Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1988-1989.1993-1995 Approved 1994 XJ Jeep Cherokee 94XJ_8B

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94XJ_8B

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J BATTERY/STARTER/GENERATOR SERVICE 8B - 1

BATTERY/STARTER/GENERATOR SERVICE

CONTENTS
page page

BATTERY SERVICE PROCEDURES . . . . . . . . . . 1 GENERATOR SERVICE PROCEDURES . . . . . . . . 7
ENGINE STARTER MOTOR SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 10
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 4

BATTERY SERVICE PROCEDURES
GENERAL INFORMATION
This section covers battery removal and installa-
tion procedures only. For diagnostic procedures, refer
to Group 8A - Battery/Starting/Charging Systems Di-
agnostics.

BATTERY MAINTENANCE
(1) Inspect cable terminals for corrosion and dam-
age. Remove the corrosion using a wire brush, or
post and terminal cleaner, and a sodium bicarbonate/
water solution. Replace cables that have damaged or
deformed terminals.
Be sure filler caps or vents are installed when
washing battery to prevent solution from enter-
ing battery.
(2) Clean outside of battery case if the original
battery is to be installed. Clean top cover with di- Fig. 1 Removing Filler Cap
luted ammonia or a sodium bicarbonate/water solu-
WARNING: WEAR A SUITABLE PAIR OF RUBBER
tion to remove acid film. Flush with clean water.
Ensure that cleaning solution does not enter cells. GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-
(3) Remove corrosion from the terminals with a MOVING A BATTERY BY HAND. SAFETY GLASSES
wire brush or post and terminal cleaner. Inspect the ALSO SHOULD BE WORN. IF THE BATTERY IS
case for cracks or other damage that would result in CRACKED OR LEAKING, THE ELECTROLYTE CAN
leakage of electrolyte. BURN THE SKIN AND EYES.
(4) Check electrolyte level in the battery. Use a
putty knife or other suitable wide tool to pry filler (4) Remove battery holddown, and remove battery
caps off low maintenance battery (Fig. 1). Do not use from vehicle (Figs. 2 and 3).
a screwdriver. Add distilled water to each cell until (5) Inspect battery tray and holddowns for corro-
the liquid reaches the bottom of the vent well. DO sion. Remove corrosion using a wire brush and a so-
NOT OVERFILL. dium bicarbonate/water solution. Paint any exposed
(5) Operate the engine immediately after adding bare metal. Replace damaged components (Figs. 4
water (particularly in cold weather) to assure proper and 5).
mixing of the water and acid.
INSTALLATION
BATTERY REPLACEMENT--LEFT HAND DRIVE (1) Refer to Specifications to determine if battery
has correct classification and rating for the vehicle.
REMOVAL (2) Use a hydrometer to test the battery electro-
(1) Make sure ignition switch is in OFF position lyte. Charge battery if necessary.
and all electrical accessories are OFF. (3) Position battery in tray. Ensure that positive
(2) Loosen the cable terminal clamps. and negative terminals (posts) are correctly located.
(3) If necessary, use a puller to remove cable ter- The cables must reach their terminals (posts) with-
minal clamps. Remove negative cable terminal clamp out stretching (Figs. 2 and 3).
first.
8B - 2 BATTERY/STARTER/GENERATOR SERVICE J

Fig. 2 Battery Holddown--XJ
Fig. 4 Battery Tray--XJ

Fig. 3 Battery Holddown--YJ
Fig. 5 Battery Tray--YJ
(4) Ensure that tang at battery base is positioned
(7) Apply a thin coating of petroleum jelly or chas-
in tray properly before tightening holddown.
sis grease to cable terminals and battery posts.
CAUTION: It is imperative that the cables are con- (8) Inspect negative cable connections on engine
nected to the battery positive-to-positive and nega- and vehicle body for condition, security and electrical
tive-to-negative. Reverse polarity will damage the continuity.
generator diodes and radio(s).
BATTERY REPLACEMENT--RIGHT HAND DRIVE
(5) Place felt washer on positive battery terminal.
REMOVAL
(6) Connect positive cable first. Then connect neg-
(1) Make sure ignition switch is in OFF position
ative cable. Tighten both cable terminal bolts to 8.5
and all electrical accessories are OFF.
N m (75 in. lbs.).
J BATTERY/STARTER/GENERATOR SERVICE 8B - 3

(2) Remove bolt and negative cable from battery CRACKED OR LEAKING, THE ELECTROLYTE CAN
(Fig. 6). BURN THE SKIN AND EYES.

