Jeep XJ. Manual — part 92
INSTALLATION
(1) Position generator to engine and snap field
wire connector into rear of generator.
(2) Install B+ terminal to generator mounting
stud. Tighten mounting nut to 8.5 N·m (75 in. lbs.)
torque.
(3) If equipped, snap plastic cover to B+ terminal.
(4) LHD Vehicles: Install generator fasteners and
tighten as follows:
• Generator upper mounting bolt-55 N·m (41 ft.
lbs.) torque.
• Generator lower pivot bolt/nut-55 N·m (41 ft.
lbs.) torque.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
(5) LHD Vehicles: Install generator drive belt.
Refer to Group 7, Cooling System for procedures.
(6) RHD Vehicles: Install upper nut (generator
adjustment nut) and both belt adjustment bolts.
Install generator lower nut/bolt.
(7) RHD Vehicles: On vehicles equipped with RHD,
the generator is used to adjust the serpentine belt.
Refer to Group 7, Cooling System for belt routing,
belt adjustment and bolt tightening procedures.
(8) Install negative battery cable to battery.
Fig. 2 Remove/Install Generator—4.0L Engine—LHD
1 – UPPER MOUNTING BRACKET
2 – GENERATOR
3 – UPPER BOLT
4 – LOWER BOLT
Fig. 3 Remove/Install Generator—4.0L Engine—RHD
1 – UPPER NUT
2 – LOWER BOLT
3 – GENERATOR
4 – BELT ADJUSTMENT BOLTS
Fig. 4 Generator Connectors—Typical Denso
1 – FIELD WIRES
2 – B+ (OUTPUT TERMINAL)
3 – FIELD WIRE CONNECTOR
8C - 4
CHARGING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
BATTERY TEMPERATURE SENSOR
The battery temperature sensor is located under
vehicle battery (Fig. 5) and is attached to a mounting
hole on battery tray.
REMOVAL
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Disconnect sensor pigtail harness from engine
wire harness.
(3) Pry sensor straight up from battery tray
mounting hole.
INSTALLATION
(1) Feed pigtail harness through hole in top of bat-
tery tray and press sensor into top of battery tray.
(2) Connect pigtail harness.
(3) Install battery. Refer to Group 8A, Battery for
procedures.
SPECIFICATIONS
GENERATOR RATINGS
TYPE
PART NUMBER
RATED SAE AMPS
ENGINES
MINIMUM TEST AMPS
DENSO
56041685AA
117
4.0L
88
DENSO
56041565AA
81
4.0L
57
DENSO
56005684AB
81
2.5L
57
DENSO
56005685AC
117
2.5L
88
DENSO
56041822AA
124
2.5L/4.0L
90
TORQUE CHART
Right Hand Drive= RHD, Left Hand Drive= LHD.
Description
Torque
Generator Mounting Bolt—LHD—2.5L/4.0L
Engine . . . . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)
Generator Pivot Bolt/Nut—LHD—2.5L/4.0L
Engine . . . . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)
Battery Terminal Nut—LHD or
RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)
Description
Torque
Ground Terminal Nut—LHD or
RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)
Harness Hold-down Nut—LHD or
RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)
Field Terminal Nuts—LHD or
RHD . . . . . . . . . . . . . . . . . . 2.8 N·m (25 in. lbs.)
Fig. 5 Battery Temperature Sensor
1 – BATTERY TEMPERATURE SENSOR
2 – BATTERY TRAY
XJ
CHARGING SYSTEM
8C - 5
REMOVAL AND INSTALLATION (Continued)
CHARGING SYSTEM
TABLE OF CONTENTS
page
page
REMOVAL AND INSTALLATION
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
GENERATOR
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
(1) Disconnect negative battery cable.
(2) Remove generator drive belt. Refer to Group 7,
Cooling System for procedure.
(3) Remove the nut securing battery output cable
to B+ terminal at rear of generator (Fig. 1).
(4) Unplug field terminal connector at rear of gen-
erator (Fig. 1).
(5) Remove upper generator mounting bolt (Fig. 2).
(6) Remove lower generator mounting bolt (Fig. 2)
and remove generator from vehicle.
(7) Reverse the removal procedures for installa-
tion. Tighten hardware in order as follows:
• Upper Generator Mounting Bolt—27.5 N·m (20
ft. lbs.)
• Lower Generator Mounting Bolt—47 N·m (35 ft.
lbs.)
• Battery Terminal (generator B+ terminal) Nut—
8.5 N·m (75 in. lbs.)
Fig. 1 Generator Electrical
1 – GENERATOR FIELD WIRE CONNECTOR
2 – GENERATOR B+ CONNECTION
XJ
CHARGING SYSTEM
8C - 1
2000 JEEP CHEROKEE
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