Content .. 87 88 89 90 ..

Jeep XJ. Manual - part 89

(6) Disconnect the solenoid terminal wire harness

connector from the connector receptacle on the
starter solenoid. Always support the starter motor

during this process. Do not let the starter motor
hang from the wire harness.

(7) Remove the starter motor and any starter

motor shims (if used) from the engine block.

4.0L ENGINE

(1) Disconnect and isolate the battery negative

cable.

(2) Raise and support the vehicle.
(3) Remove the lower screw (forward facing) that

secures the starter motor to the manual transmission
clutch housing or the automatic transmission torque
converter housing (Fig. 16).

(4) While supporting the starter motor with one

hand, use the other hand to remove the upper screw
(rearward facing) that secures the starter motor to
the manual transmission clutch housing or the auto-
matic transmission torque converter housing.

(5) Lower the starter motor from the front of the

manual transmission clutch housing or automatic
transmission torque converter housing far enough to
access and remove the nut that secures the battery
positive cable eyelet terminal to the starter solenoid
B(+) terminal stud (Fig. 15). Always support the
starter motor during this process. Do not let the
starter motor hang from the wire harness.

(6) Remove the battery positive cable eyelet termi-

nal from the solenoid B(+) terminal stud. Always
support the starter motor during this process. Do not
let the starter motor hang from the wire harness.

(7) Disconnect the solenoid terminal wire harness

connector from the connector receptacle on the

Fig. 14 Starter Motor Remove/Install - 2.5L Engine

1 – STARTER MOTOR
2 – SCREW (2)
3 – SHIM

Fig. 15 Starter Connections Remove/Install - Typical

1 – STARTER MOTOR
2 – SOLENOID B(+) TERMINAL STUD
3 – BATTERY POSITIVE CABLE EYELET TERMINAL
4 – NUT
5 – SOLENOID TERMINAL WIRE HARNESS CONNECTOR
6 – SOLENOID TERMINAL CONNECTOR RECEPTACLE

Fig. 16 Starter Motor Remove/Install - 4.0L Engine

1 – SCREW
2 – STARTER MOTOR
3 – SCREW

8B - 12

STARTING SYSTEMS

REMOVAL AND INSTALLATION (Continued)

starter solenoid. Always support the starter motor
during this process. Do not let the starter motor
hang from the wire harness.

(8) Remove the starter motor from the manual

transmission clutch housing or automatic transmis-
sion torque converter housing.

INSTALLATION

2.5L ENGINE

(1) Position the starter motor to the engine block.
(2) Reconnect the solenoid terminal wire harness

connector to the connector receptacle on the starter
solenoid. Always support the starter motor during
this process. Do not let the starter motor hang from
the wire harness.

(3) Install the battery positive cable eyelet termi-

nal onto the starter solenoid B(+) terminal stud.
Always support the starter motor during this process.
Do not let the starter motor hang from the wire har-
ness.

(4) Install and tighten the nut that secures the

battery positive cable eyelet terminal to the starter
solenoid B(+) terminal stud. Tighten the nut to 11.3
N·m (100 in. lbs.). Always support the starter motor
during this process. Do not let the starter motor
hang from the wire harness.

(5) Position the starter motor and any starter

motor shims that were removed during the starter
motor removal procedure to the engine block. Loosely
install the two starter motor mounting screws to
secure the starter motor and shims to the engine
block.

NOTE: Shim thickness available is 0.381 mm (0.015
in.). Refer to Starter Motor Noise - 2.5L Engine in
the index of this service manual for the location of
the proper starter motor noise diagnosis and test-
ing procedures.

(6) Tighten the two screws that secure the starter

motor and shims to the engine block. Tighten the
screws to 44.7 N·m (33 ft. lbs.).

(7) Lower the vehicle.
(8) Reconnect the battery negative cable.

4.0L ENGINE

(1) Position the starter motor to the manual trans-

mission clutch housing or automatic transmission
torque converter housing.

(2) Reconnect the solenoid terminal wire harness

connector to the connector receptacle on the starter
solenoid. Always support the starter motor during
this process. Do not let the starter motor hang from
the wire harness.

(3) Install the battery positive cable eyelet termi-

nal onto the starter solenoid B(+) terminal stud.

Always support the starter motor during this process.
Do not let the starter motor hang from the wire har-
ness.

(4) Install and tighten the nut that secures the

(5) Position the starter motor to the manual trans-

mission clutch housing or automatic transmission
torque converter housing. Loosely install the two
starter motor mounting screws to secure the starter
motor to the manual transmission clutch housing or
automatic transmission torque converter housing.

(6) Tighten the lower (forward facing) screw that

secures the starter motor to the manual transmission
clutch housing or automatic transmission torque con-
verter housing. Tighten the screw to 40.7 N·m (30 ft.
lbs.).

(7) Tighten the upper (rearward facing) screw that

secures the starter motor to the manual transmission
clutch housing or automatic transmission torque con-
verter housing. Tighten the screw to 47.5 N·m (35 ft.
lbs.).

(8) Lower the vehicle.
(9) Reconnect the battery negative cable.

STARTER RELAY

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the cover from the Power Distribution

Center (PDC) (Fig. 17).

