Flow of Diagnosis

WARNING
^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
^ WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY, DAMAGE TO THE VEHICLE OR BATTERY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.

1. Verify the customer's concern by operating the engine to duplicate the concern.
2. Inspect to determine if one of the mechanical or electrical concerns apply:

VISUAL INSPECTION CHART

Mechanical
Before attempting to test a battery, it is important to give it a thorough examination to determine if it has been damaged.

Preliminary checks to the charging system should be made regardless of the fault condition. These checks include:
^ Check the fuses/fuse links to the generator to make sure that they are not burned or damaged. This condition, resulting in an open circuit or high resistance, can cause erratic or intermittent charging system concerns.
^ Check battery posts and cable terminals for clean and tight connections. Clean the posts and the cables to make sure electrical contact is good.
^ Check for secure connections at the generator output and engine ground. Also check connection at load distribution point.
^ Check generator drive belt for proper tension and no slip between generator pulley and drive belt.
^ Check the battery for fullcharge.

Electrical
Batteries are tested to determine the state of charge and ability to crank an engine. The result of these tests is to show that the battery is either good, needs recharging, or must be replaced.

Before performing the charging system tests on the vehicle, note the conditions such as: slow cranking, discharged battery, charge indicator lamp stays on with the engine running, charge indicator lamp does not illuminate with the ignition switch in RUN and the engine not running, etc. This information will aid in isolating the part of the system causing the symptom.
^ When a relatively new battery is discharged, test for current drain. These are some of the most common current drain sources:
- Glove compartment lamp stays on with the door closed.
- Engine compartment lamp stays on constantly.
- Other electronic component malfunctions.

3. If the inspection reveals obvious concern(s) that can be readily identified, service as required.
4. If the concern(s) remains after the inspection, determine the symptom(s) and go to the Symptom Chart. Symptom Related Diagnostic Procedures