(4) Remove battery holddown and battery from ve-
hicle.
(5) Inspect battery tray and holddowns for corro-
sion. Remove corrosion using a wire brush and a so-
dium bicarbonate/water solution. Paint any exposed
bare metal. Replace damaged components.

INSTALLATION
(1) Refer to Specifications to determine if battery
has correct classification and rating for the vehicle.
(2) Use a hydrometer to test the battery electro-
lyte. Charge battery if necessary.
(3) Position battery in tray. Ensure that positive
and negative terminals are correctly located. The ca-
bles must reach their terminals without stretching
(Fig. 6).
(4) Ensure that battery base is positioned in tray
properly before tightening holddown.

CAUTION: It is imperative that the cables are con-
nected to the battery positive-to-positive and nega-
tive-to-negative. Reverse polarity will damage the
Fig. 6 Battery Cable Attachment
generator diodes and radio(s).
(3) Remove bolt and positive cable from battery.
(5) Connect positive cable first. Then connect neg-
WARNING: WEAR A SUITABLE PAIR OF RUBBER ative cable. Tighten both cable terminal bolts to
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE- 10-20 N m (90-178 in. lbs.).
MOVING A BATTERY BY HAND. SAFETY GLASSES (6) Inspect negative cable connections on engine
ALSO SHOULD BE WORN. IF THE BATTERY IS and vehicle body for condition, security and electrical
continuity.
8B - 4 BATTERY/STARTER/GENERATOR SERVICE J

ENGINE STARTER MOTOR SERVICE PROCEDURES

INDEX
page page
2.5L Starter General Information . . . . .. . . . . . . . . 4 General Information . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5L Starter Motor Removal/Installation . . . . . . . . . 5 Park/Neutral Position Switch . . . . . . . . . . . . . . . . . 6
4.0L Starter General Information . . . . .. . . . . . . . . 6 Starter Relay Replacement . . . . . . . . . . . . . . . . . . 4
4.0L Starter Motor Removal/Installation . . . . . . . . . 6

GENERAL INFORMATION
This section will cover the starting system compo-
nent service procedures only. For diagnostic proce-
dures, refer to Group 8A - Battery/Starting/Charging
Systems Diagnostics.
Starting system components: battery, starter mo-
tor, starter relay, starter solenoid, ignition switch,
connecting wires and battery cables. A park/neutral
position switch is used with automatic transmissions.

STARTER RELAY REPLACEMENT
The starter relay is located in the Power Distribu-
tion Center (Figs. 1 and 2). Refer to underside of
Power Distribution Center cover for relay location.
(1) Disconnect negative cable from battery.
(2) Replace relay.
(3) Connect negative cable to battery.
(4) Test relay operation.

Fig. 2 Power Distribution Center--YJ
makes it possible to reduce the dimensions of the
starter. This also makes it possible to obtain a higher
rotational speed to produce the same torque at the
pinion.
The permanent magnet field consists of six two-
component high strength magnets. The magnets are
aligned according to their polarity and are perma-
nently fixed in the starter frame.
The brush holder plate consists of a plastic base-
plate with four tubular brush holders.
This unit is highly sensitive to hammering, shocks
and external pressure.

CAUTION: The starter motor MUST NOT BE
CLAMPED in a vise by the starter frame. Doing so
may damage the magnets. It may be clamped by the
mounting flange ONLY.
Fig. 1 Power Distribution Center--XJ
2.5L STARTER GENERAL INFORMATION CAUTION: Do not connect starter motor incorrectly
The 2.5L engine starter motor incorporates several when tests are being performed. The magnets may
features to create an efficient, lightweight unit. be damaged and rendered unserviceable.
A planetary gear system (intermediate transmis-
sion) between the electric motor and pinion shaft

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