battery capacity CHRYSLER VOYAGER 1996 Service Manual

located in the Power Distribution Center (PDC).
Refer to the PDC cover for proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1ÉC (30ÉF) BATTERY. PER-
SONAL INJURY MAY RESULT.
The time required to charge a battery will vary
depending upon the following factors.
SIZE OF BATTERY
A completely discharged large heavy-duty battery
may require more recharging time than a completely
discharged small capacity battery, refer to the Bat-
tery Charging Timetable for charging times.
TEMPERATURE
A longer time will be needed to charge a battery at
-18ÉC (0ÉF) than at 27ÉC (80ÉF). When a fast charger
is connected to a cold battery, current accepted by
battery will be very low at first. In time, the battery
will accept a higher rate as battery temperature
warms.
CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a
charger that can supply 20 amperes or more.
STATE OF CHARGE
A completely discharged battery requires more
charging time than a partially charged battery. Elec-
trolyte is nearly pure water in a completely dis-
charged battery. At first, the charging current
amperage will be low. As water is converted back to
sulfuric acid inside the battery, the current amp rate
will rise. Also, the specific gravity of the electrolyte
will rise, bringing the green ball (Fig. 1) into view at
approximately 75 percent state-of-charge.
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR
USING TEST INDICATOR
The Test Indicator (Fig. 1), (Fig. 2) and (Fig. 3)
measures the specific gravity of the electrolyte. Spe-
cific Gravity (SG) of the electrolyte will show state-
of-charge (voltage). The test indicator WILL NOT
show cranking capacity of the battery. Refer to Bat-
tery Load Test for more information. Look into the
sight glass (Fig. 1), (Fig. 3) and note the color of the
indicator. Refer to the following description of colors:
NOTE: GREEN = 75 to 100% state-of-charge
The battery is adequately charged for further test-
ing and may be returned to use. If the vehicle will
not crank for a maximum 15 seconds, refer to BAT-
TERY LOAD TEST in this Group for more informa-
tion.
NOTE: BLACK OR DARK=0to75%state-of-charge
The battery is INADEQUATELY charged and must
be charged until green dot is visible, (12.4 volts or
greater) before the battery is tested or returned to
BATTERY CHARGING TIMETABLE
Charging
Amperage5
Amperes10
Amperes20
Amperes
Open Circuit
VoltageHours Charging at 21ÉC (70ÉF)
12.25 to 12.39 6 hours 3 hours 1.5 hours
12.00 to 12.24 8 hours 4 hours 2 hours
11.95 to 11.99 12 hours 6 hours 3 hours
10.00 to 11.94 14 hours 7 hours 3.5 hours
less than 10.00 See Charging Completely
Discharged Battery
Fig. 1 Reading Test Indicator
Fig. 2 Battery Construction and Test Indicator
8A - 2 BATTERYNS
DESCRIPTION AND OPERATION (Continued)

BATTERY OPEN CIRCUIT VOLTAGE TEST
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a battery
has open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 6). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 7).
(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 9).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity. Refer to Battery Open Circuit
Voltage table.
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first. (Fig. 4) before charging battery to avoid dam-
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions
supplied with charging equipment
NOTE: The battery cannot be refilled with water, it
must be replaced.
A battery is considered fully charged when it will
meet all the following requirements.
²It has an open circuit voltage charge of at least
12.4 volts.
²It passes the 15 second load test, refer to the
Load Test Temperature chart.
²The built in test indicator dot is GREEN (Fig.
1).
Battery electrolyte will bubble inside of battery
case while being charged properly. If the electrolyte
boils violently, or is discharged from the vent holes
while charging, immediately reduce charging rate or
turn off charger. Evaluate battery condition. Battery
damage may occur if charging is excessive.
Some battery chargers are equipped with polarity
sensing devices to protect the charger or battery from
being damaged if improperly connected. If the bat-
tery state of charge is too low for the polarity sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operating instructions provided
with battery charger being used.
CAUTION: Charge battery until test indicator
appears green. Do not overcharge.
It may be necessary to jiggle the battery or vehicle
to bring the green dot in the test indicator into view.
Fig. 9 Testing Open Circuit Voltage
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit VoltsCharge Per-
centage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
8A - 6 BATTERYNS
DIAGNOSIS AND TESTING (Continued)

