT USE A
SCREWDRIVER.Add distilled water to each bat-
tery cell until the liquid reaches the bottom of the
vent well or one centimeter above the battery plates.
DO NOT OVERFILL THE BATTERY CELLS.
(6) Inspect the battery built-in test indicator sight
glass for an indication of the battery condition. If the
battery is discharged, charge as required. Refer to
Standard Procedures for the proper battery built-in
indicator test procedures. Also refer to Standard Pro-
cedures for the proper battery charging procedures.
BATTERY
BATTERY
DESCRIPTION
A large capacity, low-maintenance storage battery
(Fig. 5) is standard factory-installed equipment on this
model. Male post type terminals made of a soft lead
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
Fig. 4 Removing Battery Cell Caps - Typical
1 - PUTTY KNIFE
Fig. 5 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
8F - 6 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)
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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)
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