ECO mode CHRYSLER VOYAGER 2004 User Guide

izer, do not remove the locking pliers until
reinstallation of the cable is complete.(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 100).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 100). (5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 101). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 101).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
REMOVAL - PARKING BRAKE CABLE (RIGHT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in the rear parking brake cables
by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 102).
(5) Disconnect the right rear parking brake cable
from the connector on the intermediate cable (Fig.
103). (6) To remove the right parking brake cable hous-
ing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers (Fig. 104). The alternate method
using an aircraft type hose clamp will not work on
the right side of the vehicle. (7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
Fig. 100 Parking Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 101 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 102 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RS BRAKES5s-63
CABLES - PARKING BRAKE (Continued)

(5) AWD only - Remove the spring washer (Fig.
115) from the stub shaft of the outer C/V joint.
(6) AWD only - Remove the hub nut and washer
(Fig. 116) from the stub shaft of the outer C/V joint.
(7) Release the parking brake. (8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 117).
(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 118).
Fig. 115 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 116 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 117 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 118 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 70 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.
(15) Install the park brake cable into its mounting
hole in the adapter. Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter. (16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 121). (17) Attach park brake cable to adapter using
mounting bolt. (18) Remove the locking pliers (Fig. 117) from the
front park brake cable. (19) Adjust the park brake drum-in-hat brake
shoes. (Refer t o 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS). (20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 119).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 118).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.). (23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 116) on the stub shaft of
the outer C/V joint. (24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.). (26) AWD only - Install the spring washer (Fig.
115) on the stub shaft of the outer C/V joint. (27) AWD only - Install the nut retainer and cotter
pin (Fig. 114) on the stub shaft of the outer C/V joint. (28) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.). (29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum. (5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent, accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
137). (6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 138).
Fig. 136 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 76 BRAKESRS
SHOES - PARKING BRAKE (Continued)

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM.............................3
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT.......................6
DIAGNOSIS AND TESTING - CLUTCH
COVER AND DISC RUNOUT..............6
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS.................6
SPECIAL TOOLS - T850 TRANSAXLE........6
CLUTCH RELEASE LEVER AND BEARING
REMOVAL.............................6
INSTALLATION..........................7
MASTER CYLINDER - RHD
REMOVAL.............................8
INSTALLATION..........................9
MASTER CYLINDER - LHD
REMOVAL.............................9INSTALLATION.........................10
MODULAR CLUTCH ASSY - 2.4L GAS
REMOVAL.............................11
INSTALLATION.........................11
SLAVE CYLINDER
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH DISC AND PRESSURE PLATE - 2.5L TD
REMOVAL.............................11
INSTALLATION.........................12
FLYWHEEL
REMOVAL.............................12
INSTALLATION.........................12
CLUTCH PEDAL INTERLOCK SWITCH
REMOVAL.............................13
INSTALLATION.........................14
CLUTCH PEDAL UPSTOP SWITCH
REMOVAL.............................15
INSTALLATION.........................16
CLUTCH
DESCRIPTION
CLUTCH COMPONENTS
Models equipped with a 2.4L Gas engine utilize a
modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.
Models equipped with the 2.5L Turbo Diesel engine
utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it ishighly
recommended that the clutch cover and disc be
replaced as a set.
Fig. 1 Modular Clutch AssemblyÐ2.4L Gas Engines
1 - MODULAR CLUTCH ASSEMBLY
RSCLUTCH6-1

