Battery: Description and Operation
BATTERY SYSTEMA single 12-volt battery system is standard factory-installed equipment on this model All of the components of the battery system are located within the engine compartment of the vehicle. The service information for the battery system in this vehicle covers the following related components, which are covered in further detail elsewhere in this service manual:
- Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle.
- Battery Cable - The battery cables connect the battery terminal posts to the vehicle electrical system.
- Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment.
- Battery Thermowrap - The battery thermowarp insulates the battery to protect it from engine compartment temperature extremes.
- Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery 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 Maintenance for the recommended battery maintenance 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 service 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.
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 accessory 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 system 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.
BATTERY
There are three different batteries available on this model. Vehicles equipped with a diesel engine utilize a spiral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery This additional power is required by a diesel engine during cold cranking. Vehicles equipped with a gasoline engine utilize a conventional battery Refer to the following information for detailed differences and descriptions of these batteries.
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 reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, 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 combines with hydrogen from the sulfuric acid, causing 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 terminals.
As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage 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 current 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 whenever 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.
Conventional Battery - Gasoline Engine
Fig.5 Battery Cell Cap Removal/Installation - Low-Maintanance Gasoline Engine Battery:
Low-maintenance batteries are used on vehicles equipped with a gasoline engine, these batteries have removable battery cell caps (Fig. 5). Water can be added to this battery Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates. However these batteries may require additional distilled water after years of service.
Fig.6 Maintenance - Free Battery:
Maintenance-free batteries are 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 (Fig. 6) 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 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.
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). Insulators or plate separators made of a non-conductive material are inserted between the positive and negative plates to prevent them from contacting or shorting 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 condition. For more information on the use of the built-in test indicator, refer to Standard Procedures 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 System for 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 Specifications in this group for the location of the proper factory-installed battery specifications.
BATTERY HOLDDOWN
The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of the battery tray and support unit, a molded steel hold down bracket and a single hex nut with a coned washer.
When installing a battery into the battery tray, be certain 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 Downs in this section of this service manual for the location of the proper battery hold down installation procedures, including the proper hold down fastener tightness specifications.
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 lubrication of the battery holddown hardware is recommended to prevent hardware seizure at a later date.
NOTE: Never operate a vehicle without a battery holddown device properly installed. Damage to the vehicle, components and battery could result.
BATTERY CABLES
The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. Refer to Wiring Diagrams in the index of this service manual for the location of the proper battery cable wire gauge information.
A clamping type female battery terminal made of stamped metal is attached to 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 insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp.
The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some models. Refer to Wiring Diagrams in the index of this service manual for the location of more information on the various wiring circuits included in the battery wire harness for the vehicle being serviced.
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 restoring 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 provide secure and reliable connection of the battery cables to the vehicle electrical system.
The battery positive cable terminal clamp is attached to the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Integrated Power Module (IPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp is also attached to the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the left 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 left front fender inner shield, near the battery.
BATTERY TRAY
The battery is mounted in a molded plastic battery tray and support unit located in the left front corner of the engine compartment. The battery tray and support unit is secured with two nuts, one is located directly under the battery and the other is located on the right side of the tray which also serves as a coolant bottle neck retaining bolt. An additional bolt is located directly under the battery.
Fig.17 RS Battery Tray:
The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit (Fig. 17). And a drainage hose, located in the front of the unit (Fig. 17).
The battery tray provides a secure mounting location and supports the battery. The battery tray also provides the anchor point for the battery holddown hardware. The battery tray and the battery hold-down hardware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both.
The battery tray used on this model also includes a engine vacuum reservoir and drainage hose. The vacuum reservoir provides a storage container for engine vacuum. Refer to the engine section of the service manual for more engine vacuum information. The drainage hose provides means for any liquid that might collect in the bottom of the battery tray to drain under the vehicle.
Fig.19 Battery Position & Orientation:
THERMOWRAP
A one-piece slip-on thermowrap unit shields the battery case from engine compartment heat (Fig. 19).
The thermowrap protects the battery from engine compartment temperature extremes. The temperature of the battery can affect battery life. The air trapped in the padded material of the thermowrap creates a dead air space, which helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment.