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BATTERY/STARTER/GENERATOR SERVICE
8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page
page
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
Group 8B covers battery, starter and generator ser-
vice procedures. For diagnosis of these components
and their related systems, refer to Group 8A - Bat-
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
STARTER AND STARTER RELAY . . . . . . . . . . . . . 4
tery/Starting/Charging Systems Diagnostics. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
BATTERY
GENERAL INFORMATION
This section covers battery service procedures only.
For battery maintenance procedures, refer to Group 0
- Lubrication and Maintenance. While battery charg-
ing can be considered a service or maintenance pro-
cedure, this information is located in Group 8A -
Battery/Starting/Charging Systems Diagnostics. This
was done because the battery must be fully charged
before any diagnosis is performed.
It is important that the battery, starting, and
charging systems be thoroughly tested and inspected
any time a battery needs to be charged or replaced.
The cause of abnormal discharge, over-charging, or
premature failure of the battery must be diagnosed
and corrected before a battery is replaced or returned
to service. Refer to Group 8A - Battery/Starting/
Charging Systems Diagnostics.
The factory installed low-maintenance battery (Fig.
1) has removable battery cell caps. Water can be
added to this battery. The battery is not sealed and
has vent holes in the cell caps. The chemical compo-
sition within the low-maintenance battery reduces
battery gassing and water loss at normal charge and
discharge rates. Therefore, the battery should not re-
quire additional water in normal service.
However, low electrolyte can be caused by an over-
charging condition. Be certain to diagnose charging
system before returning vehicle to service. Refer to
Group 8A - Battery/Starting/Charging Systems Diag-
nostics for more information.
Fig. 1 Low-Maintenance Battery
(2) Loosen the cable terminal clamps and remove
both battery cables, negative cable first. If necessary,
use a puller to remove terminal clamps from battery
posts (Fig. 2).
BATTERY REMOVE/INSTALL
(1) Turn ignition switch to OFF position. Make
sure all electrical accessories are off.
Fig. 2 Remove Battery Terminal Clamp
(3) Inspect the cable terminals for corrosion and
damage. Remove corrosion using a wire brush or post
8B - 2
BATTERY/STARTER/GENERATOR SERVICE
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and terminal cleaning tool, and a sodium bicarbonate
(baking soda) and warm water cleaning solution (Fig.
3). Replace cables that have damaged or deformed
terminals.
Fig. 5 Battery Holddown—YJ
(5) Inspect battery tray (Fig. 6 or 7) and hold-
downs for corrosion or damage. Remove corrosion us-
ing a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal and replace any damaged parts.
Fig. 3 Clean Battery Cable Terminal
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-
MOVING A BATTERY BY HAND. SAFETY GLASSES
SHOULD ALSO BE WORN. IF THE BATTERY IS
CRACKED OR LEAKING, THE ELECTROLYTE CAN
BURN THE SKIN AND EYES.
(4) Remove battery holddowns (Fig. 4 or 5) and re-
move battery from vehicle.
Fig. 6 Battery Tray—XJ
(6) Inspect the battery case for cracks or other
damage that could result in electrolyte leaks. Also
check battery terminal posts for looseness. Batteries
with damaged cases or loose posts must be replaced.
(7) Check electrolyte level in the battery. Use a
putty knife or other suitable wide-bladed flat tool to
Fig. 4 Battery Holddown—XJ
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BATTERY/STARTER/GENERATOR SERVICE
8B - 3
Fig. 9 Clean Battery
Fig. 7 Battery Tray—YJ
pry cell caps off (Fig. 8). Do not use a screwdriver.
Add distilled water to each cell until the liquid
reaches the bottom of the vent well. DO NOT OVER-
FILL. If battery is discharged, charge as required.
Refer to Group 8A - Battery/Starting/Charging Sys-
tems Diagnosis for more information.
(9) Clean corrosion from battery posts (Fig. 10)
with a wire brush or post and terminal cleaner, and
sodium bicarbonate (baking soda) and warm water
cleaning solution.
Fig. 8 Removing Cell Cap
(8) If the battery is to be reinstalled, clean outside
of battery case and top cover with sodium bicarbon-
ate (baking soda) and warm water cleaning solution
(Fig. 9) to remove acid film. Flush with clean water.
Ensure that cleaning solution does not enter cells
through the vent holes. If the battery is being re-
placed, refer to Specifications in Group 8A - Battery/
Starting/Charging Systems Diagnostics to confirm
replacement has correct classification and ratings for
the vehicle.
Fig. 10 Clean Battery Post
(10) Position battery in tray. Ensure that positive
and negative posts are correctly positioned. The cable
terminals must reach the correct battery post with-
out stretching.