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY NOT BE
READING HIGH.1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture too concentrated or
too diluted.2. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
3. Incorrect cooling system
pressure cap.3. Install correct pressure cap.
HOSE(S) COLLAPSE AS ENGINE
COOLS DOWN.1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
recovery system.1. (a) Pressure cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING)
Replace as necessary.
(b) Hose between the radiator and
overflow container is plugged or
pinched. Clean and repair as
necessary.
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent
and repair as necessary.
(d) Reserve/overflow container is
internally blocked. Clean and repair
as necessary.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED).1. Radiator and/or A/C condenser is
restricted, obstructed, or dirty
(insects, leaves, etc.).1. Remove restriction and/or clean
as necessary.
2. Electrical radiator fan not
operating when A/C is operated.2. For test procedure (Refer to
appropriate Diagnostic Information).
Repair as necessary.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.3. Correct overheating condition.
4. All models are equipped with air
seals at the radiator and/or A/C
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.4. Check for missing or damaged air
seals and repair as necessary.
INADEQUATE HEATER
PERFORMANCE.1. Check for a Diagnostic trouble
code (DTC).1. For procedures, (Refer to
appropriate Diagnostic Information).
Repair as necessary.
2. Coolant level low. 2. (Refer to 7 - COOLING -
STANDARD PROCEDURE) Repair
as necessary.
RSENGINE7-15
ENGINE (Continued)

for checking coolant level and adjusting level at
atmospheric pressure without removing the radiator
pressure cap. It also provides some reserve coolant to
cover deaeration, evaporation, or boiling losses.
DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator.
(1) With the engineoffand cooling systemnot
under pressure, drain several ounces of coolant from
the radiator draincock while observing the coolant
recovery container. Coolant level in the container
should drop.
(2) Remove the radiator pressure cap. The coolant
level should be full to the top radiator neck. If not,
and the coolant level in the container is at or above
the MIN mark, there is an air leak in the coolant
recovery system.
(3) Check hose and hose connections to the con-
tainer, radiator filler neck or the pressure cap seal to
the radiator filler neck for leaks.
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the lower attaching screws (Fig. 2).
(3) Lower the vehicle.
(4) Remove the upper attaching screw (Fig. 2).
(5) Disconnect recovery hose from container (Fig.
2).
(6) Remove the recovery container.
INSTALLATION
(1) Connect the recovery hose to container (Fig. 2).
(2) Position the recovery container on the frame
rail (Fig. 2).
(3) Install the upper attaching screw and tighten
to 7 N´m (60 in. lbs.) (Fig. 2).
(4) Raise the vehicle on hoist.
(5) Install the lower attaching screws and tighten
to 8.5 N´m (75 in. lbs.) (Fig. 2).
(6) Lower the vehicle.
(7) Add coolant to container as necessary. (Refer to
7 - COOLING - STANDARD PROCEDURE)
ENGINE BLOCK HEATER
DESCRIPTION
The engine block heater is available as an optional
accessory on all models. The heater is operated by
ordinary house current (110 Volt A.C.) through a
power cord located behind the radiator grille. This
provides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures. The heater is mounted in a core
hole (in place of a core hole plug) in the engine block,
with the heating element immersed in coolant.
OPERATION
The block heater element is submerged in the cool-
ing system's coolant. When electrical power (110 volt
A.C.) is applied to the element, it creates heat. This
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
(2) Disconnect the power cord plug from heater.
(3) Loosen screw in center of heater. Remove the
heater assembly.
INSTALLATION
(1) Clean block core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
Fig. 2 Coolant Recovery Container
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
7 - 20 ENGINERS
COOLANT RECOVERY CONTAINER (Continued)

