perform service JEEP LIBERTY 2002 KJ / 1.G User Guide

²Battery Thermal Guard- The battery thermal
guard insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintenance for the proper battery jump start-
ing procedures. While battery charging can be consid-
ered a maintenance procedure, the battery charging
procedures and related information are located in the
service procedures section of this service manual.
This was done because the battery must be fully-
charged before any battery system diagnosis or test-
ing procedures can be performed. Refer to Standard
Procedures for the proper battery charging proce-
dures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be testedas a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MIDTRONICS ELECTRICAL SYSTEM TESTER
The Midtronicstautomotive battery and charging
system tester is designed to help the dealership tech-
nicians diagnose the cause of a defective battery or
charging system. Follow the instruction manual sup-
plied with the tester to properly diagnose a vehicle. If
the instruction manual is not available refer to the
standard procedure in this section, which includes
the directions for using the midtronics electrical sys-
tem tester.
8F - 2 BATTERY SYSTEMKJ
BATTERY SYSTEM (Continued)

(4) Clean the battery thermal guard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.
(5) Clean any corrosion from the battery terminal
posts with a wire brush or a post and terminal
cleaner, and a sodium bicarbonate (baking soda) and
warm water cleaning solution (Fig. 3).
INSPECTION
The following information details the recommended
inspection procedures for the battery and related
components. In addition to the maintenance sched-
ules found in this service manual and the owner's
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp.
(2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case.
Inspect the battery case for cracks or other damagethat could result in electrolyte leaks. Also, check the
battery terminal posts for looseness. Batteries with
damaged cases or loose terminal posts must be
replaced.
(4) Inspect the battery thermal guard for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged.
(5) Inspect the battery built-in test indicator sight
glass for an indication of the battery condition. If the
battery is discharged, charge as required. Refer to
Standard Procedures for the proper battery built-in
indicator test procedures. Also refer to Standard Pro-
cedures for the proper battery charging procedures.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
8F - 6 BATTERY SYSTEMKJ
BATTERY SYSTEM (Continued)

battery reduces battery gassing and water loss, at
normal charge and discharge rates. Therefore, the
battery should not require additional water in nor-
mal service. If the electrolyte level in this battery
does become low, water must be added. However,
rapid loss of electrolyte can be caused by an over-
charging condition. Be certain to diagnose the charg-
ing system after replenishing the water in the
battery for a low electrolyte condition and before
returning the vehicle to service. Refer to Charging
System for the proper charging system diagnosis and
testing procedures.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
top, posts and terminal clamps should be properly
cleaned and inspected before diagnostic procedures
are performed. Refer to Battery System Cleaning for
the proper cleaning procedures, and Battery System
Inspection for the proper battery inspection proce-
dures. Refer to Standard Procedures for the proper
battery charging procedures.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condition of a battery is determined by two cri-
teria:
²State-Of-Charge- This can be determined by
checking the specific gravity of the battery electrolyte
(built-in indicator test or hydrometer test), or bychecking the battery voltage (open-circuit voltage
test).
²Cranking Capacity- This can be determined
by performing a battery load test, which measures
the ability of the battery to supply high-amperage
current.
First, determine the battery state-of-charge. This
can be done in one of three ways. If the battery has a
built-in test indicator, perform the built-in indicator
test to determine the state-of-charge. If the battery
has no built-in test indicator but does have remov-
able cell caps, perform the hydrometer test to deter-
mine the state-of-charge. If the battery cell caps are
not removable, or a hydrometer is not available, per-
form the open-circuit voltage test to determine the
state-of-charge. Refer to open-circuit voltage test in
the Standard Procedures section of this group.
Second, determine the battery cranking capacity by
performing a load test. The battery must be charged
before proceeding with a load test if:
²The battery built-in test indicator has a black or
dark color visible.
²The temperature corrected specific gravity of the
battery electrolyte is less than 1.235.
²The battery open-circuit voltage is less than 12.4
volts.
A battery that will not accept a charge is faulty,
and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is
faulty and must be replaced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
A battery is fully-charged when:
²All battery cells are gassing freely during charg-
ing.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three corrected specific gravity tests, taken at
one-hour intervals, indicate no increase in the spe-
cific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.4 volts
or greater.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery charging can be performed fast or slow, it
terms of time.Slowbattery charging is the best
means of restoring a battery to full potential. Fast
8F - 8 BATTERY SYSTEMKJ
BATTERY (Continued)

battery charging should only be performed when
absolutely necessary due to time restraints. A battery
is fully-charged when:
²All of the battery cells are gassing freely during
battery charging.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.65 volts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1É C [30É F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
NOTE: Models equipped with the diesel engine
option are equipped with two 12-volt batteries, con-
nected in parallel (positive-to-positive and negative-
to-negative). In order to ensure proper charging of
each battery, these batteries MUST be disconnected
from each other, as well as from the vehicle electri-
cal system, while being charged.
Some battery chargers are equipped with polarity-
sensing circuitry. This circuitry protects the battery
charger and the battery from being damaged if they
are improperly connected. If the battery state-of-
charge is too low for the polarity-sensing circuitry to
detect, the battery charger will not operate. This
makes it appear that the battery will not acceptcharging current. See the instructions provided by
the manufacturer of the battery charger for details
on how to bypass the polarity-sensing circuitry.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine the battery
cranking capacity. Refer to Standard Procedures for
the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
and must be replaced.
Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat-
tery System Inspection for the proper battery system
inspection procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce-
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure the voltage at the battery posts with a
voltmeter, accurate to 1/10 (0.10) volt (Fig. 6). If the
reading is below ten volts, the battery charging cur-
rent will be low. It could take some time before the
battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
(2) Disconnect and isolate the battery negative
cable. Connect the battery charger leads. Some bat-
tery chargers are equipped with polarity-sensing cir-
cuitry. This circuitry protects the battery charger and
the battery from being damaged if they are improp-
erly connected. If the battery state-of-charge is too
low for the polarity-sensing circuitry to detect, the
battery charger will not operate. This makes it
appear that the battery will not accept charging cur-
rent. See the instructions provided by the manufac-
Fig. 6 Voltmeter - Typical
KJBATTERY SYSTEM 8F - 9
BATTERY (Continued)

To read the built-in indicator, look into the sight
glass and note the color of the indication (Fig. 8). The
battery condition that each color indicates is
described in the following list:
²Green- Indicates 75% to 100% battery state-of-
charge. The battery is adequately charged for further
testing or return to service. If the starter will not
crank for a minimum of fifteen seconds with a fully-
charged battery, the battery must be load tested.
Refer to Standard Procedures for the proper battery
load test procedures.
²Black or Dark- Indicates 0% to 75% battery
state-of-charge. The battery is inadequately charged
and must be charged until a green indication is visi-
ble in the sight glass (12.4 volts or more), before the
battery is tested further or returned to service. Refer
to Standard Procedures for the proper battery charg-
ing procedures. Also refer to Diagnosis and Testing
for more information on the possible causes of the
discharged battery condition.
²Clear or Bright- Indicates a low battery elec-
trolyte level. The electrolyte level in the battery is
below the built-in indicator. A maintenance-free bat-
tery with non-removable cell caps must be replaced if
the electrolyte level is low. Water must be added to a
low-maintenance battery with removable cell caps
before it is charged. Refer to Standard Procedures for
the proper battery filling procedures. A low electro-
lyte level may be caused by an overcharging condi-
tion. Refer to Charging System for the proper
charging system diagnosis and testing procedures.
STANDARD PROCEDURE - HYDROMETER TEST
The hydrometer test reveals the battery state-of-
charge by measuring the specific gravity of the elec-
trolyte.This test cannot be performed on
maintenance-free batteries with non-removable
cell caps.If the battery has non-removable cell caps,
refer to Diagnosis and Testing for alternate methods
of determining the battery state-of-charge.
Specific gravity is a comparison of the density of
the battery electrolyte to the density of pure water.Pure water has a specific gravity of 1.000, and sulfu-
ric acid has a specific gravity of 1.835. Sulfuric acid
makes up approximately 35% of the battery electro-
lyte by weight, or 24% by volume. In a fully-charged
battery the electrolyte will have a temperature-cor-
rected specific gravity of 1.260 to 1.290. However, a
specific gravity of 1.235 or above is satisfactory for
the battery to be load tested and/or returned to ser-
vice.
Before testing, visually inspect the battery for any
damage (a cracked case or cover, loose posts, etc.)
that would cause the battery to be faulty. Then
remove the battery cell caps and check the electrolyte
level. Add distilled water if the electrolyte level is
below the top of the battery plates. Refer to Battery
System Cleaning for the proper battery inspection
procedures.
See the instructions provided by the manufacturer
of the hydrometer for recommendations on the cor-
rect use of the hydrometer that you are using.
Remove only enough electrolyte from the battery cell
so that the float is off the bottom of the hydrometer
barrel with pressure on the bulb released. To read
the hydrometer correctly, hold it with the top surface
of the electrolyte at eye level (Fig. 9).
CAUTION: Exercise care when inserting the tip of
the hydrometer into a battery cell to avoid damag-
ing the plate separators. Damaged plate separators
can cause early battery failure.
Hydrometer floats are generally calibrated to indi-
cate the specific gravity correctly only at 26.7É C.
When testing the specific gravity at any other tem-
perature, a correction factor is required. The correc-
tion factor is approximately a specific gravity value
of 0.004, which may also be identified as four points
of specific gravity. For each 5.5É C above 26.7É C, add
four points. For each 5.5É C below 26.7É C, subtract
four points. Always correct the specific gravity for
temperature variation.
EXAMPLE:A battery is tested at -12.2É C and has
a specific gravity of 1.240. Determine the actual spe-
cific gravity as follows:
(1) Determine the number of degrees above or
below 26.7É C:26.7É C + -12.2É C = 14.5É C below
the 26.7É C specification
(2) Divide the result from Step 1 by 5.5É C:14.5É
C ÷ 5.5É C = 2.64
(3) Multiply the result from Step 2 by the temper-
ature correction factor (0.004):2.64 X 0.004 = 0.01
(4) The temperature at testing was below 26.7É C;
therefore, the temperature correction factor is sub-
tracted:1.240 - 0.01 = 1.23
(5) The corrected specific gravity of the battery cell
in this example is 1.23.
Fig. 8 Built-In Indicator Sight Glass Chart
KJBATTERY SYSTEM 8F - 11
BATTERY (Continued)

negative jumper posts. Select TESTING AT JUMPER
POST when connecting to that location.
(3) Connect the tester to the battery or jumper
posts, the red clamp to positive (+) and the black
clamp to negative (±).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
NOTE: When testing the battery in a PT Cruiser,
always test at the battery terminals
(4) Using the ARROW key selectinoroutof vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
tery rating for your area (see menu). The tester will
then run its self programmed test of the battery and
display the results. Refer to the test result table
noted below.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicle's cables and battery exists. After discon-
necting the vehicle's battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) While viewing the battery test result, press the
CODE button and the tester will prompt you for the
last 4 digits of the VIN. Use the UP/DOWN arrow
buttons to scroll to the correct character; then press
ENTER to select and move to the next digit. Then
press the ENTER button to view the SERVICE
CODE. Pressing the CODE button a second time will
return you to the test results.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post (Fig. 16).
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Remove the battery holddowns from the bat-
tery. Refer to Battery Holddown for the proper bat-
tery holddown removal procedures.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery and the battery thermal
guard from the battery tray as a unit.
(8) Remove the battery thermal guard from the
battery case. Refer to Thermal Guard for the proper
battery thermal guard removal procedures.
INSTALLATION
(1) Clean and inspect all of the battery system
components. Refer to Battery System Cleaning for
the proper cleaning procedures, and refer to Battery
System Inspection for the proper inspection proce-
dures.
Fig. 16 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
8F - 16 BATTERY SYSTEMKJ
BATTERY (Continued)

²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test in 8, Battery for more information.
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBtscan tool. Per-form the following inspections before attaching the
scan tool.
(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in 7, Cooling System.
(6) Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) Inspect generator electrical connections at gen-
erator field, battery output, and ground terminal (if
equipped). Also check generator ground wire connec-
tion at engine (if equipped). They should all be clean
and tight. Repair as required.
SPECIFICATIONS
TORQUE - EXCEPT DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Generator Horizontal Mounting Bolts - 3.7L 57 42 -
Generator Vertical Mounting Bolt - 3.7L 40 29 -
Generator Mounting Bolts - 2.4L 57 42 -
B+ Terminal Nut at Top of Generator 13 - 115
Generator Decoupler 110 81 -
GENERATOR RATINGS - GAS ENGINES
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56044530AB 124 2.4L 88
DENSO 56044532AB 136 2.4L 96
DENSO 56041693AA 136 3.7L 96
DENSO 56029914AA 160 3.7L 112
KJCHARGING SYSTEM 8F - 23
CHARGING SYSTEM (Continued)

Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER ENGAGES,
FAILS TO TURN
ENGINE.1. Battery discharged or
faulty.1. Refer to Battery. Charge or replace battery if required.
2. Starting circuit wiring
faulty.2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits if required.
3. Starter motor faulty. 3. If all other starting system components and circuits test
OK, replace starter motor assembly.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation.
Remove starter motor to inspect starter ring gear.
Replace starter ring gear if required.
2. Starter motor faulty. 2. If all other starting system components and circuits test
OK, replace starter motor assembly.
STARTER DOES NOT
DISENGAGE.1. Starter motor
improperly installed.1. Refer to Starter Motor Removal and Installation.
Tighten starter mounting hardware to correct torque
specifications.
2. Starter relay faulty. 2. Refer to Starter Relay Diagnosis and Testing. Replace
starter relay if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
4. Starter motor faulty. 4. If all other starting system components and circuits test
OK, replace starter motor.
INSPECTION
For complete starter wiring circuit diagrams, refer
to 8, Wiring Diagrams. Before removing any unit
from starting system for repair or diagnosis, perform
the following inspections:
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS-
TEMS, BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
²Battery- Visually inspect battery for indica-
tions of physical damage and loose or corroded cable
connections. Determine state-of-charge and cranking
capacity of battery. Charge or replace battery if
required. Refer toBatteryin 8, Battery.Note: If
equipped with diesel engine, a dual battery sys-
tem may be used, and both batteries must be
inspected.
²Ignition Switch- Visually inspect ignition
switch for indications of physical damage and loose
or corroded wire harness connections. Refer toIgni-
tion Switch and Key Lock Cylinder.²Clutch Pedal Position Switch- If equipped
with manual transmission, visually inspect clutch
pedal position switch for indications of physical dam-
age and loose or corroded wire harness connections.
Refer toClutch Pedal Position Switchin 6,
Clutch.
²Park/Neutral Position Switch- If equipped
with automatic transmission, visually inspect park/
neutral position switch for indications of physical
damage and loose or corroded wire harness connec-
tions. Refer toPark/Neutral Position Switchin
21, Transmission.
²Starter Relay- Visually inspect starter relay
for indications of physical damage and loose or cor-
roded wire harness connections.
²Starter Motor- Visually inspect starter motor
for indications of physical damage and loose or cor-
roded wire harness connections.
²Starter Solenoid- Visually inspect starter sole-
noid for indications of physical damage and loose or
corroded wire harness connections.
²Wiring- Visually inspect wire harnesses for
damage. Repair or replace any faulty wiring, as
required. Refer to 8, Wiring Diagrams.
8F - 34 STARTING SYSTEMKJ
STARTING SYSTEM (Continued)

