Battery care (Defender 2007+)

1. Introduction

This publication is intended for dealers/retailers worldwide and sets out the requirements for the care and maintenance of batteries from the time vehicles are handed over to the dealer/retailer until handover to the customer or, in the case of a spare battery, from delivery to the dealer/retailer until installation in the customer's vehicle.

It applies to all types of 12 Volt lead-acid batteries used, regardless of whether they use standard fill technology or glass microfibre absorbent baffle (AGM) technology, and also applies to both primary and secondary or auxiliary batteries.

Clearly laid out and illustrated sections provide dealers/retailers with information on all stages of receiving, storing, preparing and handing over vehicles and spare parts to the customer. This guide can be used as a reference for battery maintenance and care. It is important to understand that if all battery maintenance requirements for each vehicle are not met, the customer will receive a vehicle with a battery or a spare battery that will not provide the required performance and service life.

It is very important that you follow all the tests in this document carefully. If they are not followed correctly, batteries will quickly fail. For more information, see the section on testing batteries.



Also note the following key points:

• Most vehicles shipped from the factory have a transit relay installed and/or transit mode programmed into the vehicle's control units. This transit relay must be removed and the transit mode deactivated (if applicable) using a certified diagnostic system NO LATER THAN 24 HOURS before handing over the vehicle to the buyer;
• 12-volt lead-acid batteries rely on internal chemical processes to create voltage and deliver current. These processes and the internal chemistry of the battery can be damaged if the battery is allowed to discharge over several weeks/months or if it is left in a discharged state for a long time. Therefore, the battery should be checked and recharged if necessary monthly, and MUST be recharged after three months of storage. Refer to the vehicle storage manual and make a note in the vehicle service book;
• do not disconnect the battery while the engine is running, as this may cause the alternator to produce very high output voltage. High transient voltage will damage the vehicle's electronics. Loose or incompletely secured battery cables may also cause high transient voltage;
• in cars with traditional ignition keys, it is prohibited to leave the key in the ignition after removing the transit relay, since in this case the quiescent current will increase and the battery will discharge much faster;
• There are two types of lead-acid batteries used: standard flooded and AGM (with absorbent glass microfiber partitions) or VRLA (valve regulated lead acid). AGM batteries have increased resistance to cyclic loads observed during stop and start. AGM batteries are completely sealed and cannot be refilled with electrolyte.

Dealers and retailers who store and transport vehicles and spare batteries are responsible for ensuring that only vehicles and spare parts with fully functional batteries are distributed further through the distribution chain.

NOTE: It is very important that all testing procedures in this document be followed exactly. Failure to follow these procedures may result in unnecessary damage to batteries or continued use of a battery that is not fully functional. For more information, see the section on battery testing.

2. General rules for battery care

Frequency of battery health checks

Any battery in storage, whether on a vehicle or as a spare, must have its state of charge 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 Cars

Due to the high level of discharge that a dealer demo vehicle battery may be subjected to, demo vehicle batteries must be connected to a power source/charger capable of delivering 50 amps or more of current when the vehicle is being demonstrated with the engine off. This will prevent damage to the battery due to wear and tear caused by the energy output during the demonstration.

Workshop activities involving software reinstallation, SDD operation or ignition switching

Due to the high electrical current demand and high levels of discharge that can occur during software reinstallation, SDD operation, or ignition key related work, the electrical system of vehicles on which such work is performed MUST be connected to a power source/battery charger/charge maintainer capable of delivering at least 50A of current.

Starting new vehicles from external battery until delivery to the customer.

• It is the responsibility of the dealer/retailer to prevent battery discharge by following the instructions and procedures provided in this manual.
• However, if circumstances require a new vehicle to be jump started due to a discharged battery while the vehicle is at the dealer/retailer, the battery must be replaced with a new one before delivery to the customer at the dealer/retailer's expense.
• It is also necessary to check the car to find out the reason for the battery discharge.
• Do not connect the jumper cable to the negative (-) battery terminal. Always connect to the recommended ground point. As described in the owner's manual or service documentation for this vehicle.

