Temperature DODGE RAM 2001 Service Service Manual

Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO/POOR TAPE
OPERATION1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.2. Remove foreign objects and test operation.
3. Dirty cassette tape
head.3. Clean head with Mopar Cassette Head Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on
CD.2. Clean CD and test operation.
3. Condensation on CD
or optics.3. Allow temperature of vehicle interior to stabilize and test
operation.
4. Faulty CD player. 4. Exchange or replace radio, if required.
SPECIAL TOOLS
AUDIO SYSTEMS
ANTENNA BODY & CABLE
DESCRIPTION
The antenna body and cable are not readily visible
in their installed positions in the vehicle. The most
visible component of the antenna body and cable are
the antenna adapter and the antenna cap nut, which
are located on the top of the right front fender panel
of the vehicle, near the right end of the cowl plenum.
The antenna body and cable are secured below the
fender panel by the antenna cap nut through a pre-
fabricated and dedicated mounting hole in the top of
the right front fender. The primary coaxial antenna
cable is then routed beneath the fender sheet metal
and through a prefabricated and dedicated cable
entry hole in the right cowl side panel into the inte-
rior of the vehicle. Inside the vehicle, the primary
coaxial cable is connected to a secondary instrument
panel antenna coaxial cable with an in-line connector
that is located behind the right end of the instrumentpanel. The secondary coaxial cable is then routed
behind the instrument panel to the back of the radio.
The factory-installed radio antenna body and cable
consists of the following components:
²Antenna adapter- The antenna adapter is
sometimes also referred to as the antenna bezel or
escutcheon.
²Antenna body- The die cast white metal
antenna body is the mating structure between the
antenna mast and the primary antenna coaxial cable.
²Antenna cable- This vehicle uses a two-piece
antenna coaxial cable. The primary antenna cable is
integral to the antenna body, and the secondary
antenna cable connects the primary cable to the
radio.
²Antenna cap nut- The antenna cap nut is a
special, bright-plated threaded fastener that captures
the antenna adapter and retains the antenna body to
the fender sheet metal.
The components of the radio antenna body and
cable cannot be adjusted or repaired. All factory-in-
stalled radios automatically compensate for radio
antenna trim. Therefore, no antenna trimmer adjust-
ment is required or possible after replacing the
antenna body and cable or the radio. If an antenna
body and cable component is damaged or faulty, it
must be replaced. Other than the primary antenna
cable, which is integral to the antenna body, the indi-
vidual components of the antenna are available for
service replacement.
OPERATION
The antenna body and cable connects the antenna
mast to the radio. The radio antenna is an electro-
magnetic circuit component used to capture radio fre-
quency signals that are broadcast by local
Antenna Nut Wrench C-4816
8A - 4 AUDIOBR/BE
AUDIO (Continued)

ENGINE CONTROL MODULE
DESCRIPTION - ECM
The ECM is bolted to the left side of the engine
behind the fuel filter (Fig. 14). It is a separate com-
ponent and can be serviced. The FPCM is internal to
the fuel injection pump (Fig. 15) and cannot be ser-
viced.
OPERATION - ECM
The main functions of the Engine Control Module
(ECM) and Fuel Injection Pump Control Module
(FPCM) are to electrically control the fuel system.
The Powertrain Control Module (PCM)does not
controlthe fuel system.
The ECM can adapt its programming to meet
changing operating conditions.If the ECM has
been replaced, flashed or re-calibrated, the
ECM must learn the Accelerator Pedal Position
Sensor (APPS) idle voltage. Failure to learn
this voltage may result in unnecessary diagnos-
tic trouble codes. Refer to ECM Removal/Instal-
lation for learning procedures.
The ECM receives input signals from various
switches and sensors. Based on these inputs, the
ECM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to asECM Outputs.The sensors
and switches that provide inputs to the ECM are
consideredECM Inputs.NOTE: ECM Inputs:
²Accelerator Pedal Position Sensor (APPS) Volts
²APPS Idle Validation Switches #1 and #2
²Battery voltage
²Camshaft Position Sensor (CMP)
²CCD bus (+) circuits
²CCD bus (-) circuits
²Crankshaft Position Sensor (CKP)
²Data link connection for DRB scan tool
²(FPCM) Fuel Injection Pump Control Module
²Engine Coolant Temperature (ECT) sensor
²Ground circuits
²Intake manifold Air Temperature (IAT) sensor
²Manifold Air Pressure Sensor (Boost Pressure
Sensor)
²Oil pressure sensor
²PCM
²Power Take Off (PTO)
²Power ground
²Sensor return
²Signal ground
²Water-In-Fuel (WIF) sensor
Fig. 14 Engine Control Module (ECM) Location
1 - ENGINE CONTROL MODULE (ECM)
2 - HEX HEADED BOLT
3 - 50-WAY CONNECTOR
4 - FUEL TRANSFER PUMP
5 - MOUNTING BOLTS (3)
Fig. 15 Fuel Injection Pump Control Module (FPCM)
Location
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
BR/BEELECTRONIC CONTROL MODULES 8E - 13

During Open Loop modes, the PCM receives input
signals and responds only according to preset PCM
programming. Input from the oxygen (O2S) sensors
is not monitored during Open Loop modes.
During Closed Loop modes, the PCM will monitor
the oxygen (O2S) sensors input. This input indicates
to the PCM whether or not the calculated injector
pulse width results in the ideal air-fuel ratio. This
ratio is 14.7 parts air-to-1 part fuel. By monitoring
the exhaust oxygen content through the O2S sensor,
the PCM can fine tune the injector pulse width. This
is done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
²Ignition switch ON
²Engine start-up (crank)
²Engine warm-up
²Idle
²Cruise
²Acceleration
²Deceleration
²Wide open throttle (WOT)
²Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem-
perature) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following
actions occur:²The PCM pre-positions the idle air control (IAC)
motor.
²The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
strategy.
²The PCM monitors the engine coolant tempera-
ture sensor input. The PCM modifies fuel strategy
based on this input.
²Intake manifold air temperature sensor input is
monitored.
²Throttle position sensor (TPS) is monitored.
²The auto shutdown (ASD) relay is energized by
the PCM for approximately three seconds.
²The fuel pump is energized through the fuel
pump relay by the PCM. The fuel pump will operate
for approximately three seconds unless the engine is
operating or the starter motor is engaged.
²The O2S sensor heater element is energized via
the ASD relay. The O2S sensor input is not used by
the PCM to calibrate air-fuel ratio during this mode
of operation.
ENGINE START-UP MODE
This is an Open Loop mode. The following actions
occur when the starter motor is engaged.
The PCM receives inputs from:
²Battery voltage
²Engine coolant temperature sensor
²Crankshaft position sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Starter motor relay
²Camshaft position sensor signal
The PCM monitors the crankshaft position sensor.
If the PCM does not receive a crankshaft position
sensor signal within 3 seconds of cranking the
engine, it will shut down the fuel injection system.
The fuel pump is activated by the PCM through
the fuel pump relay.
Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off.
The PCM determines the proper ignition timing
according to input received from the crankshaft posi-
tion sensor.
ENGINE WARM-UP MODE
This is an Open Loop mode. During engine warm-
up, the PCM receives inputs from:
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
Fig. 17 PCM Location
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
BR/BEELECTRONIC CONTROL MODULES 8E - 15
POWERTRAIN CONTROL MODULE (Continued)

²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal (in the distribu-
tor)
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
Based on these inputs the following occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off.
²The PCM adjusts engine idle speed through the
idle air control (IAC) motor and adjusts ignition tim-
ing.
²The PCM operates the A/C compressor clutch
through the clutch relay. This is done if A/C has been
selected by the vehicle operator and requested by the
A/C thermostat.
²When engine has reached operating tempera-
ture, the PCM will begin monitoring O2S sensor
input. The system will then leave the warm-up mode
and go into closed loop operation.
IDLE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At idle speed, the PCM
receives inputs from:
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal (in the distribu-
tor)
²Battery voltage
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Oxygen sensors
Based on these inputs, the following occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
injection sequence and injector pulse width by turn-
ing the ground circuit to each individual injector on
and off.
²The PCM monitors the O2S sensor input and
adjusts air-fuel ratio by varying injector pulse width.
It also adjusts engine idle speed through the idle air
control (IAC) motor.
²The PCM adjusts ignition timing by increasing
and decreasing spark advance.²The PCM operates the A/C compressor clutch
through the clutch relay. This happens if A/C has
been selected by the vehicle operator and requested
by the A/C thermostat.
CRUISE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At cruising speed, the PCM
receives inputs from:
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
²Battery voltage
²Engine coolant temperature sensor
²Crankshaft position sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal (in the distribu-
tor)
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Oxygen (O2S) sensors
Based on these inputs, the following occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then adjust
the injector pulse width by turning the ground circuit
to each individual injector on and off.
²The PCM monitors the O2S sensor input and
adjusts air-fuel ratio. It also adjusts engine idle
speed through the idle air control (IAC) motor.
²The PCM adjusts ignition timing by turning the
ground path to the coil on and off.
²The PCM operates the A/C compressor clutch
through the clutch relay. This happens if A/C has
been selected by the vehicle operator and requested
by the A/C thermostat.
ACCELERATION MODE
This is an Open Loop mode. The PCM recognizes
an abrupt increase in throttle position or MAP pres-
sure as a demand for increased engine output and
vehicle acceleration. The PCM increases injector
pulse width in response to increased throttle opening.
DECELERATION MODE
When the engine is at operating temperature, this
is an Open Loop mode. During hard deceleration, the
PCM receives the following inputs.
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
²Battery voltage
²Engine coolant temperature sensor
²Crankshaft position sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
8E - 16 ELECTRONIC CONTROL MODULESBR/BE
POWERTRAIN CONTROL MODULE (Continued)

²Camshaft position sensor signal (in the distribu-
tor)
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Vehicle speed sensor
If the vehicle is under hard deceleration with the
proper rpm and closed throttle conditions, the PCM
will ignore the oxygen sensor input signal. The PCM
will enter a fuel cut-off strategy in which it will not
supply a ground to the injectors. If a hard decelera-
tion does not exist, the PCM will determine the
proper injector pulse width and continue injection.
Based on the above inputs, the PCM will adjust
engine idle speed through the idle air control (IAC)
motor.
The PCM adjusts ignition timing by turning the
ground path to the coil on and off.
WIDE OPEN THROTTLE MODE
This is an Open Loop mode. During wide open
throttle operation, the PCM receives the following
inputs.
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal (in the distribu-
tor)
During wide open throttle conditions, the following
occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off. The PCM ignores the oxygen sensor input
signal and provides a predetermined amount of addi-
tional fuel. This is done by adjusting injector pulse
width.
²The PCM adjusts ignition timing by turning the
ground path to the coil on and off.
IGNITION SWITCH OFF MODE
When ignition switch is turned to OFF position,
the PCM stops operating the injectors, ignition coil,
ASD relay and fuel pump relay.
DESCRIPTION - 5 VOLT SUPPLIES
Two different Powertrain Control Module (PCM)
five volt supply circuits are used; primary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
This circuit ties the ignition switch to the Power-
train Control Module (PCM).
DESCRIPTION - POWER GROUNDS
The Powertrain Control Module (PCM) has 2 main
grounds. Both of these grounds are referred to as
power grounds. All of the high-current, noisy, electri-
cal devices are connected to these grounds as well as
all of the sensor returns. The sensor return comes
into the sensor return circuit, passes through noise
suppression, and is then connected to the power
ground.
The power ground is used to control ground cir-
cuits for the following PCM loads:
²Generator field winding
²Fuel injectors
²Ignition coil(s)
²Certain relays/solenoids
²Certain sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return circuits are internal to the Pow-
ertrain Control Module (PCM).
Sensor Return provides a low±noise ground refer-
ence for all engine control system sensors. Refer to
Power Grounds for more information.
DESCRIPTION - SIGNAL GROUND
Signal ground provides a low noise ground to the
data link connector.
OPERATION - PCM - GAS ENGINES
The PCM operates the fuel system. The PCM is a
pre-programmed, triple microprocessor digital com-
puter. It regulates ignition timing, air-fuel ratio,
emission control devices, charging system, certain
transmission features, speed control, air conditioning
compressor clutch engagement and idle speed. The
PCM can adapt its programming to meet changing
operating conditions.
The PCM receives input signals from various
switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to as Powertrain Control Module
(PCM) Outputs. The sensors and switches that pro-
vide inputs to the PCM are considered Powertrain
Control Module (PCM) Inputs.
The PCM adjusts ignition timing based upon
inputs it receives from sensors that react to: engine
rpm, manifold absolute pressure, engine coolant tem-
perature, throttle position, transmission gear selec-
tion (automatic transmission), vehicle speed and the
brake switch.
The PCM adjusts idle speed based on inputs it
receives from sensors that react to: throttle position,
vehicle speed, transmission gear selection, engine
coolant temperature and from inputs it receives from
the air conditioning clutch switch and brake switch.
BR/BEELECTRONIC CONTROL MODULES 8E - 17
POWERTRAIN CONTROL MODULE (Continued)

Based on inputs that it receives, the PCM adjusts
ignition coil dwell. The PCM also adjusts the gener-
ator charge rate through control of the generator
field and provides speed control operation.
NOTE: PCM Inputs:
²A/C request (if equipped with factory A/C)
²A/C select (if equipped with factory A/C)
²Auto shutdown (ASD) sense
²Battery temperature
²Battery voltage
²Brake switch
²CCD bus (+) circuits
²CCD bus (-) circuits
²Camshaft position sensor signal
²Crankshaft position sensor
²Data link connection for DRB scan tool
²Engine coolant temperature sensor
²Fuel level
²Generator (battery voltage) output
²Ignition circuit sense (ignition switch in on/off/
crank/run position)
²Intake manifold air temperature sensor
²Leak detection pump (switch) sense (if equipped)
²Manifold absolute pressure (MAP) sensor
²Oil pressure
²Output shaft speed sensor
²Overdrive/override switch
²Oxygen sensors
²Park/neutral switch (auto. trans. only)
²Power ground
²Sensor return
²Signal ground
²Speed control multiplexed single wire input
²Throttle position sensor
²Transmission governor pressure sensor
²Transmission temperature sensor
²Vehicle speed inputs from ABS or RWAL system
NOTE: PCM Outputs:
²A/C clutch relay
²Auto shutdown (ASD) relay
²CCD bus (+/-) circuits for: speedometer, voltme-
ter, fuel gauge, oil pressure gauge/lamp, engine temp.
gauge and speed control warn. lamp
²Data link connection for DRB scan tool
²EGR valve control solenoid (if equipped)
²EVAP canister purge solenoid
²Five volt sensor supply (primary)
²Five volt sensor supply (secondary)
²Fuel injectors
²Fuel pump relay
²Generator field driver (-)
²Generator field driver (+)
²Generator lamp (if equipped)²Idle air control (IAC) motor
²Ignition coil
²Leak detection pump (if equipped)
²Malfunction indicator lamp (Check engine lamp).
Driven through CCD circuits.
²Overdrive indicator lamp (if equipped)
²Service Reminder Indicator (SRI) Lamp (MAINT
REQ'D lamp). Driven through CCD circuits.
²Speed control vacuum solenoid
²Speed control vent solenoid
²Tachometer (if equipped). Driven through CCD
circuits.
²Transmission convertor clutch circuit
²Transmission 3±4 shift solenoid
²Transmission relay
²Transmission temperature lamp (if equipped)
²Transmission variable force solenoid
OPERATION - DIESEL
Two different control modules are used: The Pow-
ertrain Control Module (PCM), and the Engine Con-
trol Module (ECM). The ECMcontrolsthe fuel
system. The PCMdoes not controlthe fuel system.
The PCM's main function is to control: the vehicle
charging system, speed control system, transmission,
air conditioning system and certain bussed messages.
The PCM can adapt its programming to meet
changing operating conditions.
The PCM receives input signals from various
switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to asPCM Outputs.The sensors
and switches that provide inputs to the PCM are con-
sideredPCM Inputs.