(11) Loosely install battery holddown hardware.
Ensure that battery base is correctly positioned in
tray, then tighten holddowns to 2.2 N m (20 in. lbs.)
torque.
8B - 4
BATTERY/STARTER/GENERATOR SERVICE
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terminal clamp. Both cable clamp bolts require
torque of 8.5 N m (75 in. lbs.).
(14) Apply a thin coating of petroleum jelly or
chassis grease to cable terminals and battery posts.
CAUTION: Be certain that battery cables are con-
nected to the correct battery terminals. Reverse po-
larity can damage electrical components.
(12)
minal
(13)
minal
Place oiled felt washer on battery positive ter-
post.
Install and tighten battery positive cable ter-
clamp. Then install and tighten negative cable
STARTER AND STARTER RELAY
GENERAL INFORMATION
This section covers starter and starter relay service
procedures only. For diagnostic procedures, refer to
Group 8A - Battery/Starting/Charging Systems Diag-
nostics. Service procedures for other starting system
components can be found as follows:
•
battery - see Battery, in this group
•
ignition switch - refer to Group 8D - Ignition Sys-
tems
•
park/neutral position switch (automatic transmis-
sion) - refer to Group 21 - Transmission and Transfer
Case
•
wiring harness and connectors - refer to Group 8W
- Wiring Diagrams.
CAUTION: Do not connect starter motor incorrectly
when tests are being performed. The permanent
magnets may be damaged and rendered unservice-
able.
STARTER RELAY
The starter relay is an International Standards Or-
ganization (ISO) type relay, and is located in the
Power Distribution Center (PDC). Refer to underside
of PDC cover for relay location.
STARTER REMOVE/INSTALL—2.5L
XJ MODELS
(1) Disconnect battery negative cable.
(2) Remove exhaust clamp from bracket (Fig. 11).
STARTER
The starter motor incorporates several features to
create a reliable, efficient, compact and lightweight
unit. A planetary gear system (intermediate trans-
mission) is used between the electric motor and pin-
ion gear. This feature makes it possible to reduce the
dimensions of the starter. At the same time, it allows
higher armature rotational speed and delivers in-
creased torque through the pinion gear to the fly-
wheel or drive plate ring gear.
The use of a permanent magnet field also reduces
starter size and weight. This field consists of six
high-strength permanent magnets. The magnets are
aligned according to their polarity and are perma-
nently fixed in the starter field frame.
The starter motors for all engines are activated by
a solenoid mounted to the overrunning clutch hous-
ing. However, the starter motor/solenoid are serviced
only as a complete assembly. If either component
fails, the entire assembly must be replaced.
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 field frame. Doing
so may damage the magnets. It may be clamped by
the mounting flange ONLY.
Fig. 11 Exhaust Clamp and Brace Remove (XJ—
2.5L)
(3) Remove nut and bolt from forward end of brace
rod (automatic transmission only).
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(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. 12).
BATTERY/STARTER/GENERATOR SERVICE
8B - 5
Fig. 13 Starter Remove/Install (YJ—2.5L)
(3) Disconnect battery cable and solenoid feed wire
from solenoid.
(4) Remove starter lower mounting bolt (Fig. 14).
Fig. 12 Starter Remove/Install (XJ—2.5L)
(8) Remove starter mounting bolts, starter motor
and shims.
Shim thickness available is 0.381 mm (0.015
in.). Refer to 2.5L Starter Noise Diagnosis in
Group 8A - Battery/Starting/Charging Systems
Diagnostics for proper shim selection.
(9) Reverse removal procedures to install and
torque mounting hardware as shown in Specifica-
tions.
YJ MODELS
(1) Disconnect battery negative cable.
(2) Disconnect battery cable from solenoid battery
terminal (Fig. 13).
(3) Disconnect solenoid feed wire.
(4) Remove starter mounting bolts.
(5) Remove starter motor and shims.
Shim thickness available is 0.381 mm (0.015
in.). Refer to 2.5L Starter Noise Diagnosis in
Group 8A - Battery/Starting/Charging Systems
Diagnosis for proper shim selection.
(6) Reverse removal procedures to install and
torque mounting hardware as shown in Specifica-
tions.
Fig. 14 Starter Remove/Install—4.0L
(5) Remove starter upper mounting bolt and re-
move starter.
(6) Reverse removal procedures to install and
torque mounting hardware as shown in Specifica-
tions.
STARTER REMOVE/INSTALL—4.0L
(1) Disconnect battery negative cable.
(2) Raise and support vehicle.

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