Forced charging or starting the serviced vehicle from an external battery

Do not connect the jumper cable to the negative (-) battery terminal. Always connect to the recommended ground point. As described in the owner's manual or service documentation for this vehicle.

Charging AGM batteries

AGM batteries should not be charged using voltages higher than 14.8V. This will damage them.

Checking AGM batteries

Midtronics 393, 394, 493 and 494 testers are not suitable for testing AGM batteries and may give incorrect results.
If AGM battery testing is required, use the Midtronics EXP1080 Tester or GR1 Diagnostic Charger.

3. Equipment (standard minimum)

Charger for traction battery (or similar stand-alone charger)



Midtronics EXP1080 Handheld Tester



Digital Multimeter or Digital Volt-Ohmmeter (DVOM)



Diagnostic charger Midtronics GR-1

4. Health and Safety Precautions

Warning: Battery cells contain sulfuric acid and explosive hydrogen-oxygen mixtures. Therefore, the following safety precautions must be strictly observed.

Warning: Batteries constantly emit explosive hydrogen, especially during charging. To prevent the potential risk of ignition when working in the vicinity of the battery:

• do not smoke near batteries;
• do not allow sparks, short circuits or other sources of fire near the battery;
• when disconnecting/connecting current-carrying cables, be sure to turn off the power first;
• Ensure adequate ventilation of the battery charging area.
• The charger must be switched off in the following cases: a) when connected to a battery; b) when disconnected from the battery.
• The ground wire ("mass") must be disconnected from the battery first and connected last.

Warning: Batteries contain poisonous and highly corrosive acid. To prevent injury, damage to clothing or the vehicle, the following procedures must be followed when adding, checking the specific gravity of the electrolyte, removing, installing or carrying batteries:

• be sure to wear appropriate protective clothing (apron or similar protective equipment), safety glasses, protective mask and suitable gloves;
• if acid gets on your clothes or body, you must immediately neutralize it and then wash it off with clean water. You can use a solution of baking soda or household ammonia as a neutralizer;
• if acid gets on your skin, rinse the affected area thoroughly with water. If it gets into your eyes, rinse the affected area with cold, clean water for about 15 minutes, then seek immediate medical attention;
• if battery acid gets on any parts of the car, it must be neutralized and washed with clean water;
• when mixing acid with water, heat is released. If you want to prepare an electrolyte with a certain specific gravity, SLOWLY and little by little pour the concentrated acid into the water (not water into acid), stirring the solution constantly. If the electrolyte noticeably heats up, let it cool down. Be sure to use non-metallic containers and/or funnels (exceptions may be made for lead or lead-lined tanks). Do not store acid in places with excessively high temperatures or in direct sunlight.

Warning: The disposal of batteries is strictly regulated due to their high environmental hazard. In the event of a battery failure, be sure to follow the safety precautions for disposal as provided by local environmental legislation. If in doubt, contact your local authorities for information on disposal organizations.

5. Determining the condition of the battery

The tools used to determine the battery condition depend on whether the battery is installed on the vehicle or is a spare part. For an installed battery, the methods differ if the vehicle is new or already in use by the customer.

NOTE: The term "new vehicle" means a vehicle at any stage of the delivery process from the time it leaves the factory until it reaches its destination port, dealership, retail facility, including all warehouse facilities along the route and the storage of the vehicle prior to sale at the dealership/retail facility.

NOTE: Do not use the Midtronics 393, 394, 493, and 494 testers to test AGM batteries as they are not suitable for testing AGM batteries and may give false results. To test an AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.

New cars

To assess the condition of the battery of new cars, it is necessary to use the Midtronics tester. The results of the test should be recorded in the warehouse form (see vehicle storage guide).

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

1. Within 24 hours of delivery to the dealer/retailer, do the following:

• Perform a battery test using the Midtronics tester (see Appendix A).
• follow the relevant recommendations.

2. If the Midtronics test result is "battery good", the vehicle can be stored.

• All new vehicles in storage MUST have a bypass relay installed or have the bypass mode engaged if used. On vehicles without a bypass relay or bypass mode, the negative battery cable MUST BE DISCONNECTED from the battery.

