engine JEEP CHEROKEE 1994 Service Repair Manual

BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY SERVICE PROCEDURES.......... 1
ENGINE STARTER MOTOR SERVICE
PROCEDURES......................... 4GENERATOR SERVICE PROCEDURES........ 7
SPECIFICATIONS....................... 10
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-
luted ammonia or a sodium bicarbonate/water solu-
tion to remove acid film. Flush with clean water.
Ensure that cleaning solution does not enter cells.
(3) Remove corrosion from the terminals with a
wire brush or post and terminal cleaner. Inspect the
case for cracks or other damage that would result in
leakage of electrolyte.
(4) Check electrolyte level in the battery. Use a
putty knife or other suitable wide tool to pry filler
caps off low maintenance battery (Fig. 1). Do not use
a screwdriver. Add distilled water to each cell until
the liquid reaches the bottom of the vent well. DO
NOT OVERFILL.
(5) Operate the engine immediately after adding
water (particularly in cold weather) to assure proper
mixing of the water and acid.
BATTERY REPLACEMENTÐLEFT HAND DRIVE
REMOVAL
(1) Make sure ignition switch is in OFF position
and all electrical accessories are OFF.
(2) Loosen the cable terminal clamps.
(3) If necessary, use a puller to remove cable ter-
minal clamps. Remove negative cable terminal clamp
first.WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-
MOVING A BATTERY BY HAND. SAFETY GLASSES
ALSO SHOULD BE WORN. IF THE BATTERY IS
CRACKED OR LEAKING, THE ELECTROLYTE CAN
BURN THE SKIN AND EYES.
(4) Remove battery holddown, and remove battery
from vehicle (Figs. 2 and 3).
(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 (Figs. 4
and 5).
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 (posts) are correctly located.
The cables must reach their terminals (posts) with-
out stretching (Figs. 2 and 3).
Fig. 1 Removing Filler Cap
JBATTERY/STARTER/GENERATOR SERVICE 8B - 1

(4) Ensure that tang at 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
generator diodes and radio(s).
(5) Place felt washer on positive battery terminal.
(6) Connect positive cable first. Then connect neg-
ative cable. Tighten both cable terminal bolts to 8.5
Nzm (75 in. lbs.).(7) Apply a thin coating of petroleum jelly or chas-
sis grease to cable terminals and battery posts.
(8) Inspect negative cable connections on engine
and vehicle body for condition, security and electrical
continuity.
BATTERY REPLACEMENTÐRIGHT HAND DRIVE
REMOVAL
(1) Make sure ignition switch is in OFF position
and all electrical accessories are OFF.
Fig. 2 Battery HolddownÐXJ
Fig. 3 Battery HolddownÐYJ
Fig. 4 Battery TrayÐXJ
Fig. 5 Battery TrayÐYJ
8B - 2 BATTERY/STARTER/GENERATOR SERVICEJ

(2) Remove bolt and negative cable from battery
(Fig. 6).
(3) Remove bolt and positive cable from battery.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-
MOVING A BATTERY BY HAND. SAFETY GLASSES
ALSO SHOULD BE WORN. IF THE BATTERY ISCRACKED OR LEAKING, THE ELECTROLYTE CAN
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
generator diodes and radio(s).
(5) Connect positive cable first. Then connect neg-
ative cable. Tighten both cable terminal bolts to
10-20 Nzm (90-178 in. lbs.).
(6) Inspect negative cable connections on engine
and vehicle body for condition, security and electrical
continuity.
Fig. 6 Battery Cable Attachment
JBATTERY/STARTER/GENERATOR SERVICE 8B - 3

ENGINE STARTER MOTOR SERVICE PROCEDURES
INDEX
page page
2.5L Starter General Information.............. 4
2.5L Starter Motor Removal/Installation......... 5
4.0L Starter General Information.............. 6
4.0L Starter Motor Removal/Installation......... 6General Information........................ 4
Park/Neutral Position Switch................. 6
Starter Relay Replacement.................. 4
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.
2.5L STARTER GENERAL INFORMATION
The 2.5L engine starter motor incorporates several
features to create an efficient, lightweight unit.
A planetary gear system (intermediate transmis-
sion) between the electric motor and pinion shaftmakes 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.
CAUTION: Do not connect starter motor incorrectly
when tests are being performed. The magnets may
be damaged and rendered unserviceable.
²Ensure cleanliness when performing repairs.
Fig. 1 Power Distribution CenterÐXJ
Fig. 2 Power Distribution CenterÐYJ
8B - 4 BATTERY/STARTER/GENERATOR SERVICEJ