After the battery has been charged to 12.4 volts or
greater, perform a load test to determine cranking
capacity. Refer to Battery Load Test in this Group. If
the battery passes the load test, return the battery to
use. If battery will not endure a load test, it must be
replaced. Properly clean and inspect battery hold
downs, tray, terminals, cables, posts, and top before
completing service.
CHARGING COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless procedure is
properly followed, a good battery may be needlessly
replaced. Refer to Battery Charging Rate table.
(1) Measure the voltage at battery posts with a
voltmeter accurate to 1/10 volt (Fig. 10). If below 10
volts, charge current will be low, and it could take
some time before it accepts a current in excess of a
few milliamperes. Such low current may not be
detectable on amp meters built into many chargers.
(2) Connect charger leads. Some chargers feature
polarity protection circuitry that prevents operation
unless charger is connected to battery posts correctly.
A completely discharged battery may not have
enough voltage to activate this circuitry. This may
happen even though the leads are connected properly.
(3) Battery chargers vary in the amount of voltage
and current they provide. For the time required for
the battery to accept measurable charger current at
various voltages, refer to Battery Charging Rate
table. If charge current is still not measurable after
charging times, the battery should be replaced. Ifcharge current is measurable during charging time,
the battery may be good, and charging should be
completed in the normal manner.
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to
enter vent holes, as damage to battery can result.
(1) Clean top of battery with a solution of warm
water and baking soda.
(2) Apply soda solution with a bristle brush and
allow to soak until acid deposits loosen (Fig. 11).
(3) Rinse soda solution from battery with clear
water and blot battery dry with paper toweling. Dis-
pose of toweling in a safe manner. Refer to the
WARNINGS on top of battery.
(4) Inspect battery case and cover for cracks, leak-
age or damaged hold down ledge. If battery is dam-
aged replace it.
(5) Inspect battery tray for damage caused by acid
from battery. If acid is present, clean area with bak-
ing soda solution.
(6) Clean battery posts with a battery post clean-
ing tool (Fig. 12).
(7) Clean battery cable clamps with a battery ter-
minal cleaning tool (Fig. 13). Replace cables that are
frayed or have broken clamps.
BATTERY CHARGING RATE
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
Fig. 10 Voltmeter Accurate to 1/10 Volt (Connected)
Fig. 11 Cleaning Battery
NSBATTERY 8A - 7
SERVICE PROCEDURES (Continued)

SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACITY RATING
The length of time a battery can deliver 25 amps
and maintain a minimum terminal voltage of 10.5
volts at 27ÉC (80ÉF).
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt....................14N´m(125 in. lbs.)
Fig. 19 Speed Control Servo Removal
Load Test
(Amps)Cold Cranking
Rating @ 0ÉFReserve
Capacity
250 Amp 500 Amp 110 Minutes
300 Amp 600 Amp 120 Minutes
340 Amp 685 Amp 125 Minutes
8A - 10 BATTERYNS
REMOVAL AND INSTALLATION (Continued)

