EXJ_8B99 jeep xj service manual

7/29/2019 EXJ_8B99 jeep xj service manual

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STARTING SYSTEMS

CONTENTS

page page

GENERAL INFORMATIONINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DESCRIPTION AND OPERATION

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2

DIAGNOSIS AND TESTINGCOLD CRANKING TEST . . . . . . . . . . . . . . . . . . 3

CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . 6FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . 3

STARTER NOISE - 2.5L ENGINE . . . . . . . . . . . . 7STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3

REMOVAL AND INSTALLATIONSTARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 9STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPECIFICATIONSSTARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 10

GENERAL INFORMATION

OVERVIEW

T h e ba t t e r y , s t a r t i n g , a n d c h a r g i n g s y s t e m s o p e r -

a t e w i t h o n e a n o t h e r , a n d m u s t b e t e s t e d a s a c o m -

p let e s y st e m. I n or d er f or t h e v eh i cl e t o s t a r t a n d

ch a r g e p r op er l y, a l l of t h e com p on e n t s i n vol v ed i n

these systems must perform within specifications.

G roup 8A covers t he ba ttery, G roup 8B covers th e

s t a r t i n g s y s t em , a n d Gr o u p 8 C c ov er s t h e c h a r g i n g

s y s t em . R ef er t o Gr o u p 8W - Wi r in g Di a g r a m s f or

complete circuit descriptions an d diagra ms. We h ave

s ep a r a t e d t h e s e s y st e m s t o m a k e i t e a s i er t o l oca t et h e i n f o r m a t i o n y o u a r e s e e k i n g w i t h i n t h i s Se r v i c e

M a n u a l . H o w e v e r , w h e n a t t e m p t i n g t o d i a g n o s e a n y

o f t h e s e s y s t e m s , i t i s i m p o r t a n t t h a t y o u k e e p t h e i r

interdependency in mind.

Th e d i a g n os t i c p r oce d ur e s u s ed i n t h e s e g r ou p s

include the most basic conventional diagnostic meth-

ods, to the more sophisticated On-Board Diagnostics

(O B D ) b ui lt i nt o t h e P o w er t r a in C on t r ol M od ul e

(P CM). U se of a induction mill iampere ammeter, volt/

ohmmeter, bat tery cha rger, carbon pile rh eosta t (load

tester), and 12-volt test lamp may be required.

Al l O B D -s en s ed s y st e ms a r e m on i t or ed b y t h e

P C M . E a c h m o n i t o r e d c i r c u i t i s a s s i g n e d a Di a g n o s -tic Trouble Code (DTC). The P CM w ill store a DTC in

electronic memory for any fai lure i t detects. See the

O n -B o a r d Di a g n o st i cs Te st i n Gr o u p 8C - C h a r g i n g

System for more information.

INTRODUCTION

The starting system consists of:

B a t t e r y

S t a r t e r r el a y

St a r t e r w i t h a n i n t e g r a l s o l e n o i d

Ignition switch

C l u t c h p e d a l p o s i t i o n s w i t c h (m a n u a l t r a n s m i s -

sion)

P a r k /n e u t r a l p os i t ion s w i t ch (a u t o m a t i c t r a n s -

mission)

Wire ha rness an d connections.

This group covers diagnosis of the complete start-

i n g s y s t em , e xce pt t h e ba t t e r y. H o w e ve r, t h i s g r ou p

on l y cov er s s er v i ce p r oce d ur e s f or t h e s t a r t e r a n d

s t a r t e r r e la y . Se r v ice p r oce d ur e s f or ot h e r s t a r t i n g

system components can be located as fol lows: B a t t e r y - r ef er t o G r ou p 8A - B a t t er y f or t h e

diagnostic and service procedures

I g n it i on s w i t ch - r e fe r t o G r o up 8D - I g n it i on

Systems for the service procedures

Clutch pedal position switch - refer to Group 6 -

Clutch for the service procedures

P ark/neutra l position switch - refer t o G roup 21

- Tra nsmission for t he service procedures

Wi r e h a r n e ss a n d con n e ct i on s - r e fe r t o Gr o u p

8W - Wiring Dia grams for the service procedures.

NOTE: This group covers both Left-Hand Drive

(LHD) and Right-Hand Drive (RHD) versions of thismodel. Whenever required and feasible, the RHDversions of affected vehicle components have beenconstructed as mirror-image of the LHD versions.While most of the illustrations used in this group

represent only the LHD version, the diagnostic andservice procedures outlined can generally beapplied to either version. Exceptions to this rulehave been clearly identified as LHD or RHD, if aspecial illustration or procedure is required.

XJ STARTING SYSTEMS 8B - 1


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DESCRIPTION AND OPERATION

STARTING SYSTEM

The starting system components form two separate

circuits. A high-amperage feed circuit tha t feeds the

starter between 150 and 350 amperes, and a low-am-

p er a g e con t r o l c ir cu i t t h a t op er a t e s o n l es s t h a n 20amperes.

I f t h e v e h icl e i s e q u i pp ed w i t h a n a u t o m a t i c t r a n s -

mission, battery voltage is supplied through the low-

a m p e r a g e c on t r o l c ir cu i t t o t h e coi l ba t t e r y t e r m in a l

of t h e s ta r t er r ela y w h en t h e ig nit ion s w it ch is

turned to t he S ta rt position. The pa rk/neutra l posi-

t i o n s w i t c h i s i n s t a l l e d i n s e r i e s be t w e e n t h e s t a r t e r

relay coil ground terminal and ground. This normally

op en s w i t ch p re ve nt s t h e s t a r t er r el a y f r om b ei n g

e ne rg iz ed u n le ss t h e a u t om a t i c t r a n s m is si on g ea r

selector is in the Neutral or Park positions.

I f t h e v e h icl e i s e q u ip pe d w i t h a m a n u a l t r a n s m is -

sion, i t has a clutch pedal position switch instal led ins e r i e s be t w e e n t h e i g n i t i o n s w i t c h a n d t h e c o i l ba t -

tery terminal of the starter relay. This normally open

s w i t ch p rev en t s t h e s t a r t er r el a y f r om b ei n g e ne r-

gized unless the clutch pedal is depressed, preventing

s t a r t e r op er a t i on w h i le t h e cl ut ch d i sc a n d t h e f ly -

wheel are engaged. The starter relay coil ground ter-

m i n a l i s a l w a y s g r o u n d e d o n v e h i c l e s w i t h a m a n u a l

transmission.

W h e n t h e s t a r t e r r e l a y c o i l i s e n e r g i z e d , t h e n o r -

m a l l y op en r e la y con t a ct s cl os e. Th e r e la y con t a c t s

connect the relay common feed terminal to the relay

n or m a l l y op en t e r m in a l . Th e cl os ed r e la y con t a c t s

energize the starter solenoid coil windings.

The energized solenoid pull-in coil pulls in the sole-

n oi d p lu n g er. Th e s ol en oi d p lu n g er p u ll s t h e s h i ft

lever in the starter. This engages the starter overrun-

n in g cl ut ch a n d p in ion g ea r w i t h t h e s t a r t er r in g

g e a r o n t h e m a n u a l t r a n s m i s s i o n f l y w h e e l , o r o n t h e

automatic transmission torque converter drive plate.

As t h e s ol en oi d p lu n g er r ea c h es t h e e nd of i t s

travel , the solenoid contact disc completes the high-

amperage starter feed circuit and energizes the sole-

noid plunger hold-in coil. Current now flows between

t h e s o l e n o i d ba t t e r y t e r m i n a l a n d t h e s t a r t e r m o t o r ,

energizing the starter.

Once th e engine sta rts, the overrunning clutch pro-

t e ct s t h e s t a r t e r f r om d a m a g e by a l low i n g t h e s t a r t e r

pi ni on g ea r t o s pi n f a st er t h a n t h e p in ion s ha f t .

W h e n t h e d r i v e r r e l e a s e s t h e i g n i t i o n s w i t c h t o t h e

O n p os i t ion , t h e s t a r t e r r e la y coi l i s d e -e n er g i ze d .

Th i s ca u s es t h e r el a y con t a c t s t o op en . Wh en t h e

r el a y con t a c t s op en , t h e s t a r t e r s ol en oi d p lu n ge r

hold-in coil is de-energized.

When the solenoid plunger hold-in coil is de-ener-

gized, the solenoid plunger return spring returns the

plunger to i ts relaxed position. This causes the con-

tact disc to open the starter feed circuit , and the shift

lever to disengage the overrunning clutch and pinion

g e a r f r o m t h e s t a r t e r r i n g g e a r .

STARTER

The starter motor incorporates several features to

creat e a reliable, efficient, compact, a nd l ightweightu n it . A p la n e t a r y g ea r s y st e m (i n t er m ed i a t e t r a n s -

m i s s i o n ) i s u s e d be t w e e n t h e e l e c t r i c m o t o r a n d t h e

pinion gear. This feature makes i t possible to reduce

t h e d i me ns ion s of t h e s t a r t e r. At t h e s a m e t i m e, i t

a l l ow s h i g h er a r m a t u r e r o t a t i o n a l s p ee d a n d d e li v er s

i ncr ea s ed t or q ue t h r ou gh t h e pi ni on g ea r t o t h e

s t a r t er r in g g ea r on t h e a u t om a t ic t r a n sm is si on

torque converter or torque converter drive plate, or

on t h e m a n u a l t r a n s m i s si on f ly w h e el .

The use of a perma nent ma gnet field a lso reduces

t h e s iz e a n d w e ig h t of t h e s t a r t er. Th e p er m a n en t

m a g n e t f i el d con s i st s of f ou r h i g h -s t r e n gt h p er m a -

n e n t m a g n e t s . Th e m a g n e t s a r e a l ig n ed a c cor d i n g t ot h e i r p o l a r i t y , a n d a r e p e r m a n e n t l y m o u n t e d i n t h e

s t a r t e r f i e l d f r a m e .

The starter motors for al l engines are activated by

a solenoid mounted to t he overrunning clutch hous-

ing. However, the starter motor and solenoid are ser-

v iced on ly a s a com plet e a s sem bl y. I f eit h er

com p on e n t i s f a u l t y or d a m a g e d, t h e e n t i r e s t a r t e r

assembly must be replaced.

CAUTION: Permanent magnet starters are highly sensi-

tive to hammering, shocks, and external pressure.

The permanent magnets may be damaged and thestarter rendered unserviceable, if subjected to anyof these conditions. The starter motor must not be clamped in a

vise by the starter field frame. Doing so may dam-

age the permanent magnets. The starter shouldonly be clamped by the mounting flange. Do not connect the starter motor incorrectly

when testing. Reverse polarity may damage the per-

manent magnets and render the starter unservice-able.

STARTER RELAYTh e s t a r ter r el a y i s a I n t er n a t ion a l S t a n d a r ds

Organization (ISO)-type relay. The starter relay is a

e le ct r o me ch a n i ca l d e vi ce t h a t s w i t ch e s ba t t e r y cu r -

r e n t t o t h e p u ll -i n coi l o f t h e s t a r t e r s ol en oi d w h e n

t h e i gn i t ion s w i t ch i s t u r n ed t o t h e S t a r t p os it i on .

Se e t h e Di a g n o si s a n d Te st i n g s ect i on of t h i s g r ou p

f o r m o r e i n f o r m a t i o n o n t h e o p e r a t i o n o f t h e s t a r t e r

relay.

T h e s t a r t e r r e l a y i s l o c a t e d i n t h e P o w e r Di s t r i bu -

tion Center (PDC), in the engine compartment. Refer

to the PDC label for relay identification and location.

8B - 2 STARTING SYSTEMS XJ


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T h e s t a r t e r r e l a y c a n n o t be r e p a i r e d a n d , i f f a u l t y

o r d a m a g e d , i t m u s t be r e p l a c e d .

DIAGNOSIS AND TESTING

STARTING SYSTEM

F or ci r cu it d es cr i pt i on s a n d d ia g r a m s , r ef er t o

8W-21 - Starting System in Group 8W - Wiring Dia-

g r a m s .

WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANY

STEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-

BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.

INSPECTION

B e f or e r e m ov i n g a n y u n i t f r o m t h e s t a r t i n g s y s t em

for repair or diagnosis, perform the following inspec-

tions:

Battery - Visually inspect the battery for indi-ca t i on s of p hy s ica l d a m a g e a n d l oos e or cor r od ed

cable connections. D etermine t he sta te-of-charge an d

cr a n k i n g ca p a c it y of t h e ba t t e r y. C h a r g e or r e pl a c e

t h e ba t t e r y , i f r e q u i r e d . R e f e r t o Gr o u p 8 A - B a t t e r y

for more informa tion.

Ignition Switch - Visually inspect the ignitions w i t ch f or i n d ica t i on s of p h y si ca l d a m a g e a n d l oos e

or corroded wire harness connections.

Clutch Pedal Position Switch - Visuallyi n s pe ct t h e cl u t ch p ed a l p os i t ion s w i t ch f or i n d ica -

t i o n s o f p h y s i c a l d a m a g e a n d l o o s e o r c o r r o d e d w i r e

harness connections.

Park/Neutral Position Switch - Vi s u a l lyinspect the park/neutra l position switch for indica-

t i o n s o f p h y s i c a l d a m a g e a n d l o o s e o r c o r r o d e d w i r e


Starter Relay - Vi s ua l l y i n s pe ct t h e s t a r t e rrelay for indications of physical damage and loose or

corroded wire harness connections.

Starter - Vi s u a l l y i n s p e c t t h e s t a r t e r f o r i n d i -cations of physical dama ge a nd loose or corroded wire


Starter Solenoid - Visually inspect the startersolenoid for indications of physical damage and loose

or corroded wire harness connections.

Wiring - Visually inspect the wire harness ford a m a g e. R ep a ir or r epl a ce a n y f a ul t y w i ri ng , a s

required.

COLD CRANKING TEST



g r a m s . T h e ba t t e r y m u s t be f u l l y - c h a r g e d a n d l o a d -

tested before proceeding. R efer to G roup 8A - Ba tt ery

for more informa tion.

(1) C o n ne ct a s u it a bl e v o lt -a m p e r e t e st e r t o t h eb a t t e r y t e rm i na l s (F i g. 1). R ef er t o t h e op er a t i n g

instructions provided with the tester being used.

(2) Fu l ly e n ga g e t h e p a r k in g br a k e .

(3) I f t h e v eh i cl e i s e qu i pp ed w i t h a n a u t om a t i c

transmission, place the gearshift selector lever in the

P a r k p os i t ion . I f t h e v e h icl e i s e q u i pp ed w i t h a m a n -

ual transmission, place the gearshift selector lever in

t h e N eu t r a l p os it i on a n d f ul ly d ep res s t h e cl ut ch

pedal .