3. The battery should be checked and/or recharged monthly and MUST be recharged every three months.



4. Record the results of the checks in the warehouse form (see Car Storage Guide), so that you can easily determine the timing of mandatory recharging.

Scenario 2 - Delivery to the buyer (responsibility: Dealer/Retailer)

NOTE: The following procedures must be completed within 24 hours prior to the agreed pick-up time:

1. Perform a battery test using the Midtronics tester (see Appendix A).

2. Follow the relevant recommendations.

3. The car must be handed over to the buyer only if the battery test result is "battery is OK".

Spare batteries

Lead acid batteries will slowly discharge over time due to natural chemical processes (even when the circuit is open and there is no electrical load).

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

Batteries should be stored in a dry place away from direct sunlight.

All dropped batteries must be disposed of. This is a mandatory requirement even in the absence of obvious external damage.

Scenario 1 - spare batteries in dealer warehouse, not yet installed in the vehicle (responsibility: Dealer/Retailer)

1. For a battery that is part of a dealer's spare parts or a ready-to-use part not yet installed on a vehicle, the following rules must be observed:

• Check the battery condition upon receipt by running a Midtronics test (see Appendix A).
• Batteries should only be returned to storage if the Midtronics tester shows a "good battery" result.
• The battery condition should be checked every 30 days by performing a Midtronics test (see Appendix A).
• If necessary, the batteries should be charged according to the instructions in the "Battery Charging and Maintenance" section of this manual.

2. 2 All accumulators must be distributed using the FIFO method (in order of priority), so that older batteries do not remain in stock and all batteries do not age unnecessarily.

Vehicles in use

To determine the battery condition of the vehicles in use, it is recommended to use a Midtronics handheld tester or a Midtronics diagnostic charger. The test results should be recorded in the "Report on the batteries of the vehicles in use" form (see Appendix B).

Midtronics Test - Testing of Used Batteries Only

NOTE: Before performing this test, the battery surface charge must be removed as specified in Appendix A. Ensure that the battery terminals are clean. When connecting the Midtronics tester, first connect the RED clamp to the positive (+) battery terminal, then the BLACK clamp to the negative (-) battery terminal. Rock the clamps back and forth to ensure proper contact with the battery posts.

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

2. Follow the relevant recommendations.

6. Battery charging and maintenance

Charging the battery

To charge the batteries, the dealer/retailer must have a designated area with good ventilation. Similarly, a marked area should be set aside for defective batteries. Dealers / retailers are advised to always have fully charged, ready-to-use batteries in stock. However, the vehicle's battery pack should ALWAYS be checked and recharged once a month and recharged once every three months, regardless of the results of the checks.

Warnings:

• During storage, batteries should be recharged at least once every 3 months (see the "Stock Form" section in the New Vehicle Storage Guide).
• When using a traction battery charger or other stand-alone charger, it is very important to set the charger to the correct battery type before charging. If the switch position is incorrect, the battery will not be fully charged and/or the battery may overheat. Follow the manufacturer's operating instructions.
• Do not charge AGM batteries using voltages higher than 14.8V as this will damage the battery.

To restore a healthy but completely discharged battery to working condition, do the following:

• Check the electrolyte level and top up if necessary.
• Charge the battery using a Midtronics diagnostic charger (USA) or a traction battery charger (other countries), following the operating instructions provided by the manufacturer.

NOTE: When using the Midtronics Diagnostic Charger, you must always use the Automatic mode. After charging and analyzing, the charger may display a message "Top-Off Charging" (Charging complete), press STOP to stop. Do not stop charging until the current drops to 5A or less. Otherwise, the battery will not be fully charged.

Methods of checking after charging

New batteries, batteries in stock and used batteries.

The purpose of this test is to check the battery's full charge during the charging process.

NOTE: It is recommended to perform this check at least 24 hours after charging is complete.

CAUTION: DO NOT connect the tester to other circuits or points on the chassis.

1. Connect the Midtronics tester to the battery.

2. Follow the tester's instructions to check the battery. Be sure to select the battery type and size.

3. Perform the necessary actions depending on the tester results (see the tester results table in the "Vehicles in Use" subsection of the "Determining Battery Condition" section).

4. Enter the obtained readings and the test result code into the "Report on batteries of operated vehicles".

NOTE: Do not use the Midtronics 393, 394, 493, and 494 testers to test AGM batteries as they are not suitable for testing AGM batteries and may give false results. To test an AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.

Replacing the battery

If it is determined that the battery requires replacement, be sure to check the appropriate section of the repair manual for the procedure for removing the battery from the vehicle and installing it.

On existing vehicles equipped with a battery monitoring system (BMS), the BMS module must be reset after installing a new battery. The BMS module reset procedure must be performed using the recommended diagnostic system.

Checking/topping up battery electrolyte - applies only to certain flooded battery types.

Warnings:

• Batteries using AGM technology are completely sealed for life and no attempt should be made to check the electrolyte level or add electrolyte.
• Before checking and adding electrolyte, please read the Health and Safety Precautions section.

Make sure that the type of battery allows for topping up of electrolyte. On the top panel of such types of batteries there are plugs or a removable cover under which there are jars.

If the battery case is transparent or translucent with level marks, visually check the maximum level indicator on the case to make sure it shows sufficient electrolyte level above the separators in the battery.

If the battery case is black, remove the can caps or the common cover and check the electrolyte level using the indicator in the can opening. You may need a flashlight to check the electrolyte level in this type of battery.

CAUTION: DO NOT FILL ABOVE the required level.

If the electrolyte level is low, add distilled water.

Maintenance-free batteries and valve-regulated batteries (AGM) are sealed, so adding electrolyte is not possible.

Testing and diagnostics of the charging system

For all vehicles, refer to "Charging System - Diagnosis and Testing" in section 414-00 of the workshop manual.

Checking the quiescent current

NOTE: On vehicles equipped with a Battery Monitoring System (BMS), the diagnostic procedure to check for quiescent current leakage should be used with the recommended diagnostic system.

NOTE: If the customer complains of constant battery discharge or discharge after prolonged non-use, it is recommended to perform a quiescent current leakage test as described below.

NOTE: Battery discharge should be measured using the recommended diagnostic system or a digital multimeter (DVOM). The vehicle must be locked, armed, and (i.e. the alarm is fully on), all doors, hood, trunk lid are open and locked (they should appear electrically closed). The test should be performed after the vehicle has been in the full shutdown mode. The time required for this after the ignition is turned off varies by model - see "Static Discharge" in section 414-00 of the workshop manual.

NOTE: When the vehicle alarm is armed, the blinking of the alarm LED will cause a pulsation in the measured leakage current. In this case, the average current value should be obtained (to do this, use a digital multimeter with an average value function), or use the obtained current value without taking into account short-term peak values.

Equipment

Recommended diagnostic system with current probe or digital multimeter (DVOM) with current probe.

Using the recommended diagnostic system

• 1. Turn off all electrical consumers and ignition.
• 2. Connect the current measurement probe to the certified diagnostic system.
• 3. Calibrate the feeler gauge.
• 4. Install the clamp on the battery cable/terminal box cable.
• 5. Go to the "Checking the Quiescent Current" section.

Using a digital multimeter (DVOM).

NOTE: Do not use a linear digital multimeter to measure quiescent current leakage on vehicles equipped with an electronic throttle. The current exceeds the maximum rating of the digital multimeter fuse.

• 1. Turn off all electrical consumers and ignition.
• 2. Connect the current probe to the digital multimeter.
• 3. Calibrate the feeler gauge.
• 4. Install the clamp on the battery cable/terminal box cable.
• 5. Proceed to the next section "Checking the Quiescent Current".