equipped models use dual batteries. If equipped
with dual battery system, this procedure must
be performed on driver side battery only.
(6) If equipped with dual battery system (certain
diesel equipped models), connect positive lead of volt-
meter to positive battery cable clamp on battery
located on left side of vehicle. Connect negative lead
of voltmeter to positive battery terminal post on bat-
tery located on right side of vehicle. Rotate and hold
ignition switch in Start position. Observe voltmeter.
If reading is above 0.2 volt, clean and tighten battery
cables at both batteries. Repeat test. If reading is
still above 0.2 volt, replace faulty positive battery
cable.If resistance tests detect no feed circuit problems,
refer toStarter Motorin the Diagnosis and Testing.
CONTROL CIRCUIT TESTING
The starter control circuit components should be
tested in the order in which they are listed, as fol-
lows:
²Starter Relay- Refer toStarter RelayDiag-
nosis and Testing.
²Starter Solenoid- Refer toStarter Motor
Diagnosis and Testing.
²Ignition Switch- Refer toIgnition Switch
and Key Lock Cylinder
²Clutch Pedal Position Switch- If equipped
with manual transmission, refer toClutch Pedal
Position Switchin 6, Clutch.
²Park/Neutral Position Switch- If equipped
with automatic transmission, refer toPark/Neutral
Position Switchin 21, Transmission.
²Wire harnesses and connections- Refer to 8,
Wiring Diagrams.
INSPECTION - STARTING SYSTEM
The following starting system components should
be carefully inspected whenever any starting system
problem is encountered.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORM-
ING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE AIRBAG SYS-
TEM. FAILURE TO TAKE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
Battery
²Visually inspect battery for indications of physi-
cal damage and loose or corroded cable connections.
Determine state-of-charge and cranking capacity of
battery. Charge or replace battery, if required. Refer
toBatteryfor battery cleaning and inspection proce-
dures.
Ignition Switch
²Visually inspect ignition switch for indications of
physical damage and loose or corroded wire harness
connections. Clean corroded connections as required.
Refer toWiring Diagrams. Refer toIgnition
Switch and Key Lock Cylinderfor ignition switch
service procedures.
Fig. 5 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
KJSTARTING SYSTEM 8F - 37
STARTING SYSTEM (Continued)

(4) Connect the negative lead of the voltmeter to
the right side bus bar and touch each grid line at its
midpoint with the positive lead (Fig. 3). A reading of
approximately six volts indicates a line is good. A
reading of zero volts indicates a break in the grid
line between the midpoint of the grid line and the
left side bus bar. A reading of ten to fourteen volts
indicates a break between the midpoint of the grid
line and the right side bus bar. Move the positive
lead on the grid line towards the break and the volt-
age reading will change as soon as the break is
crossed.
REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The rear window defogger relay is a International
Standards Organization (ISO)-type relay. The rear
window defogger relay is a electromechanical device
that switches fused battery current to the rear glass
and outside mirror heating grids, and the indicator
lamp of the defogger switch, when the HVAC control
head rear window defogger timer and logic circuitrygrounds the relay coil. (Refer to 8 - ELECTRICAL/
HEATED GLASS/REAR WINDOW DEFOGGER
RELAY - DIAGNOSIS AND TESTING)
The rear window defogger relay is located in the
junction block, on the left side of the instrument
panel inboard to the center of the vehicle (just to the
left and above the brake pedal or behind the knee
blocker). The rear window defogger relay cannot be
repaired and, if faulty or damaged, it must be
replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER RELAY
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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
The defogger relay (Fig. 4) is located in the junc-
tion block, on the left side of the instrument panel
inboard to the center of the vehicle (just to the right
and above the brake pedal or behind the knee
blocker). Remove the defogger relay from the junction
block to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
Fig. 3 REAR WINDOW DEFOGGER
1 - DEFOGGER BACKGLASS
2 - HEATED GLASS CONNECTOR9A9
3 - HINDGE MOUNTING SCREWS (2)
4 - HINDGE (LEFT SIDE)
5 - HINDGE MOUNTING SCREWS (2)
6 - HINDGE (RIGHT SIDE)
7 - HEATED GLASS CONNECTOR9B9
8 - BACKGLASS DEFOGGER GRID
8G - 6 WINDOW DEFOGGERKJ
REAR WINDOW DEFOGGER GRID (Continued)