So, taking on board the possibility of one or two duff batteries I have charged my slave battery overnight having done some testing on the old battery yesterday.
All battery charging is taking place using a FOXSUR 3 IN 1 12V 24V Touch Screen LCD Pulse Repair Battery Charger Motorcycle Car Automatic Intelligent For Lithium Battery Lead-Acid Agm Gel Wet LiFePO4 Batteries, I have had good results with these pulse chargers in terms of "fixing" batteries and most importantly these pulse chargers will start charging a battery regardless of how low the battery voltage has been. I make this statement as some so called modern "intelligent" chargers from Lidl/Aldi/Halfords/ wherever, have got to be so intelligent that they refuse to charge a battery unless it is carrying a charge of approx 6 volts in it prior to you putting the leads into it, needless to say this is useless to us DIY guys as then we cant charge a very flat battery unless we "trick" the charger into thinking the battery has a high enough voltage to get the charger to kick in the charging process. I have read an interesting post where a guy goes into the guts of an Aldi charger and fits an override switch that enables the user to trigger the charger to charge a totally flat or low battery regardless but honestly why were they built like this in the first place !. MY other "old school" chargers simply start charging regardless of the battery voltage as you would expect of stuff built properly with the user in mind.
The link below is the one I have, it was cheap, it covers 12 and 24 volt, it covers all normal battery types and I would recommend as perfect for DIYers.
https://uk.banggood.com/FOXSUR-3-IN-1-12V-24V-Touch-Screen-LCD-Pulse-Repair-Battery-Charger-Motorcycle-Car-Automatic-Intelligent-For-Lithium-Battery-Lead-Acid-Agm-Gel-Wet-LiFePO4-Batteries-p-1707984.html?akmClientCountry=GB&a=1734803190.9465&cur_warehouse=CN
Rant over
My testing yesterday comprised leaving the battery negative lead off the night before hoping all the systems would then goto sleep. As stated before the fuse for the wiper motor had been put into fuse 25 (a slot with no terminals in it) when it should have been in slot 26 so I switched this.
The ignition is off and drivers door and bonnet locks have been "tricked" to show as closed to the cars brain. I had opened the drivers door with the key initially so in theory the car has had no cause to "wake up"
I then checked the voltage drain from the negative battery lead to the negative battery terminal, its was 12.6 volts.
I then checked the 3 fuses and the 5 cables in the positive terminal battery box by unscrewing the retaining nuts and removing the cable ends whilst watching the voltage meter to see if the drain fell. The pic shows cable 1 being tested in this way, there was no change to the voltage drain.
I then connected the negative lead to the terminal and put my voltage meter onto the positive side, I took the positive side fusebox off the main power lead itself and check between the main power lead (the thick one that goes to the starter) and the positive terminal, there was no drain. I then tested between the terminal and the positive terminal battery box, the drain re-appeared at the 12.6volts. So whatever is drawing power is coming through the fuse box. Not much I know but its all the black arts to me
I did try to check between the individual cables in the positive terminal fusebox and the fusebox itself and found low voltage draw down cables 6,5 & 4 (reading from the right and ref the Haynes) these being 6 Power steering control module, 5 Cooling fan control unit, glow plug control unit, or cooling fan control unit & 4 Starter headlights. Im a bit confused how the draw through these cables does not equate to the 12.6 volts draw I was seeing at the negative terminal measurement from earlier so I shall redo them with the slave battery soon.
At that point I reassembled the cables etc and went to to lock the car only for the car to be totally dead....I mean nothing, nada, zip, at this point I am thinking the worst and that somehow I have now b*ggered the whole thing with my hamfisted tinkering.
My wife advises I go to bed or come shopping with her.
Next day I plunked the now fully charged slave battery onto the system and took the battery that came with the car into the house to charge.
When I opened the car it seems I had left the negative terminal on the system and the battery was dead therefore once again the car systems should have all gone to sleep, so I tricked the drivers door and the bonnet latches into the closed position again and proceeded to check for current draw at the negative lead and terminal and found I was drawing next to nothing !!! This surprised me until I noticed that in my tired haste refitting the cables in the positive terminal fusebox I had placed cable 2 onto the "blank" terminal threaded stud which is situated in the gap between studs 1 and 2. DOH !! so I placed cable 2 back where it should be and suddenly the car was back to normal and the locks and lights etc all came on ok, praise the lord.
This cable 2 (SA2 on wiring diagrams) is listed in the Haynes as being "80 amp Fusebox in engine compartment Starter x contact relief" does anyone have a translation for what thats supposed to mean for christs sake ! As it happens nealry all the circuits start with this damn cable so that explains why the ignition and everything had no power !
Back to square one sort of.
So now i decided to perform a drop test on the battery to make sure it was good.
I untricked all the locks and closed. locked and opened the car doors an bonnet to ensure everything should be normal.
I connected the volt meter across the terminals using my extension cables so I could sit in the cab and start the car whilst also seeing the voltage drop, voltage was 12.93 volts prior to ignition. From the footage i recorded the voltage drops to 10.23 volts and then rapidly climbs again when i turn the key, so thats a pass in my book. At this point i noticed that the alternator was running and providing a healthy 14v to the battery so thats something else ticked off.
Most other websites advise your battery should not drop lower than 9.7 volts upon ignition. In the event you do get a sub 9.7v drop this would indicate that one or more battery cells have "dropped" and are not holding charge.
A recent site i read told me that the 6 cells in the battery carry approx 2.13v each so when you see a reading thats a multiple of 2.13 in your battery you can be sure its a knackered cell
Drop test over on the slave battery, will redo this test on the battery from the car itself tomorrow when its been repaired and charged.
So at this point I moved onto checking the fusebox in the drivers footwell. Ignition off.
With the battery all connected up properly I went through all the fuses touching all the test points on the top of the fuse bodies to see if any of them were carrying a current - none of them were.
I then removed each fuse in turn and checked the fuse for continuity between the blades of the fuse, all the fuses showed continuity ( the current passed through the fuse successfully) indicating they were all good.
I then turned on the AC as the seller had previously mumbled something about it maybe not working a bit like mumbling about the rear wiper not working...fortunately the AC seems to blow cold. I should really have checked fuse 22 to see if it was carrying voltage at the time , oh well.
So basically I am still thinking the battery is discharging when the engines not running.
So back to the battery and undo the negative lead from the battery terminal again and measure the current drain in mA.... NOTHING !!!! (well 0.002) I cant believe it......Hold on though now lets not go mental i think. I turned the dial to test for the voltage between the negative terminal and the negative lead and its still 12.8v flowing back into the battery. So i turn the dial back to test for current flow to double check and I seem to be getting 0.016 mA on the 20mA range of my meter.
Ive left the car alone for a bit , with the negative lead attached. Im going back out to check it now to see what the current draw is now.