Jeep Cherokee (XJ): Removal and installation

Starter motor

REMOVAL

2.5L ENGINE

(1) Disconnect and isolate the battery negative cable.

(2) Raise and support the vehicle.

(3) While supporting the starter motor with one hand, use the other hand to remove the two screws that secure the starter motor to the engine block (Fig. 14).

(4) Lower the starter motor from the engine block far enough to access and remove the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud (Fig. 15). Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(5) Remove the battery positive cable eyelet terminal from the starter solenoid B(+) terminal stud.

Always support the starter motor during this process.

Do not let the starter motor hang from the wire harness.

Fig. 14 Starter Motor Remove/Install - 2.5L Engine

1 - STARTER MOTOR
2 - SCREW (2)
3 - SHIM

Fig. 15 Starter Connections Remove/Install - Typical

1 - STARTER MOTOR
2 - SOLENOID B(+) TERMINAL STUD
3 - BATTERY POSITIVE CABLE EYELET TERMINAL
4 - NUT
5 - SOLENOID TERMINAL WIRE HARNESS CONNECTOR
6 - SOLENOID TERMINAL CONNECTOR RECEPTACLE

(6) Disconnect the solenoid terminal wire harness connector from the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(7) Remove the starter motor and any starter motor shims (if used) from the engine block.

4.0L ENGINE

(1) Disconnect and isolate the battery negative cable.

(2) Raise and support the vehicle.

(3) Remove the lower screw (forward facing) that secures the starter motor to the manual transmission clutch housing or the automatic transmission torque converter housing (Fig. 16).

Fig. 16 Starter Motor Remove/Install - 4.0L Engine

1 - SCREW
2 - STARTER MOTOR
3 - SCREW

(4) While supporting the starter motor with one hand, use the other hand to remove the upper screw (rearward facing) that secures the starter motor to the manual transmission clutch housing or the automatic transmission torque converter housing.

(5) Lower the starter motor from the front of the manual transmission clutch housing or automatic transmission torque converter housing far enough to access and remove the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud (Fig. 15). Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(6) Remove the battery positive cable eyelet terminal from the solenoid B(+) terminal stud. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(7) Disconnect the solenoid terminal wire harness connector from the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(8) Remove the starter motor from the manual transmission clutch housing or automatic transmission torque converter housing.

INSTALLATION

2.5L ENGINE

(1) Position the starter motor to the engine block.

(2) Reconnect the solenoid terminal wire harness connector to the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(3) Install the battery positive cable eyelet terminal onto the starter solenoid B(+) terminal stud.

Always support the starter motor during this process.

Do not let the starter motor hang from the wire harness.

(4) Install and tighten the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Tighten the nut to 11.3 N·m (100 in. lbs.). Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(5) Position the starter motor and any starter motor shims that were removed during the starter motor removal procedure to the engine block. Loosely install the two starter motor mounting screws to secure the starter motor and shims to the engine block.

NOTE: Shim thickness available is 0.381 mm (0.015 in.). Refer to Starter Motor Noise - 2.5L Engine in the index of this service manual for the location of the proper starter motor noise diagnosis and testing procedures.

(6) Tighten the two screws that secure the starter motor and shims to the engine block. Tighten the screws to 44.7 N·m (33 ft. lbs.).

(7) Lower the vehicle.

(8) Reconnect the battery negative cable.

4.0L ENGINE

(1) Position the starter motor to the manual transmission clutch housing or automatic transmission torque converter housing.

(2) Reconnect the solenoid terminal wire harness connector to the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(3) Install the battery positive cable eyelet terminal onto the starter solenoid B(+) terminal stud.

Always support the starter motor during this process.

Do not let the starter motor hang from the wire harness.

(4) Install and tighten the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Tighten the nut to 11.3 N·m (100 in. lbs.). Always support the starter motor during this process. Do not let the starter motor hang from the wire harness.

(5) Position the starter motor to the manual transmission clutch housing or automatic transmission torque converter housing. Loosely install the two starter motor mounting screws to secure the starter motor to the manual transmission clutch housing or automatic transmission torque converter housing.

(6) Tighten the lower (forward facing) screw that secures the starter motor to the manual transmission clutch housing or automatic transmission torque converter housing. Tighten the screw to 40.7 N·m (30 ft.

lbs.).

(7) Tighten the upper (rearward facing) screw that secures the starter motor to the manual transmission clutch housing or automatic transmission torque converter housing. Tighten the screw to 47.5 N·m (35 ft.

lbs.).

(8) Lower the vehicle.

(9) Reconnect the battery negative cable.

Starter relay

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Remove the cover from the Power Distribution Center (PDC) (Fig. 17).

(3) See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location.

(4) Remove the starter relay from the PDC.

INSTALLATION

(1) See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location.

(2) Position the starter relay in the proper receptacle in the PDC.

(3) Align the starter relay terminals with the terminal cavities in the PDC receptacle.

(4) Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle.

(5) Install the cover onto the PDC.

(6) Reconnect the battery negative cable.

Fig. 17 Power Distribution Center

1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER