Published: 14-Jul-2011

Battery and Charging System - General Information - Battery Care

Description and Operation

12V LEAD ACID BATTERY CARE MANUAL FOR DEALER / RETAILER USE

1. INTRODUCTION

2. GENERAL RULES FOR BATTERY CARE

3. EQUIPMENT (MINIMUM STANDARD)

4. HEALTH AND SAFETY PRECAUTIONS

5. DETERMINING BATTERY CONDITION

6. BATTERY CHARGING AND MAINTENANCE

7. CHARGING SYSTEM TEST AND DIAGNOSIS

8. VEHICLE QUIESCENT CURRENT TESTING

APPENDIX A: BATTERY TEST PROCESS

APPENDIX B: BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY

1. INTRODUCTION

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This publication sets out, for the benefit of dealers / retailers worldwide, requirements for the care and maintenance of
batteries, from the vehicles hand-over to the dealer / retailer to the handover to the customer or in the case of a spare
part battery from is delivery to the dealer / retailer to its fitment to a customer vehicle.

It applies to all types of 12 volt Lead Acid Batteries used, whether they are conventional flooded technology or Absorbed
Glass Mat (AGM) technology and also applies to both Primary and Secondary or Auxiliary Batteries.

The clearly laid out and illustrated sections guide dealers / retailers through each stage of the vehicles or spare parts
receipt, storage, pre-delivery and customer hand-over. This publication can be used as a guide to the handling and care of
batteries in service. It is vital to appreciate that unless each process is rigorously applied on all vehicles, the customer will
receive a vehicle with a battery or a spare part battery which will not provide a satisfactory service life.

It is very important that all tests quoted throughout this publication are adhered to. If they are applied incorrectly
batteries could be scrapped unnecessarily. Refer to the battery testing section for detailed information.

It is equally important therefore to note the following key points:

Most new vehicles leave the factory with either a transit relay installed and/or have a transit mode programmed
into the vehicle control modules. The transit relay must be removed and the transit mode disabled (where
applicable) using an approved diagnostic system, NOT MORE THAN 24 HOURS before the customer takes
delivery.
12 Volt Lead Acid Batteries rely on internal chemical processes to create a voltage and deliver current. These
processes and the internal chemical structure of the battery can be damaged if the battery is allowed to discharge
over a number of weeks / months, or is left in a discharged state for a lengthy time period. For this reason the
battery must be tested / re-charged if necessary every month, and MUST BE re-charged after every three month
period of storage. Refer to the vehicle storage manual and update the vehicle history sheet.
Under no circumstances should the battery be disconnected with the engine running because under these
conditions the alternator can give a very high output voltage. This high transient voltage will damage the electronic
components in the vehicle. Loose or incomplete battery connections may also cause high transient voltage.
On vehicles with conventional ignition keys, these must not be left in the ignition lock barrel when the transit relay
has been removed, otherwise quiescent current will increase and the battery will discharge more rapidly.
Two types of Lead acid batteries are used; standard Flooded type and AGM (Absorbed Glass Mat) or VRLA (Valve
regulated Lead Acid) types. AGM batteries offer improved resistance to cycling as seen in stop start applications.
AGM Batteries are fully sealed and cannot have the electrolyte level topped up.

Dealers and retailers involved in the storage, handling of vehicles and spare parts batteries have a
responsibility to ensure that only vehicles and spare parts having a fully satisfactory battery may be
processed further through the distribution selling chain.

NOTE: It is very important that test processes quoted throughout this publication are adhered to.

If they are not adhered to correctly batteries could be scrapped unnecessarily or a battery with an issue remains in use.
Refer to the battery testing section for detailed information.

2. GENERAL RULES FOR BATTERY CARE

Frequency of Battery Condition Checks.

Any battery in storage whether it is in a vehicle or in spare parts inventory must have its charge status checked every 30
days as described in Appendix A, and must be recharged every 90 days as described in the "Battery Charging and
Maintenance" section of this manual.

Dealer Demonstration Vehicles

Due to the high depth of discharge a dealer demonstration vehicle battery may experience, batteries that are fitted to
vehicles used as dealer demonstration vehicles must be connected to a power supply / charger capable of delivering 50
Amps or more whilst the vehicle is being demonstrated and the engine is not running. This will prevent the battery from
being damaged from "energy throughput " wear out during a demonstration.

Software Reflash, SDD work or Ignition On related Workshop Activities.

Due to the high electrical current demand and high depth of Discharge that can occur during vehicle software re-flash
activities, SDD work or ignition on related work in the workshop, vehicles that are undergoing such activities MUST have
the electrical system on the vehicle supported with a power supply / charger / vehicle maintainer capable of delivering 50
Amps or more.

Jump Starting New vehicles Before They Have Been Delivered to the Customer.

It is the dealer / retailers responsibility to ensure the battery is not allowed to go flat by following the instructions
and processes defined in this manual.
However if circumstances dictate that a new vehicle must be jump started due to a flat battery whilst the vehicle is
in the dealer / retailers care, the battery on this vehicle must be replaced with a new one prior to delivery to the
customer at the dealer / retailers liability.
The vehicle should also undergo investigation as to why the battery went flat.
Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the

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recommended earthing point. As defined in the owners handbook or service documentation for that vehicle.

Jump Starting or Boost Charging Vehicles in Service

Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended
earthing point. As defined in the owners handbook or service documentation for that vehicle.

Charging AGM Batteries

AGM batteries must not be charged with voltages above 14.8 Volts. Doing so will damage them.

Testing AGM Batteries

Midtronics 393, 394, 493 and 494 testers are not capable of testing AGM batteries. Doing so can give an incorrect result.

When it is necessary to test an AGM battery use the Midtronics EXP1080 tester or the GR1 Diagnostics Charger.

3. EQUIPMENT (MINIMUM STANDARD) (pictures are for illustration only)

Traction Battery Charger (or similar stand-alone charger)

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Midtronics EXP1080 Hand-Held Tester

Digital Multi-Meter or Digital Volt-Ohm Meter (DVOM)

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Midtronics GR-1 Diagnostic Charger

4. HEALTH AND SAFETY PRECAUTIONS

WARNINGS:
 BATTERY CELLS CONTAIN SULPHURIC ACID AND EXPLOSIVE MIXTURES OF HYDROGEN AND OXYGEN GASES. IT IS
THEREFORE ESSENTIAL THAT THE FOLLOWING SAFETY PRECAUTIONS ARE OBSERVED.

Batteries emit highly explosive hydrogen at all times, particularly during charging. To prevent any potential form of
ignition occurring when working in the vicinity of a battery:

Do not smoke when working near batteries.

Avoid sparks, short circuits or other sources of ignition in the battery vicinity.
Switch off current before making or breaking electrical connections.
Ensure battery charging area is well ventilated.
Ensure the charger is switched off when: a) connecting to a battery; b) disconnecting from the battery.
Always disconnect the ground cable from the battery terminal first and reconnect it last.

Batteries contain poisonous and highly corrosive acid. To prevent personal injury, or damage to clothing or the
vehicle, the following working practices should be followed when topping up, checking electrolyte specific gravity, removal,
refitting or carrying batteries:

Always wear suitable protective clothing (an apron or similar), safety glasses, a face mask and suitable gloves.
If acid is spilled or splashed onto clothing or the body, it must be neutralized immediately and then rinsed with
clean water. A solution of baking soda or household ammonia and water may be used as a neutralizer.
In the event of contact with the skin, drench the affected area with water. In the case of contact with the eyes,
bathe the affected area with cool clean water for approximately 15 minutes and seek urgent medical attention.
If battery acid is spilled or splashed on any surface of a vehicle, it should be neutralized and rinsed with clean
water.
Heat is generated when acid is mixed with water. If it becomes necessary to prepare electrolyte of a desired
specific gravity, SLOWLY pour the concentrated acid into water (not water into acid), adding small amounts of acid
while stirring. Allow the electrolyte to cool if noticeable heat develops. With the exception of lead or lead-lined

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containers, always use non-metallic receptacles or funnels. Do not store acid in excessively warm locations or in
direct sunlight.

Due to their hazardous contents, the disposal of batteries is strictly controlled. When a battery is scrapped, ensure it
is disposed of safely, complying with local environmental regulations. If in doubt, contact your local authority for advice on
disposal facilities.

5. DETERMINING BATTERY CONDITION

The tools used for determining the condition of the battery will depend upon whether it is installed in a vehicle or in spare
parts inventory. Concerning an installed battery, procedures will vary if the vehicle is new, or already in service with a
customer.

NOTE: The term `New Vehicle' refers to a vehicle at any part of the delivery process from leaving the factory to arriving at
a port of entry, dealership, retailer, including any storage facilities en route or a vehicle being stored prior to sale at
dealership / retailer.

NOTE: Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable
of correctly testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the
GR1 Diagnostics charger.

NEW VEHICLES

A Midtronics tester should be used to assess the condition of the battery for new vehicles. The test results should be
recorded on the Storage History Sheet (see Vehicle Storage manual).

Scenario 1 - Dealership / Retailer (Responsibility: Dealer / Retailer)

1. Within 24 hours of arrival at the dealer / retailer proceed as follows:

Perform a Midtronics battery test (See Appendix A.)

Carry out the recommended actions accordingly.

2. If the Midtronics result is "Good Battery" the vehicle may be stored.

For all new vehicles in storage the transit relay MUST be fitted, or the Transit Mode enabled where used. For
vehicles without a transit relay or a Transit Mode, the battery negative cable MUST BE DISCONNECTED from the
battery.

3. The battery must be tested and/or re-charged every month and MUST be re-charged after every three month period.

4. Record your test results on the Storage History Sheet (see Vehicle Storage Manual) to indicate when a re-charge will be
necessary.

Scenario 2 - Delivery to the Customer (Responsibility: Dealer / Retailer)

NOTE: It is essential that the following actions are conducted in the 24 hours prior to the agreed hand over time:

1. Perform a Midtronics Battery test (See Appendix A).

2. Carry out the recommended actions accordingly.

3. The vehicle should only be released to the customer if Midtronics has tested the battery as "Good Battery"

Spare Part Batteries

Lead acid batteries will, as a result of natural chemical processes, slowly self discharge themselves over a period of time
(even when open circuit and no electrical load applied).

In the case of spare parts batteries, a Midtronics tester should be used to assess the condition of new spare parts
batteries.

The batteries must be stored such that they cannot get wet and are not in direct sunlight.

Any batteries which are dropped must be scrapped. This applies even if no external damage is apparent.

Scenario 1 - Spare Part Batteries Within Dealer Stock But Not Yet Fitted To A Vehicle (Responsibility:
Dealer / Retailer)

1. For a battery in the Dealer parts or in ready to use stock but not yet fitted to a vehicle the following rules must be
followed:

Check the battery condition on receipt by performing a Midtronics battery test (See Appendix A).
Batteries should only be returned to storage if the Midtronics tester indicates "Good Battery".
The battery condition should be rechecked every 30 days by performing a Midtronics battery test (See Appendix
A).
If required batteries should be recharged as described in the "Battery Charging and Maintenance" section of this

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manual.

2. 2 All batteries must be controlled via a FIFO (First In First Out) process to ensure aged batteries are not held and the
batteries are not allowed to age unnecessarily.

VEHICLES IN SERVICE

The Midtronics hand-held tester or the Midtronics Diagnostic Charger are the preferred tools to assess battery condition
for vehicles in service. The test results should be recorded on the In-Service Battery Report Form (See Appendix B).

Midtronics Testing - In-Service Testing Only

NOTE: The battery surface charge must be removed before this test in accordance with the procedure in Appendix A.
Ensure that the battery terminal connectors are clean. When connecting the Midtronics testing equipment, connect the
RED clip to the positive (+) battery terminal first, and then connect the BLACK clip to the negative (-) battery terminal.
Rock the clips backward and forward to ensure a good connection to the battery.

1. Perform a Midtronics battery test (See Appendix A).

2. Carry out the recommended actions accordingly.

6. BATTERY CHARGING AND MAINTENANCE

BATTERY CHARGING
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It is essential that a suitably ventilated defined area exists in each dealership / retailer for battery charging. Likewise, an
area should be allotted for scrap batteries, and clearly indicated as such. It is recommended that dealers / retailers always
have fully charged batteries ready for use. However the battery MUST BE tested and charged if necessary every month,
and charged after three months irrespective of any test.

CAUTIONS:

Batteries must be re-charged after a maximum of 3 months storage (see Storage History sheet in the New Vehicle
Storage Manual).

It is very important that when charging batteries using the traction charger or other stand-alone chargers that the
charger is set for the correct type of battery before charging commences. If the wrong switch is selected the result would
be a battery that is not charged fully and / or overheating can occur. Follow the manufacturers operating instructions.

Do not charge AGM batteries with voltages over 14.8 volts as this will damage the battery.

To bring a serviceable but discharged battery back to a fully charged condition proceed as follows:

Check and if necessary top-up the battery electrolyte level.

Charge the battery using the Midtronics Diagnostic Charger (USA) or Traction Charger (all other markets) following
the manufacturers operating instructions.

NOTE: When using the Midtronics Diagnostic Charger, automatic mode must always be used. After charging and analysis,
the charger may display ‘Top-Off Charging’, press STOP to end. Do not stop charging until the current falls to 5A or less,
otherwise the battery will not be fully charged.

POST-CHARGE TEST METHODS

New Batteries, Batteries in Storage and In-Service Batteries

The purpose of this test is to ensure that the charging process has fully charged the battery.

NOTE: IT IS RECOMMENDED THAT THIS TEST IS CONDUCTED AT LEAST 24 HOURS AFTER THE CHARGE CYCLE IS
COMPLETED.
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CAUTION: DO NOT connect the tester to any other circuit or chassis point.

1. Attach the Midtronics Tester to the battery.

2. Follow the instructions on the tester to test the battery. Ensure the correct battery type and size is selected.

3. Perform the action based on the tester results (see the tester results chart in the Vehicles in Service sub -section of
Determining Battery Condition Section).

4. Enter the readings and test code obtained on the In Service Battery Report Form.

NOTE: Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable
of correctly testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the
GR1 Diagnostics charger.

BATTERY REPLACEMENT

If it is determined that a battery requires replacement, always refer to the appropriate section of the workshop manual for
instructions on removing and installing the battery from the vehicle.

On in service vehicles fitted with a Battery Monitoring System (BMS), the BMS module must be reset following the
installation of a new battery. The BMS module reset procedure must be performed using an approved diagnostic system.

CHECK/TOP-UP BATTERY ELECTROLYTE – Only Applicable to certain Flooded Types of Battery.

WARNINGS:

AGM TECHNOLOGY BATTERIES ARE FULLY SEALED FOR LIFE AND NO ATTEMPT SHOULD BE MADE TO CHECK OR
TOP UP THE ELECTROLYTE LEVEL.

BEFORE CHECKING AND TOPPING-UP THE BATTERY ELECTROLYTE, REFER TO THE HEALTH AND SAFETY
PRECAUTIONS SECTION.

Check to ensure the battery is of a type suitable for topping up. These types of batteries will have cell plugs visible on the
top face of the battery or a removable access panel to allow access to the cells.

On batteries with a clear or opaque case and level marks, check the electrolyte level by visual inspection of the maximum
level indicator mark on the battery casing indicating adequate level above the battery separators.
On batteries with black cases, remove the cell plugs or access panel and ensure the electrolyte level is level with the
indicator in the cell hole. A flashlight may be required to see the electrolyte level on this type of battery.

CAUTION: DO NOT overfill.

If the electrolyte level is low, top-up using distilled water.

Maintenance free and Valve Regulated (AGM) batteries are sealed and therefore cannot be topped up.

CHARGING SYSTEM TEST AND DIAGNOSIS

For all vehicles, refer to the Charging System - Diagnosis and Testing in section 414-00 of the Workshop Manual.

VEHICLE QUIESCENT CURRENT TESTING

NOTE: On vehicles fitted with a Battery Monitoring System (BMS), the diagnostic routine for quiescent drain testing in the
approved diagnostic system should be utilized.

NOTE: If a customer complains of a vehicle battery that discharges continuously or when left for a prolonged period of
time, it is recommended that a quiescent drain test is performed as described below.

NOTE: The battery drain should be measured using an approved diagnostic system or a Digital Multi-Meter (DVOM).

The vehicle should be in the locked/armed state (for example vehicle alarm fully armed), all doors, engine and luggage
compartment lids are open and latched (so as to appear closed from an electrical point of view). The test should take
place after the vehicle has entered shutdown mode. The time taken for this to occur after the ignition is switched off
varies according to model - Refer to Quiescent Drain in section 414-00 of the Workshop Manual.

NOTE: When the vehicle is armed, the effect of the security system Light Emitting Diode (LED) flashing is to cause a
pulsation in the measured current drain. In this case, either the average current should be taken (using a Digital Multi-

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Meter (DVOM) with an averaging system) or the current reading taken, ignoring the brief high current peaks.

EQUIPMENT

Approved diagnostic system with current probe or Digital Multi-Meter (DVOM) with current probe.

METHOD OF MEASUREMENT

Using an Approved Diagnostic System

1. Switch off all electrical loads and ensure that the ignition is off.

2. Connect the current probe to the approved diagnostic system.

3. Calibrate the probe.

4. Install a clamp around the battery lead/junction box lead.

5. Go to the Quiescent Current Testing section.

Using a Digital Multi-Meter (DVOM)

NOTE: Do not use an in-line DVOM to measure the quiescent drain on vehicles fitted with an electronic throttle. The
current exceeds the maximum amount the fuse in the DVOM is capable of handling.

1. Switch off all electrical loads and ensure that the ignition is off.

2. Connect the current probe to the DVOM.

3. Calibrate the probe.

4. Install a clamp around the battery lead/junction box lead.

5. Go to the following Quiescent Current Testing section.

QUIESCENT CURRENT TESTING

1. Switch ignition to ‘on’ or select ignition mode in keyless vehicles and switch to ‘off’ (do not crank).

2. Remove key from ignition switch (where applicable).

3. Open and latch all doors, hood and luggage compartment lid.

4. Lock the vehicle using the remote function on the remote handset. (Single lock only to avoid volumetric alarm arming).

5. Remove any other potential electrical drains such as accessories plugged into accessory sockets.

6. Record the amperage readings after the shutdown period. The model specific Amperage readings for quiescent drain
are referenced in Quiescent Drain in section 414-00 of the Workshop Manual
7. Record the final reading on the battery report form Appendix B.

NOTE: The preferred method of testing following an excessive current consumption figure is to use a current probe around
individual junction box leads to the various suspected circuits to identify a potential cause. This is in preference to the old
method of removing fuses for the following reasons:

Many modules take a considerable time to power down. Each time a fuse is removed and re-fitted, the quiescent
drain current may take an extended period of time to return to normal (typically up to 45 minutes).
The drain may be caused by a module remaining active and preventing the quiescent drain from reducing to
normal levels.
The drain may be caused by a relay winding that is activated. Pulling the fuse can allow this to ‘reset’ and the drain
will be lost and go un-diagnosed.

APPENDIX A BATTERY TEST PROCESS

It is recommended that this test is conducted at least 24 hours after the vehicle engine has been run or the battery
charged to avoid the need of surface charge removal or if this time constraint is unacceptable due to circumstances, then
conduct the charge strip removal process.

Part 1 - Surface Charge Removal

NOTE: Before carrying out a battery test you must ensure that there is no battery surface charge present.

NOTE: The battery may be tested either on a bench or on the vehicle.

In the case of on-vehicle testing, the battery must be isolated from the vehicle by removal of the battery negative
(-) cable from the battery terminal before the measurement is taken unless the vehicle has a transit relay fitted or
is in transit mode.

A vehicle which has had its battery charged or been driven in a 24 hour period before the test, must have its surface

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charge removed using one of the following methods:

1. If 24 hours have passed since the last time the engine was run or the battery charged, proceed to `Part 2 - Battery
Test'.

2. Turn on the ignition. Switch on the headlamps on high beam for a minimum 3 minutes.

3. Switch off the headlamps. For vehicles tested after the transit relay has been removed, disconnect the battery by
removal of the negative (-) cable. Vehicles with a transit relay fitted or with a low current transport mode enabled do not
need to have the battery disconnected.

4. Wait a maximum of 5 minutes before recording test results for any battery measurements.

Part 2 - Battery Test

NOTE: The battery surface charge must be removed before this test in accordance with the procedure in Part 1 above.
Ensure that the battery terminal connectors are clean. When connecting the Midtronics testing equipment, connect the
RED clip to the positive (+) battery terminal first, and then connect the BLACK clip to the negative (-) battery terminal.
Rock the clips backward and forward to ensure a good connection to the battery.

NOTE: Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable
of correctly testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the
GR1 Diagnostics charger.

CAUTION: DO NOT connect the tester to any other circuit or chassis point other than the battery negative terminal.

1. Attach the Midtronics tester to the battery.

2. Follow the instructions on the tester to test the battery. Ensure the correct battery type and size is selected.

3. Perform the action based on the tester results (see table below).

4. Enter the readings and test code obtained on the Battery Report Form (Appendix B) or equivalent which records as a
minimum the technician's name, Vehicle Identification Number (VIN), Date of check, Midtronics code and Battery Voltage
from the Midtronics tester.

At the end of the test, the battery negative (-) cable should be re-attached to the battery terminal.

TESTER RESULTS ACTION

GOOD BATTERY Return to service.
GOOD RE-CHARGE Fully charge battery and return to service.
CHARGE AND RE-TEST Fully charge battery. Remove surface charge. Re-test battery. If same result replace battery.
REPLACE BATTERY OR Verify surface charge removed. Disconnect battery from vehicle and re-test. If result repeats
BAD CELL BATTERY after surface charge removal, replace battery. DO NOT RECHARGE.
UNABLE TO DO TEST Disconnect battery from vehicle and re-test.

APPENDIX B : BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY

NOTE: Fields marked with * are mandatory and must be completed.

YES / YES /
General Information NO NO
Customer Name: Dealer/Retailer Code: *
Repair Order Number: * Battery Date Code: *
Repair Order Date: * Number of Times Battery *
Charged:
Repair Order Date: Technicians Name: *
Vehicle Identification Number (VIN): * Technicians Signature: *
Give a detailed description of the symptoms experienced by the customer (attach a separate sheet if necessary)
-
-
-
-
-
-
Diagnostics (Battery Testing)
1: Loose battery clamps Yes * No *
2: Loose hold down clamps Yes No
3: Corroded terminal posts Yes * No *
4: Physical damage/leaks Yes No
5: Low electrolyte Yes * No *
6: FEAD belt tension OK * Not OK *
7: Surface charge removed Yes * No *
8: Voltage (appendix A) Yes * No *

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9: Quiescent Drain mA *
10: Vent tube correctly installed Yes No
11: Midtronics test
Code before charging *
If Midtronics indicates that the battery needs re-charging, charge the
battery for 24 hours
Code after charge *
Result after charge *
If "good and re-charge" charge the battery for an additional 24 hours.
If "charge and re-test" for both before and after 24 hours charge renew the
battery
Only renew the battery if "renew battery", "bad cell" or charge and re-test
has been displayed twice.
Comments
-
-
-
-
-
 Published: 20-Oct-2011
Battery and Charging System - General Information - Quiescent Drain
Description and Operation

QUIESCENT DRAIN - TYPICAL VALUES

NOTE: The quiescent drain after the initial shutdown period should not exceed the value shown in the table.
Land Rover Quiescent Drain Values
SHUT DOWN PERIOD TYPICAL VALUES BATTERY DRAIN
MODEL (minutes) (mA)
Range Rover (LM) - Up to 2009MY 30 16.0 - 18.0
Range Rover (LM) - From 2010MY 20 (after lock/arm condition) ² <30
33 (unlocked) <30
Range Rover Sport (LS) - Up to 2007MY 20 <22
Range Rover Sport (LS) - From 2007MY to 30 <25
2010MY
Range Rover Sport (LS) - From 2010MY 3 (after lock/arm condition) ² <30
33 (unlocked) <30
Range Rover Evoque (LV) - From 2012MY 20 (after lock and arm <20
condition)
Discovery 3/LR3 (LA) - Up to 2007MY 20 <22
Discovery 3/LR3 (LA) - From 2007MY to 30 <25
2010MY
Discovery 4/LR4 (LA) - From 2010MY 3 (after lock/arm condition) ² <30
33 (unlocked) <30

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Freelander 2/LR2 (LF) - From 2007MY 35 (single locked or unlocked) <23.6
12 (double locked) <23.6
Freelander (LN) - Up to 2007MY 10 24-25 - without Becker Navigation
system
10 27-28 - with Becker Navigation system
Defender (LD) - 1998MY to 2007MY 30 <21
Defender (LD) - from 2007MY <30 <30
Discovery Series 2 (LT) 30 <30

NOTE:

1. The total current drain will be higher if certain approved accessories are fitted (for example: tracker, trailer module,
etc.)

2. Applies to vehicles without Tire Pressure Monitoring System (TPMS). Vehicle shut-down period with TPMS is
approximately 15 minutes.
 Published: 05-Dec-2011
Battery and Charging System - General Information - Charging System
Diagnosis and Testing

Principles of Operation

For a detailed description of the charging system, refer to the relevant Description and Operation section in the workshop
manual. REFER to:

Battery Care (414-00 Battery and Charging System - General Information, Description and Operation),
Battery and Cables (414-01, Description and Operation),
Generator - ID4 2.4L Diesel (414-02, Description and Operation).

Inspection and Verification

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does
not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor
vehicle.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

NOTE: Check the vehicle battery condition and state of charge before condemning any of the charging system
components. For additional information, refer to the battery care manual.

For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to section 100-00.
REFER to: (100-00)

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Diagnostic Trouble Code (DTC) Index - DTC: Engine Control Module (PCM) (Description and Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Instrument Cluster (IPC) (Description and Operation).
Visual Inspection
Mechanical Electrical
Generator Generator
Drive belt Battery
Drive belt tensioner Mega-fuse
Generator pulley Engine/generator ground connection
Check the security of the generator fixings Harness(s)
Electrical connector(s)
Engine Control Module (ECM)
Central junction box (Freelander 2 only)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.