(3) See the fuse and relay layout label affixed to

the underside of the PDC cover for starter relay iden-
tification and location.

(4) Remove the starter relay from the PDC.

INSTALLATION

(1) See the fuse and relay layout label affixed to

the underside of the PDC cover for the proper starter
relay location.

(2) Position the starter relay in the proper recep-

tacle in the PDC.

(3) Align the starter relay terminals with the ter-

minal cavities in the PDC receptacle.

(4) Push down firmly on the starter relay until the

terminals are fully seated in the terminal cavities in
the PDC receptacle.

(5) Install the cover onto the PDC.
(6) Reconnect the battery negative cable.

STARTING SYSTEMS

8B - 13

REMOVAL AND INSTALLATION (Continued)

CLEANING AND INSPECTION

STARTING SYSTEM

The following components of the starting system

should be carefully inspected whenever any starting
system problem is encountered.

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

• Battery Visually inspect the battery for indica-

tions of physical damage and loose or corroded cable
connections.

Determine

the

state-of-charge

and

cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Battery in the index
of this service manual for the location of the proper
battery cleaning and inspection procedures.

• Ignition Switch Visually inspect the ignition

switch for indications of physical damage and loose
or corroded wire harness connections. Clean corroded
connections as required. Refer to Wiring Diagrams
in the index of this service manual for the location of
the proper wiring repair or connector and terminal
service procedures. Refer to Ignition Switch and
Key Lock Cylinder in the index of this service
manual for the location of the proper ignition switch
service procedures.

• Clutch Pedal Position Switch If the vehicle is

equipped

with

manual

transmission,

visually

inspect the clutch pedal position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Clean corroded connections as
required. Refer to Wiring Diagrams in the index of
this service manual for the location of the proper wir-
ing repair or connector and terminal service proce-
dures. Refer to Clutch Hydraulic Linkage in the
index of this service manual for the location of the
proper clutch pedal position switch service proce-
dures.

• Park/Neutral Position Switch If the vehicle is

equipped with an automatic transmission, visually
inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Clean corroded connections as
required. Refer to Wiring Diagrams in the index of
this service manual for the location of the proper wir-
ing repair or connector and terminal service proce-
dures. Refer to Park/Neutral Position Switch in
the index of this service manual for the location of
the proper park/neutral position switch service proce-
dures.

• Starter Relay Visually inspect the starter relay

for indications of physical damage and loose or cor-
roded wire harness connections. Clean corroded con-
nections as required. Refer to Wiring Diagrams in
the index of this service manual for the location of
the proper wiring repair or connector and terminal
service procedures. Refer to Starter Relay in the
index of this service manual for the location of the
proper starter relay service procedures.

• Starter Motor Visually inspect the starter motor

for indications of physical damage and loose or cor-
roded wire harness connections. Clean corroded con-
nections as required. Refer to Wiring Diagrams in
the index of this service manual for the location of
the proper wiring repair or connector and terminal
service procedures. If the problem being diagnosed
involves improper starter engagement, disengage-
ment or noise complaints the starter motor should be
removed. With the starter motor removed, inspect
the starter pinion and ring gears for damaged or
missing

teeth.

Replace

faulty

components

required. Refer to Starter Motor in the index of this

Fig. 17 Power Distribution Center

1 – RIGHT FENDER
2 – BATTERY
3 – POWER DISTRIBUTION CENTER

8B - 14

STARTING SYSTEMS

REMOVAL AND INSTALLATION (Continued)

service manual for the location of the proper starter
motor removal and installation procedures.

• Starter Solenoid Visually inspect the starter

solenoid for indications of physical damage and loose
or corroded wire harness connections. Clean corroded
connections as required. Refer to Wiring Diagrams
in the index of this service manual for the location of
the proper wiring repair or connector and terminal
service procedures. Refer to Starter Motor in the
index of this service manual for the location of the
proper starter solenoid service procedures.

• Wiring Visually inspect the starting system wire

harnesses for indications of physical damage. Repair
or replace any faulty wiring, as required. Refer to
Starting System in the index of this service manual
for the location of complete starting system wiring
diagrams. Refer to Wiring Diagrams in the index of
this service manual for the location of the proper wir-
ing repair or connector and terminal service proce-
dures.

SPECIFICATIONS

STARTING SYSTEM

Starter Motor and Solenoid

Manufacturer

Mitsubishi

Engine Application

2.5L, 4.0L

Power Rating

2.5L - 1.2 Kilowatt (1.6 Horsepower)
4.0L - 1.4 Kilowatt (1.9 Horsepower)

Voltage

12 Volts

Number of Fields

Number of Poles

Number of Brushes

Drive Type

Planetary Gear Reduction

Free Running Test Voltage

11.2 Volts

Free Running Test Maximum Amperage Draw

90 Amperes

Free Running Test Minimum Speed

2.5L - 2600 rpm
4.0L - 2500 rpm

Solenoid Closing Maximum Voltage Required

7.8 Volts

*Cranking Amperage Draw Test

2.5L - 130 Amperes
4.0L - 160 Amperes

*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

STARTING SYSTEMS

8B - 15

CLEANING AND INSPECTION (Continued)

Content .. 87 88 89 90 ..