(4) Ver if y t h a t a l l l a mps a n d a cces sor ies a r e

turned off.

(5) To p r ev en t t h e e n gi n e f r om s t a r t i n g , u n p lu g

the Automat ic Shut Down (ASD ) relay. The ASD relayi s l o ca t e d i n t h e P o w e r Di s t r i bu t i on C e n t er (P D C ).

R ef er t o t h e P D C l a b el f or r el a y i de nt i fi ca t i on a n d

location.

(6) R ot a t e a n d h ol d t h e i g n i t i on s w i t ch i n t h e St a r t

p os it ion . N ot e t h e cr a n ki ng v ol t a ge a n d cu r ren t

(amperage) draw.

(a ) I f t h e v ol t a g e r e a d s bel ow 9.6 v ol t s , r e m ov e

t h e s t a r t e r f o r be n c h t e s t i n g . I f t h e s t a r t e r be n c h

t e st i s O K , r ef er t o G r ou p 9 - E n g in e f or f ur t h er

d i a g n os i s o f t h e e n gi n e. I f t h e s t a r t e r be n ch t e s t i s

n o t O K, r e p l a c e t h e f a u l t y s t a r t e r .

(b) I f t h e v o l t a g e r e a d s a bo v e 9 .6 v o l t s a n d t h e

cu r r en t (a m p e r a g e) d r a w r e a d s bel ow s p eci f ica -

tions, see t he Feed C ircuit Test procedures in this

group.

(c) If the voltage reads 12.5 volts or greater and

t h e s t a r t e r d oe s n o t t u r n , s ee t h e C o n t r ol C i r cu i t

Test procedures in th is gr oup.

(d) If the voltage reads 12.5 volts or greater and

t h e s t a r t e r t u r n s v e r y s l o w l y , s e e t h e Fe e d C i r c u i t

Test procedures in th is gr oup.

NOTE: A cold engine will increase the starter cur-

rent (amperage) draw reading, and reduce the bat-tery voltage reading.

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method)

will determine i f there is excessive resistance in the

high-am perage circuit . For circuit descriptions an d

diagra ms, refer to 8W-21 - St art ing S ystem in G roup

8W - Wiring Dia grams.

Wh en p er f or m in g t h es e t e st s , i t i s i m por t a n t t o

r e m e m be r t h a t t h e v o l t a g e d r o p i s g i v i n g a n i n d i c a -

t i on of t h e r es is t a n ce b et w een t h e t w o poi nt s a t

w h i ch t h e v ol t m et e r p r obes a r e a t t a c h e d.


DESCRIPTION AND OPERATION (Continued)


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Example: W h e n t e s t i n g t h e r e s i s t a n c e o f t h e ba t -t e r y p o s i t i v e c a bl e , t o u c h t h e v o l t m e t e r l e a d s t o t h e

battery positive cable clamp and the cable connector

a t t h e s t a r t e r s o l e n o i d . I f y o u p r o be t h e ba t t e r y p o s -

i t iv e t e r m in a l p os t a n d t h e ca b l e c on n ect or a t t h e

s t a r t e r s o l e n o i d , y o u a r e r e a d i n g t h e c o m bi n e d v o l t -

age drop in the bat tery positive cable clamp-to-termi-

nal post connection and the battery positive cable.

Th e f ol l ow i n g op er a t i on w i l l r e q u ir e a v ol t m et e r

accura te to 1/10 (0.10) volt . B efore performing the

tests, be certain the following procedures are accom-

plished:

B a t t e r y i s f u ll y -ch a r g ed . R ef er t o G r o up 8A -

Battery for more information.

Fu l l y e n g a g e t h e p a r k i n g br a k e .

I f t h e v eh icl e i s eq u ipped w i t h a n a u t om a t ic

transmission, place the gearshift selector lever in the

P a r k p o si t i on . I f t h e v e h icl e i s e q u i pp ed w i t h a m a n -

ual transmission, place the gearshift selector lever in

t h e N eu t r a l p os it i on a n d f ul ly d ep res s t h e cl ut ch

pedal.

U n p l u g t h e Au t om a t i c S h u t Do w n (ASD) r e l a y t o

p r ev en t t h e e n gi n e f r om s t a r t i n g . Th e ASD r e la y i s

l oca t e d i n t h e P o w er D i s t ri bu t i on C e nt e r (P D C ) .

Starting System Diagnosis

CONDITION POSSIBLE CAUSE CORRECTION

STARTER FAILSTO ENGAGE.

1. Battery discharged orfaulty.2. Starting circuit wiring

faulty.3. Starter relay faulty.4. Ignition switch faulty.5. Park/Neutral position

switch (auto trans) faultyor misadjusted.6. Clutch pedal positionswitch (man trans) faulty.7. Starter solenoid faulty.

8. Starter assemblyfaulty.

1. Refer to Group 8A - Battery. Charge or replace battery, ifrequired.2. See Cold Cranking Test, in this group. Test and repair feed

and/or control circuits, if required.3. See Relay Test, in this group. Replace relay, if required.4. See Ignition Switch Test, in this group. Replace switch, ifrequired.

5. See Park/Neutral Position Switch, in Group 21 - Transmissionand Transfer Case for the diagnosis and service of thiscomponent. Replace switch, if required.6. See Clutch Pedal Position Switch Test, in this group. Replaceswitch, if required.

7. See Solenoid Test, in this Group. Replace starter assembly, ifrequired.8. If all other starting system components and circuits check OK,replace starter assembly.

STARTERENGAGES,

FAILS TO TURNENGINE.

1. Battery discharged orfaulty.

2. Starting circuit wiringfaulty.3. Starter assemblyfaulty.

4. Engine seized.

1. Refer to Group 8A - Battery. Charge or replace battery, ifrequired.

2. See Cold Cranking Test, in this group. Test and repair feedand/or control circuits, if required.3. If all other starting system components and circuits check OK,replace starter assembly.

4. Refer to Group 9 - Engine, for diagnostic and serviceprocedures.

STARTER

ENGAGES,SPINS OUTBEFORE

ENGINESTARTS.

1. Broken teeth on

starter ring gear.2. Starter assemblyfaulty.

1. Remove starter as described in this group. Inspect ring gear

and replace, if required.2. If all other starting system components and circuits check OK,replace starter assembly.

STARTER DOES

NOTDISENGAGE.

1. Starter improperly

installed.2. Starter relay faulty.3. Ignition switch faulty.4. Starter assembly

faulty.

1. Install starter as described in this group. Tighten starter

mounting hardware to correct torque specifications.2. See Relay Test, in this group. Replace relay, if required.3. See Ignition Switch Test, in this group. Replace switch, ifrequired.

4. If all other starting system components and circuits check OK,replace starter assembly.


DIAGNOSIS AND TESTING (Continued)


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R e fe r t o t h e P DC l a be l f or A SD r e la y i d en t i f ica t i on

and location.

(1) C o n n ect t h e p os i t iv e l e a d of t h e v ol t m et e r t o

t h e ba t t e r y n e g a t i v e t e r m in a l p os t . C on n e ct t h e n e g-a t i v e l ea d of t h e v ol t m et e r t o t h e b a t t e ry n eg a t i ve

ca b l e cl a m p (F i g. 2). R ot a t e a n d h ol d t h e i gn i t ion

switch in the Start position. Observe the voltmeter. If

volta ge is detected, correct the poor conta ct between

t h e c a bl e c l a m p a n d t h e t e r m i n a l p o s t .

(2) C o n n ect t h e p os i t iv e l e a d of t h e v ol t m et e r t o

the battery positive terminal post . Connect the nega-tive lead of t he voltmeter t o the ba ttery positive cable

clamp (Fig. 3). Rotate and hold the ignition switch in

t h e St a r t p os i t ion . O bse r ve t h e v ol t m et e r. I f v ol t a g e

i s d et e ct e d, cor r ect t h e p oor con t a c t b et w e en t h e

c a bl e c l a m p a n d t h e t e r m i n a l p o s t .

(3) Connect the voltmeter to measure between the

ba t t e r y p os i t iv e t e r m i n a l p o st a n d t h e s t a r t e r s ol e-

n o i d ba t t e r y t e r m i n a l s t u d (Fi g . 4 ) . R o t a t e a n d h o l d

the ignition switch in the Start position. Observe the

voltmeter. If the reading is above 0.2 volt , clean and

tighten the ba ttery cable connection at the solenoid.

R ep ea t t h e t e st . I f t h e r e a d i n g i s s t i l l a bo ve 0 .2 vol t ,

replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

b a t t er y n eg a t iv e t er m in a l pos t a n d a g ood cl ea n

ground on the engine block (Fig. 5). Rotate and hold

the ignition switch in the Start position. Observe the

voltmeter. If the reading is above 0.2 volt , clean and

t i g h t e n t h e ba t t e r y n e g a t i v e c a bl e a t t a c h m e n t o n t h e

e n g i n e bl o c k . R e p e a t t h e t e s t . I f t h e r e a d i n g i s s t i l l

a b ov e 0. 2 v ol t , r ep la c e t h e f a u lt y b a t t e r y n eg a t i vecable.

(5) C o n n ect t h e p os i t iv e l ea d of t h e v ol t m et e r t o

t h e s t a r t e r h o u s in g . C o n n ect t h e n e g a t i v e l e a d of t h e

v ol t m et e r t o t h e ba t t e r y n e ga t i v e t e r m in a l p os t (Fi g .

6 ) . R o t a t e a n d h o l d t h e i g n i t i o n s w i t c h i n t h e S t a r t

p os it i on . O bs er v e t h e v ol t m et e r. I f t h e r ea d i n g i s

a b ov e 0. 2 v ol t , cor r ect t h e p oor s t a r t e r t o en g in e

block ground contact.

I f t h e r e si s t a n ce t e s t s d e t ect n o f e ed ci r cu i t p r ob-

l em s , r e m ov e t h e s t a r t e r a n d s ee t h e So le n oi d Te st

procedure in this group.

Fig. 1 Volts-Amps Tester Connections - Typical

POSITIVECLAMP NEGATIVECLAMPINDUCTION AMMETERCLAMP

Fig. 2 Test Battery Negative Connection Resistance- Typical

VOLTMETERBATTERY

Fig. 3 Test Battery Positive Connection Resistance -

Typical

Fig. 4 Test Battery Positive Cable Resistance -Typical

BATTERYVOLTMETERSTARTERMOTOR




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CONTROL CIRCUIT TEST



grams. The starter control circuit consists of:

B a t t e r y

S t a r t e r r el a y

Starter solenoid

Ignition switch

P a r k /n e ut r a l p os i t ion s w i t ch (a u t o m a t i c t r a n s -

mission)

C l u t c h p e d a l p o s i t i o n s w i t c h (m a n u a l t r a n s m i s -

sion)

Wire harness and connections.Test procedures for these components should be

p e r f o r m e d i n t h e o r d e r i n w h i c h t h e y a r e l i s t e d , a s

follows:

SOLENOID TEST

R em ov e t h e s t a r t er a s d es cr i be d i n t h i s g r ou p.

Then proceed as follows:

(1) R e m ov e t h e w i r e f r om t h e s ol en oi d f i el d coi l

terminal .

(2) Check for continuity between the solenoid ter-

m i na l a n d t h e f iel d coi l t e r m in a l w i t h a con t i n ui t y

tester (Fig. 7). There should be continuity. If OK, go

t o St e p 3 . I f n o t O K, r e p la c e t h e f a u l t y s t a r t e r a s s e m -

bly.

(3) Check for continuity between the solenoid ter-

minal and the solenoid case (Fig. 8). There should be

continuity. If OK, go to Step 4. If not OK, replace the

f a u l t y s t a r t e r a s s e m bl y .

(4) Connect the solenoid field coil wire to the field

coil terminal .

(5 ) I n s t a l l t h e s t a r t e r a s d e s c r i be d i n t h i s g r o u p .

RELAY TEST

T h e s t a r t e r r e l a y i s l o c a t e d i n t h e P o w e r Di s t r i bu -

tion Center (PDC) in the engine compartment. Refer

t o t h e P DC l a be l f o r s t a r t e r r e l a y i d e n t i f i c a t i o n a n d

location.

Remove t he st a rt er rela y fr om t he P D C a s

described in this group to perform the following tests:

(1) A r e l a y i n t h e d e -e n er g i ze d p os i t ion s h ou l d

h a v e c o n t i n u i t y be t w e e n t e r m i n a l s 8 7 A a n d 3 0 , a n d

no continuity between terminals 87 and 30. If OK, go

t o St e p 2 . I f n o t O K, r e p l a c e t h e f a u l t y r e l a y .

(2) Resistance between terminals 85 and 86 (elec-tromagnet) should be 75 5 oh m s . I f O K, g o t o St e p

3 . I f n o t O K, r e p l a c e t h e f a u l t y r e l a y .

(3) C on n ect a b a t t er y t o t er m in a l s 85 a n d 86.

Th e r e s h o ul d n ow be con t i n u it y bet w e e n t e r m in a l s

30 and 87, and no continuity between terminals 87A

an d 30. I f OK, see the Relay Circuit Test procedure

i n t h i s g r o u p . I f n o t O K, r e p l a c e t h e f a u l t y r e l a y .

RELAY CIRCUIT TEST

(1) The relay common feed terminal cavity (30) is

con n e ct e d t o ba t t e r y v ol t a g e a n d s h ou l d be h o t a t a l l

Fig. 5 Test Ground Circuit Resistance - Typical

VOLTMETERENGINEGROUND BATTERY

Fig. 6 Test Starter Ground - Typical

STARTERMOTOR BATTERYVOLTMETER

Fig. 7 Continuity Test Between Solenoid Terminaland Field Coil Terminal

SOLENOID SOLENOIDTERMINAL OHMMETERFIELD COIL TERMI-NAL

Fig. 8 Continuity Test Between Solenoid Terminaland Solenoid Case

SOLENOID SOLENOID TER-MINALOHMMETER




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t imes. If OK, go to Step 2. If not OK, repair the open

c i r c u i t t o t h e P DC f u s e a s r e q u i r e d .

(2) Th e r e la y n or m a l l y cl os ed t e r m in a l (87A) i s

connected to terminal 30 in the de-energized position,

bu t i s n o t u s e d f o r t h i s a p p l i c a t i o n . Go t o St e p 3 .

(3) The relay normally open terminal (87) is con-

nected to the common feed terminal (30) in the ener-

gized position. This terminal supplies bat tery volta ge

t o t h e s t a r t e r s ol en oi d f ie ld coi ls . Th e r e s h o u ld be

con t i n u it y bet w e e n t h e c a v i t y f or r e la y t e r m in a l 87

a n d t h e s t a r t e r s o l e n o i d t e r m i n a l a t a l l t i m e s . I f O K,

go to Step 4. If not OK, repair the open circuit to the

starter solenoid as required.

(4) The coil bat tery terminal (86) is connected to

t h e e l e c t r o m a g n e t i n t h e r e l a y . I t i s e n e r g i z e d w h e nt h e i g n i t i o n s w i t c h i s h e l d i n t h e St a r t p o s i t i o n . O n

v eh icl es w i t h a m a n ua l t r a n sm is si on , t h e cl ut ch

pedal must be fully depressed for this test . Check for

b a t t e r y v ol t a g e a t t h e c a v it y f or r el a y t e rm in a l 86

w i t h t h e i g n i t i o n s w i t c h i n t h e St a r t p o s i t i o n , a n d n o

v ol t a g e w h en t h e i gn i t ion s w i t ch i s r el ea s e d t o t h e

O n p o s i t i o n . I f O K , g o t o S t e p 5 . I f n o t O K w i t h a n

a u t o m a t i c t r a n s m i s s ion , ch e ck f or a n op en or s h or t

c i r c u i t t o t h e i g n i t i o n s w i t c h a n d r e p a i r , i f r e q u i r e d .

I f t h e c ir cu it t o t h e i gn i t ion s w i t ch i s O K , s ee t h e

Ignition S witch Test procedure in this group. If not

O K w i t h a m a n u a l t r a n s m is si on , ch eck t h e ci r cu it

b et w een t h e r el a y a n d t h e cl ut ch ped a l pos it i onswitch for an open or a short . If the circuit is OK, see

t h e C l u t ch P e d a l P o s it i on Sw i t c h Te st p r oce d ur e i n

this group.

(5) The coil ground terminal (85) is connected to

t h e e l e c t r o m a g n e t i n t h e r e l a y . O n v e h i c l e s w i t h a n

a u t o m a t i c t r a n s m is s ion , i t i s g r o u n de d t h r o u g h t h e

park/neutra l position sw itch only when the gearshift

selector lever is in the Park or Neutral positions. On

v eh i cl es w i t h a m a n u a l t r a n s m i s s ion , i t i s g r o un d e d

a t a l l t i m es . C h e ck f or con t i n ui t y t o g r ou n d a t t h e

c a v i t y f o r r e l a y t e r m i n a l 8 5 . I f n o t O K w i t h a n a u t o -

mat ic tra nsmission, check for an open or short circuit

t o t h e p a r k/n eu t r a l p os it i on s w i t ch a n d r ep a i r, i f

r e q u ir e d . I f t h e ci r cu i t i s O K, s ee t h e P a r k /Ne ut r a l

P osition Sw itch Test procedure in this group. If not

O K w i t h a m a n u a l t r a n s m is s ion , r e p a i r t h e c ir cu i t t o

ground as required.

PARK/NEUTRAL POSITION SWITCH TEST

Fo r t e s t i n g of t h e p a r k /n e u t r a l p os i t ion s w i t ch ,

refer to G roup 21 - Tran smission a nd Tran sfer Ca se.

IGNITION SWITCH TEST

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS OR

SERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.

(1) D is con n ect a n d i sol a t e t h e b a t t e r y n eg a t i ve

cable.

(2) R em ov e t h e s t eer in g col um n s hr ou ds a n d

u n p lu g t h e i g n it i on s w i t ch w i r e h a r n e s s con n e ct o r.

R e f e r t o Gr o u p 8 D - I g n i t i o n Sy s t e m s f o r t h e p r o c e -

dures.

(3) Wi t h t h e i g n it i on s w i t ch i n t h e O n p os i t ion ,

ch eck f or con t i n ui t y b et w e en t h e i gn i t ion s w i t ch

f u se d B (+ ) c i rcu i t t e r m in a l a n d t h e i g n it i on s w i t ch

ou t p u t (s t a r t ) ci r cu i t t e r m in a l . Th e r e s h o u ld be n o

continuity. If OK, go to Step 4. If not OK, replace the

f a u l t y s w i t ch .

(4) With t he ignition sw itch held in the S ta rt posi-

tion, check for continuity between the ignition switch

f u se d B (+ ) c i rcu i t t e r m in a l a n d t h e i g n it i on s w i t ch

output (sta rt) circuit terminal . There should now be

continuity. If not OK, replace the faulty switch.

STARTER NOISE - 2.5L ENGINE

Se e t h e St a r t e r No i se D i a g n os i s c h a r t (Fi g . 9 ). I f

t h e c om p la i n t i s s i m i la r t o C o n d it i on s 1 a n d 2 i n t h e

ch a r t , cor r ect i on ca n b e m a d e b y s hi mm in g t h e

starter using the following procedures:

CAUTION: Disconnect the battery negative cable toprevent the engine from starting.

(1 ) I f t h e c o m p l a i n t i s s i m i l a r t o C o n d i t i o n 1 , t h e

s t a r t e r m u s t b e m o v e d t o w a r d t h e s t a r t e r r i n g g e a r

by removing shims (Fig. 10).

NOTE: The shim thickness is 0.381 mm (0.015 in.),

and the shims may be stacked if additional thick-ness is required.

Starter Relay

TERMINAL LEGENDNUMBER IDENTIFICATIONCOMMON FEEDCOIL GROUNDCOIL BATTERYNORMALLY OPENNORMALLY CLOSED




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(2 ) I f t h e c o m p l a i n t i s s i m i l a r t o C o n d i t i o n 2 , t h e

s t a r t e r m u s t b e m o ved a w a y f r om t h e s t a r t e r r i n g

g ea r . Th i s i s d on e by i n s t a l l in g s h i m (s ) a cr os s bot h

s t a r t e r m o un t i ng p a d s. M or e t h a n on e s h i m m a y b e

required.

NOTE: This is a condition that will generally cause

broken starter (flywheel/drive plate) ring gear teethor broken starter housings.

REMOVAL AND INSTALLATION

STARTER

2.5L ENGINE


cable.

(2) Raise and support the vehicle.

(3) Disconnect the battery cable and solenoid feedwire from the starter solenoid (Fig. 11).

Fig. 9 Starter Noise Diagnosis

Fig. 10 Starter Shim

STARTERMOTOR SHIM FWD

Fig. 11 Starter Remove/Install - 2.5L Engine

FWDSTARTER NUTSCONNECTORSSCREWSHIM




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(4 ) R e m o v e t h e t w o s t a r t e r m o u n t i n g s c r e w s , t h e

s t a r t e r m o t o r , a n d a n y s t a r t e r m o t o r s h i m s .

NOTE: Shim thickness available is 0.381 mm (0.015in.). See Starter Noise - 2.5L Engine in this groupfor more information.

(5) R ev er s e t h e r em ov a l p roce du r es t o i n st a l l .

Ti g h t en t h e s t a r t e r h a r d w a r e a s f ol low s :

Mounting screws - 45 Nm (33 ft . lbs.)

Solenoid battery cable nut - 10 Nm (90 in. lbs.)

Solenoid terminal nut - 6 Nm (55 in. lbs.).

4.0L ENGINE

(1) D is con n ect a n d i sol a t e t h e b a t t e ry n eg a t i ve

cable.

(2) Raise and support the vehicle.

(3) Disconnect the battery cable and solenoid feed

wire from the starter solenoid (Fig. 12).

(4) Remove the lower starter mounting screw.

(5) Remove the upper starter mounting screw and

t h e s t a r t e r m ot o r.

(6) Re ve rs e t h e r em ov a l p roce du r es t o i n st a l l .

Ti g h t en t h e s t a r t e r h a r d w a r e a s f ol l ow s :

Upper mounting screw (rear screw) - 55 Nm (40

ft . lbs.)

L ow e r m ou n t i n g s cr e w (f r on t s cr e w ) - 41 N m

(30 ft. lbs.)

Solenoid battery cable nut - 10 Nm (90 in. lbs.) Solenoid terminal nut - 6 Nm (55 in. lbs.).

STARTER RELAY


cable.

(2) Remove the cover from the Power Distribution

Center (PDC) (Fig. 13).

(3 ) R e f e r t o t h e l a be l o n t h e P DC f o r s t a r t e r r e l a y

identification and location.

(4 ) U n p l u g t h e s t a r t e r r e l a y f r o m t h e P DC .

( 5 ) I n s t a l l t h e s t a r t e r r e l a y b y a l i g n i n g t h e r e l a y

t e r m i n a l s w i t h t h e c a v i t i e s i n t h e P D C a n d p u s h i n g

the relay firmly into place.

(6) Instal l the PDC cover.

(7) Connect the battery negative cable.(8) Test t he rela y operat ion.

Fig. 12 Starter Remove/Install - 4.0L Engine

SCREW FWD SCREWNUTSCONNECTORSTARTER

Fig. 13 Power Distribution Center

RIGHTFENDER BATTERYPOWER DISTRIBUTIONCENTER


REMOVAL AND INSTALLATION (Continued)


10/10

SPECIFICATIONS

STARTING SYSTEM

Starter and Solenoid

Manufacturer Mitsubishi

Engine Application 2.5L, 4.0L

Power Rating 1.2 Kilowatt - 2.5L1.4 Kilowatt - 4.0L

Voltage 12 Volts

Number of Fields 4

Number of Poles 4

Number of Brushes 4

Drive Type Planetary Gear Reduction

Free Running TestVoltage

11.2 Volts

Free Running TestMaximum AmperageDraw

90 Amperes

Free Running TestMinimum Speed

2600 rpm - 2.5L2500 rpm - 4.0L

Solenoid ClosingMaximum Voltage

7.8 Volts

*Cranking Amperage

Draw Test

130 Amperes - 2.5L

160 Amperes - 4.0L

*Test at operating temperature. Cold engine, tight

(new) engine, or heavy oil will increase starteramperage draw.


EXJ_8B99 jeep xj service manual

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