NOTE: PCM Inputs:
²A/C request (if equipped with factory A/C)
²A/C select (if equipped with factory A/C)
²Accelerator Pedal Position Sensor (APPS) output
from ECM
²Auto shutdown (ASD) relay sense
²Battery temperature sensor
²Battery voltage
²Brake switch
²CCD bus (+) circuits
²CCD bus (-) circuits
²Crankshaft Position Sensor (CKP) output from
ECM
²Data link connection for DRB scan tool
²Fuel level sensor
²Generator (battery voltage) output
²Ignition sense
²Output shaft speed sensor
²Overdrive/override switch
²Park/neutral switch (auto. trans. only)
8E - 18 ELECTRONIC CONTROL MODULESBR/BE
POWERTRAIN CONTROL MODULE (Continued)

²Power ground
²Sensor return
²Signal ground
²Speed control resume switch
²Speed control set switch
²Speed control on/off switch
²Transmission governor pressure sensor
²Transmission temperature sensor
²Vehicle speed inputs from ABS or RWAL system
NOTE: PCM Outputs:
After inputs are received by the PCM, certain sen-
sors, switches and components are controlled or reg-
ulated by the PCM. These are consideredPCM
Outputs.These outputs are for:
²A/C clutch relay and A/C clutch
²Auto shutdown (ASD) relay
²CCD bus (+/-) circuits for: speedometer, voltme-
ter, fuel gauge, oil pressure gauge/lamp, engine temp.
gauge and speed control warn. lamp
²Data link connection for DRB scan tool
²Five volt sensor supply
²Generator field driver (-)
²Generator field driver (+)
²Generator lamp (if equipped)
²Malfunction indicator lamp (Check engine lamp)
²Overdrive warning lamp (if equipped)
²Speed control vacuum solenoid
²Speed control vent solenoid
²Tachometer (if equipped)
²Transmission convertor clutch circuit
²Transmission 3±4 shift solenoid
²Transmission relay
²Transmission temperature lamp (if equipped)
²Transmission variable force solenoid (governor
sol.)
OPERATION - 5 VOLT SUPPLIES
Primary 5±volt supply:
²supplies the required 5 volt power source to the
Crankshaft Position (CKP) sensor.
²supplies the required 5 volt power source to the
Camshaft Position (CMP) sensor.
²supplies a reference voltage for the Manifold
Absolute Pressure (MAP) sensor.
²supplies a reference voltage for the Throttle
Position Sensor (TPS) sensor.
Secondary 5±volt supply:
²supplies the required 5 volt power source to the
oil pressure sensor.
²supplies the required 5 volt power source for the
Vehicle Speed Sensor (VSS) (if equipped).
²supplies the 5 volt power source to the transmis-
sion pressure sensor (if equipped with an RE auto-
matic transmission).
OPERATION - IGNITION CIRCUIT SENSE
The ignition circuit sense input tells the PCM the
ignition switch has energized the ignition circuit.
Battery voltage is also supplied to the PCM
through the ignition switch when the ignition is in
the RUN or START position. This is referred to as
the9ignition sense9circuit and is used to9wake up9
the PCM. Voltage on the ignition input can be as low
as 6 volts and the PCM will still function. Voltage is
supplied to this circuit to power the PCM's 8-volt reg-
ulator and to allow the PCM to perform fuel, ignition
and emissions control functions.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM is located in the engine compartment
(Fig. 18).
To avoid possible voltage spike damage to the
PCM, ignition key must be off, and negative battery
cable must be disconnected before unplugging PCM
connectors.
(1) Disconnect negative battery cable(s) at bat-
tery(s).
(2) Remove cover over electrical connectors. Cover
snaps onto PCM.
(3) Carefully unplug the three 32±way connectors
from PCM.
Fig. 18 PCM Location and Mounting
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
BR/BEELECTRONIC CONTROL MODULES 8E - 19
POWERTRAIN CONTROL MODULE (Continued)

WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condition of a battery is determined by two cri-
teria:
²State-Of-Charge- This can be determined by
checking the specific gravity of the battery electrolyte
(built-in indicator test or hydrometer test), or by
checking the battery voltage (open-circuit voltage
test).
²Cranking Capacity- This can be determined
by performing a battery load test, which measures
the ability of the battery to supply high-amperage
current.
First, determine the battery state-of-charge. This
can be done in one of three ways. If the battery has a
built-in test indicator, perform the built-in indicator
test to determine the state-of-charge. If the battery
has no built-in test indicator but does have remov-
able cell caps, perform the hydrometer test to deter-
mine the state-of-charge. If the battery cell caps are
not removable, or a hydrometer is not available, per-
form the open-circuit voltage test to determine the
state-of-charge.