²Metal chips are attracted by the magnets and may
not be completely removed from the starter frame.
Chips in the ring gear can lead to failure of the
starter.
2.5L STARTER MOTOR REMOVAL/INSTALLATION
XJÐ2.5L ENGINE
(1) Disconnect negative cable from battery.
(2) Remove exhaust clamp from bracket (Fig. 3).
(3) Remove nut and bolt from forward end of brace
rod (automatic transmission only).
(4) Remove nut from lower end of brace rod (auto-
matic transmission only).
(5) Remove brace rod and bracket (automatic
transmission only).
(6) Remove nut, bolt and bracket from bell housing
(manual transmission only).
(7) Disconnect battery cable and solenoid feed wire
from solenoid (Fig. 4).
(8) Remove starter motor mounting bolts, starter
motor and shims.
Two shim thicknesses are available. One is
0.381 mm (0.015 in.) and the other is 1.143 mm
(0.045 in.). Refer to Group 8A for proper shim se-
lection.
(9) To install starter motor, reverse the removal
procedures and torque mounting hardware as shown.
(10) Connect negative cable to battery.
YJÐ2.5L ENGINE
(1) Disconnect negative cable from battery.
(2) Disconnect battery cable from starter motor
B+ terminal (Fig. 5).(3) Disconnect solenoid feed wire.
(4) Remove starter motor mounting bolts.
(5) Remove starter motor and shims.
Two shim thicknesses are available. One is
0.381 mm (0.015 in.) and the other is 1.143 mm
(0.045 in.). Refer to Group 8A for proper shim se-
lection.
(6) To install starter motor, reverse removal proce-
dures and torque mounting hardware as shown.
(7) Connect negative cable to battery.
Fig. 3 Exhaust Clamp and Brace RemovalÐ2.5L XJ
Fig. 4 Starter Motor Removal/InstallationÐ2.5L XJ
Fig. 5 Starter Motor Removal/InstallationÐ2.5L YJ
JBATTERY/STARTER/GENERATOR SERVICE 8B - 5

GENERATOR SERVICE PROCEDURES
GENERAL
The generator is belt-driven by the engine. All en-
gines use serpentine drive. This section will cover
generator removal and installation. The generator is
not serviceable. Information covering on-vehicle test-
ing can be found in Group 8A - Battery/Starting/
Charging Systems Diagnostics.
GENERATOR REPLACEMENTÐLEFT HAND DRIVE
WARNING: FAILURE TO DISCONNECT NEGATIVE
CABLE FROM BATTERY BEFORE DISCONNECTING
RED (OUTPUT) WIRE CONNECTOR FROM GENER-
ATOR CAN RESULT IN INJURY.
ALL YJ AND XJ WITH 2.5L ENGINE
Belt tension is adjusted at the power steering pump
(or idler pulley if not equipped with power steering).
To replace generator:
(1) Disconnect negative cable from battery.
(2) Loosen rear mounting bolts (Fig. 1 or 2).
(3) Loosen power steering pump/idler pulley pivot
bolt and lock nut (Fig. 3 or 4).
(4) Loosen adjusting bolt to remove belt.
(5) Remove generator B+ terminal nut, 2 field ter-
minal nuts, ground and harness holddown nuts (Fig.
5). Remove wire connector assembly.
(6) Remove 2 generator mounting bolts and re-
move generator from vehicle.
(7) Install generator with 2 mounting bolts. Torque
bolts to 55 Nzm (41 ft. lbs.).
(8) Attach generator wires.
CAUTION: Never force a belt over a pulley rim us-
ing a screwdriver as the synthetic fiber may be
damaged.CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in-
stalled incorrectly. Refer to the belt routing label in
engine compartment, or see Group 7 - Belt Sche-
matics.
(9) Place serpentine belt over pulley.
(10) Belt tension adjustment is made at power
steering pump or idler pulley (Figs. 1 or 2).
(11) Turn adjusting bolt until belt has correct ten-
sion. See Belt Tension in Specifications.
Fig. 1 Powering Steering Pump Rear Mounting
BoltsÐExcept XJ With 4.0L
Fig. 2 Idler Pulley Rear Mounting BoltsÐExcept XJ
With 4.0L
Fig. 3 Power Steering Pump Front Mounting
BoltsÐExcept XJ With 4.0L
JBATTERY/STARTER/GENERATOR SERVICE 8B - 7

(12) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 Nzm (20 ft. lbs.) torque.
(13) Connect negative cable to battery.
XJ WITH 4.0L ENGINE
Belt tension is adjusted at the power steering
pump.
To replace generator:
(1) Disconnect negative cable from battery.
(2) Loosen rear mounting bolts (Fig. 6).
(3) Loosen power steering pump pivot bolt and lock
nut (Fig. 7).
(4) Loosen adjusting bolt to remove belt.
(5) Raise and support vehicle.(6) Remove generator B+ terminal nut, 2 field ter-
minal nuts, ground and harness holddown nuts (Fig.
5). Remove wire connector assembly.
(7) Remove 2 generator mounting bolts and re-
move generator from vehicle.
(8) Install generator with two mounting bolts.
Torque bolts to 55 Nzm (41 ft. lbs.).
(9) Attach generator wires.
Fig. 4 Idler Pulley Front Mounting BoltsÐExcept XJ
With 4.0L
Fig. 5 Remove or Install Connector Assembly
Fig. 6 Powering Steering Pump Rear Mounting
BoltsÐXJ With 4.0L
Fig. 7 Powering Steering Pump Front Mounting
BoltsÐXJ With 4.0L
8B - 8 BATTERY/STARTER/GENERATOR SERVICEJ

CAUTION: Never force a belt over a pulley rim us-
ing a screwdriver as the synthetic fiber may be
damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in-
stalled incorrectly. Refer to the belt routing label in
engine compartment, or see Group 7 - Belt Sche-
matics.
(10) Place serpentine belt over pulley.
(11) Belt tension adjustment is made at power
steering pump (Fig. 6).
(12) Turn adjusting bolt until belt has correct ten-
sion. See Belt Tension in Specifications.
(13) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 Nzm (20 ft. lbs.) torque.
(14) Remove support and lower vehicle.
(15) Connect negative cable to battery.
GENERATOR REPLACEMENTÐRIGHT HAND DRIVE
The generator used on the right hand drive is the
same as used on left hand drive. However, the
mounting and accessory drive belt installation are
different.
WARNING: FAILURE TO DISCONNECT NEGATIVE
CABLE FROM BATTERY BEFORE DISCONNECTING
RED (OUTPUT) WIRE CONNECTOR FROM GENER-
ATOR CAN RESULT IN INJURY.
(1) Remove negative cable from battery.
(2) Remove 2 screws holding electric cooling fan
(Fig. 8).
(3) Unplug electric cooling fan connector.
(4) Pull fan up and out of vehicle.
(5) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(6) Remove generator mounting bolts.
(7) Position generator to gain access to all of the
wire connectors.(8) Remove B+ terminal nut, 2 field terminal
nuts, ground and harness holddown nuts (Fig. 9). Re-
move wire connector assembly.
(9) Remove generator from vehicle.
(10) To install generator, reverse the removal pro-
cedures. Refer to Group 7 for belt installation.
(11) Tighten battery cable bolts to 10-20 Nzm (90-
178 in. lbs.).
Fig. 8 Electric Cooling Fan Removal/Installation
Fig. 9 Remove or Install Connector Assembly
JBATTERY/STARTER/GENERATOR SERVICE 8B - 9

4.0L ENGINES 2.5L ENGINES
4.0L STARTER MOTOR AND SOLENOID
TESTING SPECIFICATIONS
STARTING SYSTEM COLD CRANKING
SPECIFICATIONS
STARTER MOTOR TORQUE SPECIFICATIONS
2.5L STARTER MOTOR SPECIFICATIONS
STARTING SYSTEM COLD CRANKING
SPECIFICATIONS
STARTER MOTOR TORQUE SPECIFICATIONS
JBATTERY/STARTER/GENERATOR SERVICE 8B - 11

COMPASS REPAIR PROCEDURES
VARIATION ADJUSTMENT PROCEDURE
Variance is the difference between magnetic North
and geographic North. In some areas the difference
between magnetic and geographic north is great
enough to cause the compass to give false readings. If
this occurs, the variance must be set.
To set the variance:
(1) Turn ignition switch to the ON position.
(2) Depress both buttons and holddown until VAR
light appears. This takes about 5 seconds.
(3) Release both buttons.
(4) Using the map (Fig. 1) find your geographic lo-
cation and note the zone number.
(5) Press the U.S./METRIC button to sequentially
go through the numbers until the zone number for
your area appears in the display.
(6) Press the COMP/TEMP button to enter this
zone number.
(7) Confirm correct directions are indicated.
COMPASS CALIBRATION PROCEDURE
CAUTION: DO NOT use magnetic tools when servic-
ing the overhead console.
CAUTION: DO NOT place any external magnets
such as magnetic roof mount antennas, in the vicin-
ity of the compass.
Do not attempt to set compass near large metal ob-
jects such as other vehicles, large buildings or
bridges. The compass features an ``Auto-Cal'' design
which simplifies the calibration procedure. During
normal driving this feature automatically updates
the compass calibration. This takes into account in-
cremental changes in magnetism the vehicle may see
over its lifetime.
Whenever the compass is calibrated manually,
the variation number must also be reset.
Calibrate the compass as follows:
(1) Start the engine.
(2) Depress both buttons on the compass and hold
down until CAL light appears. This takes about 10
seconds and appears about 5 seconds after the VAR
light appears.
(3) Release buttons.
(4) Drive vehicle on a level surface that is away
from metal objects through three or more complete
Fig. 1 Variance Settings
Chart 3
8C - 4 OVERHEAD CONSOLEJ