Checking the quiescent current

• 1. Turn on the ignition or select the ignition mode (on vehicles equipped with a keyless entry system), then turn it off (without starting the engine).
• 2. Remove the key from the ignition switch (if applicable).
• 3. Open and secure all doors, hood and trunk lid.
• 4. Lock the car using the remote control. (Just locking to prevent the volumetric alarm from going off).
• 5. Remove all other potential current consumers, such as additional equipment plugged into the socket.
• 6. Record the ampere reading after the shutdown period. For the static discharge ampere reading for each model, refer to the "Static Discharge" subsection in section 414-00 of the repair manual
• 7. Record the final value in the Battery Status Report in Appendix B.

NOTE: In case of increased current consumption, it is recommended to use the following method of testing: connect the probe to each individual wire of the terminal block leading to potentially faulty circuits in turn, identify the source of the fault. This method is preferable to the previous method of removing fuses for the following reasons:

• many modules require a considerable amount of time to completely switch off. When fuses are removed and then installed, the quiescent current leakage value stabilizes over a long period of time (usually up to 45 minutes).
• the leakage may be caused by a module that is not turned off, which prevents the quiescent current leakage from decreasing to normal levels;
• the leak may be caused by an activated relay coil. Removing the fuse causes a "reset" and the leak may not be registered by the diagnostic system.

Appendix A. Battery Testing Procedure

It is recommended that this test be performed at least 24 hours after the engine has been turned off or the battery has been charged to eliminate the need for surface discharge, if time constraints exist, perform surface discharge.

Part 1 - Surface charge removal

NOTE: Before checking the battery, make sure there is no surface charge on the battery.

NOTE: Battery testing can be performed on a workbench or directly on the vehicle.

If the test is performed on a vehicle, the battery should be isolated from the vehicle by disconnecting the negative (-) wire from its terminal before taking the measurement. The exception is when the vehicle has a transport relay or is in transport mode.

If the vehicle's battery has been charged or driven within 24 hours prior to testing, the vehicle must be de-charged using one of the following methods:

• 1. If 24 hours have passed since the engine was last started or the battery was charged, proceed to "Part 2 - Checking the Battery".
• 2. Turn on the ignition. Turn on the high beam headlights for at least 3 minutes.
• 3. Turn off the headlights. On vehicles being tested after the transit relay has been removed, disconnect the battery by removing the negative (-) cable. Vehicles with a transit relay installed or with the low current transit mode engaged do not require the battery to be disconnected.
• 4. Wait no more than 5 minutes before recording any battery test results.

Part 2 - Checking the Battery

NOTE: Before performing this test, the battery surface charge must be removed as instructed in Part 1 above. Make sure the battery terminals are clean. When connecting the Midtronics tester, connect the RED clamp to the positive (+) battery terminal first, then the BLACK clamp to the negative (-) battery terminal. Rock the clamps back and forth to ensure proper contact with the battery posts.

NOTE: Do not use the Midtronics 393, 394, 493, and 494 testers to test AGM batteries as they are not suitable for testing AGM batteries and may give false results. To test an AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.

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

• 1. Connect the Midtronics tester to the battery.
• 2. Follow the tester's instructions to check the battery. Be sure to select the battery type and size.
• 3. Perform the actions required by the verification results (see table below).
• 4. Enter the readings and the resulting verification code into the battery reporting form (appendix B) or similar form that records at least the following information: technician's name, vehicle identification number (VIN), test date, Midtronics code, and battery voltage according to the Midtronics tester.

Once the test is complete, the negative (-) battery cable should be connected to the battery terminal.

RESULTS OBTAINED WITH THE TESTER	ACTION
GOOD BATTERY (The battery is normal)	Return to service.
GOOD RE-CHARGE (Battery is good, needs charging)	Fully charge the battery and return it to service.
CHARGE AND RETEST (Charge and retest)	Fully charge the battery. Remove the surface charge. Retest the battery. If the result does not change, replace the battery.
REPLACE THE BATTERY OR THE BATTERY IS DEFECTIVE	Make sure the surface charge is removed. Disconnect the battery from the vehicle and retest. If the result does not change after removing the surface charge, replace the battery. DO NOT RECHARGE.
UNABLE TO DO TEST (Unable to perform verification)	Disconnect the battery from the vehicle and retest.