Second, determine the battery cranking capacity by
performing a load test. The battery must be charged
before proceeding with a load test if:
²The battery built-in test indicator has a black or
dark color visible.
²The temperature corrected specific gravity of the
battery electrolyte is less than 1.235.²The battery open-circuit voltage is less than 12.4
volts.
A battery that will not accept a charge is faulty,
and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is
faulty and must be replaced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
A battery is fully-charged when:
²All battery cells are gassing freely during charg-
ing.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three corrected specific gravity tests, taken at
one-hour intervals, indicate no increase in the spe-
cific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.4 volts
or greater.
STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The following procedure can be used to check the
electrolyte level in the battery.
(1) Remove the battery caps (Fig. 5).
Fig. 5 Battery Caps - Export Battery
1 - BATTERY CAP
2 - BATTERY
8F - 8 BATTERY SYSTEMBR/BE
BATTERY (Continued)

(2) Look through the battery cap holes to deter-
mine the level of the electrolyte in the battery (Fig.
6). The electrolyte should be approximately 1 centi-
meter above the battery plates or until the hook
inside the battery cap holes is covered.
(3) Add only distilled water until the electrolyte
level is approx. one centimeter above the plates.
STANDARD PROCEDURE - BATTERY
CHARGING
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
²All of the battery cells are gassing freely during
battery charging.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.65 volts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1É C [30É F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
Fig. 6 Hook Inside Battery Cap Holes - Export
Battery
1 - BATTERY SURFACE COVER
2 - HOOK
BR/BEBATTERY SYSTEM 8F - 9
BATTERY (Continued)

NOTE: Models equipped with the diesel engine
option are equipped with two 12-volt batteries, con-
nected in parallel (positive-to-positive and negative-
to-negative). In order to ensure proper charging of
each battery, these batteries MUST be disconnected
from each other, as well as from the vehicle electri-
cal system, while being charged.
Some battery chargers are equipped with polarity-
sensing circuitry. This circuitry protects the battery
charger and the battery from being damaged if they
are improperly connected. If the battery state-of-
charge is too low for the polarity-sensing circuitry to
detect, the battery charger will not operate. This
makes it appear that the battery will not accept
charging current. See the instructions provided by
the manufacturer of the battery charger for details
on how to bypass the polarity-sensing circuitry.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine the battery
cranking capacity. Refer to Standard Procedures for
the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
and must be replaced.
Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat-
tery System Inspection for the proper battery system
inspection procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce-
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure the voltage at the battery posts with a
voltmeter, accurate to 1/10 (0.10) volt (Fig. 7). If the
reading is below ten volts, the battery charging cur-
rent will be low. It could take some time before the
battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
(2) Disconnect and isolate the battery negative
cable. Connect the battery charger leads. Some bat-
tery chargers are equipped with polarity-sensing cir-
cuitry. This circuitry protects the battery charger and
the battery from being damaged if they are improp-
erly connected. If the battery state-of-charge is too
low for the polarity-sensing circuitry to detect, the
battery charger will not operate. This makes it
appear that the battery will not accept charging cur-
rent. See the instructions provided by the manufac-turer of the battery charger for details on how to
bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltage
and current they provide. The amount of time
required for a battery to accept measurable charging
current at various voltages is shown in the Charge
Rate Table. If the charging current is still not mea-
surable at the end of the charging time, the battery
is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the bat-
tery may be good and the charging should be
completed in the normal manner.
CHARGE RATE TABLE
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
CHARGING TIME REQUIRED
The time required to charge a battery will vary,
depending upon the following factors:
²Battery Capacity- A completely discharged
heavy-duty battery requires twice the charging time
of a small capacity battery.
²Temperature- A longer time will be needed to
charge a battery at -18É C (0É F) than at 27É C (80É
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
²Charger Capacity- A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies
twenty amperes or more will require a shorter charg-
ing time.
²State-Of-Charge- A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
Fig. 7 Voltmeter - Typical
8F - 10 BATTERY SYSTEMBR/BE
BATTERY (Continued)