BER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SER-
VICING A BATTERY. SAFETY GLASSES ALSO
SHOULD BE WORN.
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
A completely normal vehicle will have a small
amount of current drain on the battery with the key
out of the ignition. It can range from 5 to 25 milli-
amperes after all the modules time out. If a vehicle
will not be operated for approximately a 20 days, the
IOD fuse should be pulled to eliminate the vehicle
electrical drain on the battery. The IOD fuse is
located in the Power Distribution Center (PDC).
Refer to the PDC cover for proper fuse.
CHARGING TIME REQUIRED
WARNING: NEVER EXCEED 20 AMPS WHEN
CHARGING A COLD -1ÉC (30ÉF) BATTERY. PER-
SONAL INJURY MAY RESULT.
The time required to charge a battery will vary
depending upon the following factors.
SIZE OF BATTERY
A completely discharged large heavy-duty battery
may require more recharging time than a completely
discharged small capacity battery, refer to (Fig. 2) for
charging times.
TEMPERATURE
A longer time will be needed to charge a battery at
-18ÉC (0ÉF) than at 27ÉC (80ÉF). When a fast charger
is connected to a cold battery, current accepted by
battery will be very low at first. In time, the battery
will accept a higher rate as battery temperature
warms.
CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a
charger that can supply 20 amperes or more.
STATE OF CHARGE
A completely discharged battery requires more
charging time than a partially charged battery. Elec-
trolyte is nearly pure water in a completely dis-
charged battery. At first, the charging current
amperage will be low. As water is converted back to
sulfuric acid inside the battery, the current amp rate
will rise. Also, the specific gravity of the electrolyte
will rise. The electrolyte should be tested with a
Hydrometer to check the specific gravity.
USING HYDROMETER
Before performing a hydrometer test, remove the
battery caps and check the electrolyte level. Add dis-
tilled water as required.
NOTE: Periodically disassemble the hydrometer
and wash components with soap and water. Inspect
the float for possible leaks. If the paper inside has
turned brown, the float is defective.
Before testing, visually inspect the battery for any
damage:
²Cracked container or cover
²Loose post
²Corrosion
and any other thing that would cause the battery
to be unserviceable. To interpret the hydrometer cor-
rectly, hold it with the top surface of the electrolyte
in the hydrometer at eye level.
Disregard the curvature of the liquid where the
surface rises against the float because of surface
cohesion (Fig. 3). Remove only enough electrolyte
from the battery to keep the float off the bottom of
the hydrometer barrel with pressure on the bulb
released. Keep the hydrometer in a vertical position
while drawing the electrolyte into the hydrometer
and observing the specific gravity. Exercise care
when inserting the tip of the hydrometer into a cell
to avoid damage to the separators. Damaged separa-
tors can cause premature battery failure.
Hydrometer floats are generally calibrated to indi-
cate the specific gravity correctly only at one fixed
temperature, 20ÉC (68ÉF). When testing the specific
gravity at any other temperature, a correction factor
is required, otherwise specific gravity readings will
not indicate the true state of charge.
The correction factor is approximately a specific
gravity value of 0.004, referred to as 4 points of spe-
cific gravity for every 5.5ÉC (10ÉF). If electrolyte tem-
perature is below 20ÉC (68ÉF) you subtract. If the
temperature is above 20ÉC (68ÉF) you add to the
Fig. 2 Battery Charging Time
8A - 2 BATTERYNS/GS
GENERAL INFORMATION (Continued)

(6) If battery passes load test, it is in good condi-
tion and further tests are not necessary. If it fails
load test, it should be replaced.
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a battery
has open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 6). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 7).(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 9).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity (Fig. 10).
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
Fig. 8 Load 50% Cold Crank Rating
Load Test Temperature
Minimum VoltageTemperature
ÉF ÉC
9.6 volts 70É and
above21É and
above
9.5 volts 60É 16É
9.4 volts 50É 10É
9.3 volts 40É 4É
9.1 volts 30É -1É
8.9 volts 20É -7É
8.7 volts 10É -12É
8.5 volts 0É -18É
Fig. 9 Testing Open Circuit Voltage
Fig. 10 Battery Open Circuit Voltage
8A - 6 BATTERYNS/GS
DIAGNOSIS AND TESTING (Continued)

CAUTION: Disconnect the battery NEGATIVE cable
first (Fig. 4) before charging battery to avoid dam-
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions
supplied with charging equipment
A battery is considered fully charged when it will
meet all the following requirements.
²It has an open circuit voltage charge of at least
12.4 volts (Fig. 10).
²It passes the 15 second load test, refer to the
Load Test Temperature chart.
²The specific gravity reading is 1.285 plus 0.015
or minus 0.010.
Battery electrolyte will bubble inside of battery
case while being charged properly. If the electrolyte
boils violently, or is discharged from the vent holes
while charging, immediately reduce charging rate or
turn off charger. Evaluate battery condition. Battery
damage may occur if charging is excessive.
Some battery chargers are equipped with polarity
sensing devices to protect the charger or battery from
being damaged if improperly connected. If the bat-
tery state of charge is too low for the polarity sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operating instructions provided
with battery charger being used.
CAUTION: Do not overcharge Battery.
Test the battery until the specific gravity reading
is 1.285 plus 0.015 or minus 0.010.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine cranking
capacity. Refer to Battery Load Test in this Group. If
the battery passes the load test, return the battery to
use. If battery will not endure a load test, it must be
replaced. Properly clean and inspect battery hold
downs, tray, terminals, cables, posts, and top before
completing service.
CHARGING COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless procedure is
properly followed, a good battery may be needlessly
replaced (Fig. 11).
(1) Measure the voltage at battery posts with a
voltmeter accurate to 1/10 volt (Fig. 12). If below 10
volts, charge current will be low, and it could take
some time before it accepts a current in excess of a
few milliamperes. Such low current may not be
detectable on amp meters built into many chargers.
(2) Connect charger leads. Some chargers feature
polarity protection circuitry that prevents operation
unless charger is connected to battery posts correctly.
A completely discharged battery may not haveenough voltage to activate this circuitry. This may
happen even though the leads are connected properly.
(3) Battery chargers vary in the amount of voltage
and current they provide. For the time required for
the battery to accept measurable charger current at
various voltages, refer to (Fig. 11). If charge current
is still not measurable after charging times, the bat-
tery should be replaced. If charge current is measur-
able during charging time, the battery may be good,
and charging should be completed in the normal
manner.VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to
enter vent holes, as damage to battery can result.
(1) Clean top of battery with a solution of warm
water and baking soda.
(2) Apply soda solution with a bristle brush and
allow to soak until acid deposits loosen (Fig. 13).
(3) Rinse soda solution from battery with clear
water and blot battery dry with paper toweling. Dis-
pose of toweling in a safe manner. Refer to the
WARNINGS on top of battery.
(4) Inspect battery case and cover for cracks, leak-
age or damaged hold down ledge. If battery is dam-
aged replace it.
Fig. 11 Charging Rate
Fig. 12 Voltmeter Accurate to 1/10 Volt (Connected)
NS/GSBATTERY 8A - 7
SERVICE PROCEDURES (Continued)

TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt...................14N´m(125 in. lbs.)
Fig. 20 Speed Control Servo Removal
Reserve Cold Cranking Reserve
(Amps) Rating @ -17.8C (0.0F) Capacity
DIN/BCI
200 Amp 500 Amp 110
Minutes
250 Amp 600 Amp 120
Minutes
315 Amp 685 Amp 125
Minutes
8A - 10 BATTERYNS/GS
SPECIFICATIONS (Continued)

The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints).
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
REMOVAL AND INSTALLATION
GEARSHIFT KNOB
REMOVAL
(1) Pull shifter boot down and away from shifter
roll pin.
(2) Pry legs of shift knob away from shift lever roll
pin using a flat blade pry tool (Fig. 6).(3) Remove knob from shifter handle.
INSTALLATION
(1) For installation, reverse removal procedure,
omitting step (2).
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 7).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 8).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT CABLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect gearshift cable ends from transaxle
shift levers (Fig. 9) (Fig. 10).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 5 Transaxle Drain Plug
Fig. 6 Shifter Knob
Fig. 7 Shifter Boot
NS/GSA±598 MANUAL TRANSAXLE 21 - 5
SERVICE PROCEDURES (Continued)

(3) Remove resistor block by inserting a flat blade
pry tool on the side of the resistor block and pushing
inward. Two guide lines are shown on the right hand
edge of the resistor block to help guide the blade
position. This will release the clips on the side of the
resistor block. Pull resistor block out.
INSTALLATION
For installation, reverse the above procedures.
Make sure the ªTOPº lettering is on the top of the
resistor. The coils on the Resistor Block should not be
contacting one another. Before installation, gently
separate the coils (with fingers only) if one coil is
contacting another.
BLOWER MOTOR WHEEL
The blower motor wheel is not serviced separately.
If the wheel needs to be replaced it is serviced as an
assembly of the blower motor. For service procedure
information, refer to Blower Motor Replacement in
this group.
COMPRESSOR (2.5L TURBO DIESEL)
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE
PROCEDURES FOR INFORMATION REGARDING
PROPER RECOVERY OF THE REFRIGERANT
BEFORE ATTEMPTING TO REMOVE THE COM-
PRESSOR.(1) Disconnect negative battery cable.
(2) Reclaim refrigerant.
(3) Raise vehicle on hoist.
(4) Remove refrigerant lines from compressor and
cap all lines (Fig. 10).
(5) Remove flex drive bolts from behind the power
steering pump (Fig. 20).
(6) Remove compressor mounting bolts (Fig. 20).
(7) pry compressor off of the dowel pins and
remove compressor.
INSTALLATION
(1) Transfer mounting spacer/bushings onto the
new compressor.
(2) Lift compressor into place and start compressor
mounting bolts. Do not tighten bolts at this time. The
compressor may have to be moved slightly to align
the flex drive bolts.
(3) Align compressor clutch with flex drive. Then
start both flex drive bolts. Tighten the bolts after
both flex drive bolts have been installed.
(4) Tighten compressor mounting bolts.
(5) Lower vehicle and install refrigerant lines.
Always replace O-rings and gaskets.
(6) Evacuate refrigerant system. Charge system
with the correct amount of R-134a refrigerant. The
refrigerant capacity is .91 kg.67 gm. (32 oz.62.0
oz.).
24 - 22 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)