AUDIO
TABLE OF CONTENTS
page page
AUDIO/VIDEO
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - AUDIO..........2
ANTENNA BODY AND CABLE
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE..........................4
REMOVAL.............................5
INSTALLATION..........................6
ANTENNA MODULE - EXPORT
DESCRIPTION..........................6
OPERATION............................6
DIAGNOSIS AND TESTING - ANTENNA
MODULE - EXPORT....................7
REMOVAL.............................7
INSTALLATION..........................7
CD CHANGER
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................8
INSTALLATION..........................8
DVD PLAYER
DESCRIPTION..........................8
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................8
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL.............................8
INSTALLATION..........................9QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - QUARTER
GLASS INTEGRAL ANTENNA - EXPORT.....9
RADIO
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - RADIO.........10
REMOVAL.............................11
INSTALLATION.........................11
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION.........................11
OPERATION...........................12
REMOTE SWITCHES
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - REMOTE
SWITCHES..........................12
REMOVAL.............................13
INSTALLATION.........................14
SPEAKER
DIAGNOSIS AND TESTING - SPEAKER......14
REMOVAL.............................14
INSTALLATION.........................15
VIDEO SCREEN
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
AUDIO/VIDEO
DESCRIPTION
An audio system is standard factory-installed
equipment on this model. A rear seat video system is
an available option. Several combinations of radio
receivers are offered on this model. The audio/video
system uses an ignition switched source of battery
current so that the system will only operate when
the ignition switch is in the RUN or ACCESSORY/
ACCESSORY DELAY positions.
The audio system includes the following compo-
nents:
²Antenna
²CD changer (if equipped)
²DVD player (if equipped)²Radio noise suppression components
²Radio receiver
²Speakers
²Video screen (if equipped)
Certain functions and features of the audio/video
system rely upon resources shared with other elec-
tronic modules in the vehicle over the Programmable
Communication Interface (PCI) bus network. The
data bus network allows the sharing of sensor infor-
mation. For diagnosis of these electronic modules or
of the data bus network, the use of a DRB IIItscan
tool and the proper Diagnostic Procedures manual
are recommended.
Refer to the appropriate wiring information in this
service manual for complete standard and premium
audio system circuit diagrams. The wiring informa-
tion includes proper wire and connector repair proce-
RSAUDIO8A-1

motors, and fuel pumps that have been found to be
potential sources of RFI or EMI.
OPERATION
There are two common strategies that can be used
to suppress Radio Frequency Interference (RFI) and
ElectroMagnetic Interference (EMI) radio noise. The
first suppression strategy involves preventing the
production of RFI and EMI electromagnetic signals
at their sources. The second suppression strategy
involves preventing the reception of RFI and EMI
electromagnetic signals by the audio system compo-
nents.
The use of braided ground straps in key locations
is part of the RFI and EMI prevention strategy.
These ground straps ensure adequate ground paths,
particularly for high current components such as
many of those found in the starting, charging, igni-
tion, engine control and transmission control sys-
tems. An insufficient ground path for any of these
high current components may result in radio noise
caused by induced voltages created as the high cur-
rent seeks alternative ground paths through compo-
nents or circuits intended for use by, or in close
proximity to the audio system components or circuits.
Preventing the reception of RFI and EMI is accom-
plished by ensuring that the audio system compo-
nents are correctly installed in the vehicle. Loose,
corroded or improperly soldered wire harness connec-
tions, improperly routed wiring and inadequate audio
system component grounding can all contribute to
the reception of RFI and EMI. A properly grounded
antenna body and radio chassis, as well as a shielded
antenna coaxial cable with clean and tight connec-
tions will each help reduce the potential for reception
of RFI and EMI.
REMOTE SWITCHES
DESCRIPTION
A remote radio control switch option is available on
some models. Two rocker-type switches are mounted
on the back (instrument panel side) of the steering
wheel spokes (Fig. 12). The switch on the left spoke
is the seek switch and has seek up, seek down, and
preset station advance functions. The switch on the
right spoke is the volume control switch and has vol-
ume up, and volume down functions. The switch on
the right spoke also includes a ªmodeº control that
allows the driver to sequentially select AM radio, FM
radio, cassette player, CD player or CD changer (if
equipped).
OPERATION
These switches are resistor multiplexed units that
are hard-wired to the Body Control Module (BCM)
through the clockspring. The BCM sends the proper
messages on the Programmable Communications
Interface (PCI) data bus network to the radio
receiver. For diagnosis of the BCM or the PCI data
bus, the use of a DRB IIItscan tool and the proper
Diagnostic Procedures manual are recommended. For
more information on the operation of the remote
radio switch controls, refer to the owner's manual in
the vehicle glove box.
DIAGNOSIS AND TESTING - REMOTE
SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
Fig. 12 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
8A - 12 AUDIORS
RADIO NOISE SUPPRESSION COMPONENTS (Continued)

SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
There are three different batteries available on this
model. Vehicles equipped with a diesel engine utilize
a spiral wound plate designed battery with recombi-
nation technology. This is a maintenance-free battery
that is capable of delivering more power than a con-
ventional battery. This additional power is required
by a diesel engine during cold cranking. Vehicles
equipped with a gasoline engine utilize a conven-
tional battery. Refer to the following information for
detailed differences and descriptions of these batter-
ies.
SPIRAL PLATE BATTERY - DIESEL ENGINE
Spiral plate technology takes the elements of tradi-
tional batteries - lead and sulfuric acid - to the next
level. By tightly winding layers of spiral grids and
acid-permeated vitreous separators into cells, the
manufacturer has developed a battery with more
power and service life than conventional batteries the
same size. The spiral plate battery is completely, per-
manently sealed. Through gas recombination, hydro-
gen and oxygen within the battery are captured
during normal charging and reunited to form the
water within the electrolyte, eliminating the need to
add distilled water. Therefore, these batteries havenon-removable battery vent caps (Fig. 4). Watercan-
notbe added to this battery.
The acid inside a spiral plate battery is bound
within the vitreous separators, ending the threat of
acid leaks. This feature allows the battery to be
installed in any position anywhere in the vehicle.
Spiral plate technology is the process by which the
plates holding the active material in the battery are
wound tightly in coils instead of hanging flat, like
conventional batteries. This design has a lower inter-
nal resistance and also increases the active material
surface area.
WARNING: NEVER EXCEED 14.4 VOLTS WHEN
CHARGING A SPIRAL PLATE BATTERY. PERSONAL
INJURY AND/OR BATTERY DAMAGE MAY RESULT.
Due to the maintanance-free design, distilled water
cannot be added to this battery. Therefore, if more
than 14.4 volts are used during the spiral plate bat-
tery charging process, water vapor can be exhausted
through the pressure-sensitive battery vents and lost
for good. This can permanently damage the spiral
plate battery. Never exceed 14.4 volts when charging
a spiral plate battery. Personal injury and/or battery
damage may result.
CONVENTIONAL BATTERY - GASOLINE ENGINE
Low-maintenance batteriesare used on export
vehicles equipped with a gasoline engine, these bat-
teries have removable battery cell caps (Fig. 5).
Watercanbe added to this battery. Under normal
MICRO 420 BATTERY TESTER
Fig. 4 MAINTENANCE-FREE DIESEL ENGINE
BATTERY
RSBATTERY SYSTEM8F-7
BATTERY SYSTEM (Continued)

service, the composition of this battery reduces gas-
sing and water loss at normal charge rates. However
these batteries may require additional distilled water
after years of service.
Maintenance-free batteriesare standard facto-
ry-installed equipment on all domestic versions of
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 sys-
tem. The battery positive terminal post is visibly
larger in diameter than the negative terminal post,
for easy identification. The lettersPOSandNEGare
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 thenegative 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
chemical composition of the metal coated plates
within the low-maintenance battery used in export
models reduces battery gassing and water loss at
normal charge and discharge rates. Therefore, the
battery should not require additional water in nor-
mal service. If the electrolyte level in this battery
does become low, distilled water must be added. How-
ever, 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 toCharging
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
Fig. 5 BATTERY CELL CAP REMOVAL/
INSTALLATION - LOW-MAINTANANCE GASOLINE
ENGINE BATTERY - EXPORT
1 - BATTERY CELL CAP
2 - BATTERY CASE
Fig. 6 Maintenance-Free Battery - Domestic
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - INDICATOR EYE (if equipped)
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - MAINTENANCE-FREE BATTERY
8F - 8 BATTERY SYSTEMRS
BATTERY (Continued)