DTC Index

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation,
prior to the installation of a new module/component.

NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the
scan tool to the first five digits of the seven digit code listed to identify the fault (the last two digits give extra information
read by the manufacturer-approved diagnostic system).

NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to three
decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the
DMM leads into account.

NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may
be the cause. Always check for loose connections and corroded terminals.

Symptom Possible Cause Action

Charge warning lamp does not Warning Check the warning lamp function with the ignition
illuminate lamp/circuit - fault on and the engine off
Generator - Repair the circuit as necessary
internal fault Check for DTCs indicating a generator, CAN or
CAN Bus - circuit engine control module fault
fault
 Engine control
module - internal
fault

Charge warning lamp stays Accessory drive Check the battery and generator cables
on/battery discharges belt - fault Refer to the electrical guides
Generator pulley Check for DTCs indicating a generator fault
slipping on shaft Check the accessory drive belt condition and
Generator - tension
internal fault Check that the pulley does not rotate
Battery cable - independently of the generator
fault Check for DTCs indicating a CAN, central junction
CAN Bus - circuit box or engine control module fault
fault
Engine control
module internal
fault
Central junction
box

Charge warning lamp intermittent Accessory drive NOTE: Use of a power pack or boost charger may bring
belt slipping the warning lamp on until disconnected
Battery cable -
fault Check the accessory drive belt condition and
Generator - circuit tension
fault Check the battery and generator cables refer to
Generator - the electrical guides
internal fault Check for DTCs indicating a generator or CAN
CAN Bus - circuit circuit fault

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fault

Battery discharges without the Battery - fault Check the battery condition
charge warning lamp staying on Battery quiescent Check for battery quiescent drain
drain Check for DTCs indicating a generator fault
Intermittent If no other reason for discharge can be found,
generator - fault check the circuit. Refer to the electrical guides

Noise (mechanical) Accessory drive Check the accessory drive belt condition and
belt slipping tension
Disconnect the accessory drive belt and check that
the generator rotates freely

Test Procedure

PINPOINT TEST A : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: MIDTRONICS BATTERY TEST
NOTE: The battery must be fully charged and any battery defects rectified before continuing with generator diagnosis
NOTE: The voltmeter must display readings to three decimal places (i.e. 0.001V)
NOTE: Ignition on is position 2 on a keyed ignition system
NOTE: Ignition on is two short presses of the start button (power mode 6) with keyless ignition system
1 Using a Midtronics hand held tester or the Midtronics GR-1 diagnostic charger, carry out the
"Midtronics battery test" as detailed in the battery care manual.
REFER to: Battery Care (414-00 Battery and Charging System - General Information, Description and
Operation).
2 Record battery diagnostic result on the provided form
Does the battery pass the "Midtronics battery test"?
Yes
GO to B1.
No
Rectify any battery defects before continuing with generator diagnosis GO to Pinpoint Test B.

PINPOINT TEST B : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
B1: GENERATOR OUTPUT
NOTE: Freelander 2 = The heated rear screen is timed to operate for 12 minutes
NOTE: Defender = The heated rear screen is timed to operate for 8 minutes
1 Connect a voltmeter to the vehicle battery
2 Switch ignition state to on (engine off)
 3 Turn off all electrical loads e.g. (blower, radio, interior lights etc.)
4 Start the engine, switch on the heated rear screen

Ensure the heated rear screen is on (see note above) and that the air conditioning system is off.

5 Wait 90 seconds
6 Record the battery voltage (V1) shown on the multimeter
Does battery voltage (V1) = 14.8 volts or greater at idle?
Yes
Install a new generator. Refer to the warranty policy and procedures manual, or determine if any prior
approval programme is in operation, prior to the installation of a new module/component
No
GO to B2.
B2: BATTERY VOLTAGE AT IDLE
1 Using battery voltage reading (V1)
Does battery voltage (V1) = 13 volts or greater at idle (But less than 14.8 volts)?
Yes
GO to B3.
No
GO to Pinpoint Test C.
B3: BATTERY WARNING LAMP
1 The battery voltage is (V1) = 13 volts or greater at idle (but less than 14.8 volts)
Is the battery warning lamp illuminated?
Yes
GO to Pinpoint Test C.
No
The generator output is within the expected range, Do not replace the generator. If customer
concern is still evident contact dealer technical support

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PINPOINT TEST C : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART
TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
C1: CIRCUIT CHECKS
NOTE: Freelander 2 = Charge warning lamp is driven by the central junction box (from the powertrain control module) to
the instrument panel cluster via the CAN bus
NOTE: Defender = Charge warning lamp is driven by the powertrain control module to the instrument panel cluster via
the CAN bus
1 Freelander 2 = Refer to the electrical circuit diagrams and check the (LIN) circuit between the
generator and the engine control module for short circuit to ground, short circuit to power, open
circuit, high resistance faults
2 Defender = Refer to the electrical circuit diagrams and check the (D+ and ALTMON) circuits between
the generator and the engine control module for short circuit to ground, short circuit to power, open
circuit, high resistance faults
Are any circuit faults evident?
Yes
Repair the circuit as required GO to Pinpoint Test B.
No
GO to Pinpoint Test D.

PINPOINT TEST D : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
D1: CIRCUIT CHECKS 1
NOTE: Freelander 2 = The heated rear screen is timed to operate for 12 minutes
NOTE: Defender = The heated rear screen is timed to operate for 8 minutes
1 Connect a voltmeter to the vehicle battery
2 Switch ignition state to on (engine off)
3 Turn off all electrical loads e.g. (blower, radio, interior lights etc.)
4 Start the engine, switch on the heated rear screen

Ensure the heated rear screen is on (see note above) and that the air conditioning system is off.

5 Voltage measurement

Measure the voltage drop between the generator body and battery negative terminal and record
the value (V2)

Does the voltage drop value (V2) = less than 0.3 Volts ?
Yes
GO to D2.
No
Switch off engine. Circuit check. Refer to the electrical circuit diagrams, check the generator body
 and battery negative cables for loose or corroded connections. Repair any circuit faults, retest the
generator GO to Pinpoint Test B.
D2: CIRCUIT CHECKS 2
1 Voltage measurements

Measure the voltage drop between the generator B+ terminal and battery positive terminal
and record value (V3)

Does the voltage drop value (V3) = less than 0.3 Volts ?
Yes
Install a new generator. Refer to the warranty policy and procedures manual, or determine if any prior
approval programme is in operation, prior to the installation of a new module/component
No
Switch off engine. Circuit check. Refer to the electrical circuit diagrams check the generator B+
terminal and positive battery cables for loose or corroded connections. Repair any circuit faults,
retest the generator GO to Pinpoint Test B.

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 Published: 11-May-2011
Battery, Mounting and Cables -
Torque specifications
Description Nm lb-ft
Battery terminal nuts 5 4
Battery clamp nuts 9 7
Battery ground cable to transmission stud 30 22

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 Published: 11-May-2011
Battery, Mounting and Cables - Battery Disconnect and Connect
General Procedures

WARNINGS:

Batteries normally produce explosive gases which may cause personal injury, therefore do not allow lighted
substances to come near the battery. When charging or working near the battery always shield your face and protect your
eyes. Always provide adequate ventilation. Failure to follow these instructions may result in personal injury.

Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Shield your face and protect your eyes
when working near the battery to guard against possible splashing of the acid solution. In case of acid contact with the
skin or eyes, flush immediately for a minimum of 15 minutes and seek prompt medical attention. If swallowed, call a
physician immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Make sure the engine is not running before disconnecting the battery ground cable. Failure to follow this
instruction may result in damage to the vehicles electrical system.

NOTE: This procedure should be used to disconnect the battery while carrying out repairs that refer to the battery being
disconnected.

NOTE: Before disconnecting the battery make sure that no data is required from the engine control module (ECM), as
battery cable disconnection will erase any fault codes and idle/drive values held in the keep alive memory (KAM).

1. Obtain and record the audio unit keycode and preset radio
frequencies.

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2. Remove the LH front seat cushion.
For additional information, refer to: Front Seat Cushion (501-10
Seating, Removal and Installation).

3. NOTE: RH illustration is shown, LH is similar.

Remove the battery cover.

Release the clip.

4. CAUTION: Failure to follow the procedure below

could result in the alarm sounder self activating when the
battery is disconnected.

Disconnect the battery ground cable.

Loosen the nut.
Turn the ignition key to the run position.
Turn the ignition key to the off position.
Within 17 seconds of turning the ignition key to the
off position, release the battery ground cable from
the battery.
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