Jeep Wrangler TJ. Manual — part 288
(3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 4). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 5). Rotate and
hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
(5) Connect the positive lead of the voltmeter to
the starter housing. Connect the negative lead of the
voltmeter to the battery negative terminal post (Fig.
6). Rotate and hold the ignition switch in the Start
position. Observe the voltmeter. If the reading is
above 0.2 volt, correct the poor starter to engine
block ground contact.
If the resistance tests detect no feed circuit prob-
lems, refer to Starter Motor.
Fig. 3 Test Battery Positive Connection Resistance -
Typical
1 - VOLTMETER
2 - BATTERY
Fig. 4 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
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
TJ
STARTING
8F - 35
STARTING (Continued)
CONTROL CIRCUIT TEST
The starter control circuit components should be
tested in the order in which they are listed, as fol-
lows:
Starter Relay
• Refer to Starter Relay.
Starter Solenoid
• Refer to Starter Motor.
Ignition Switch
• Refer to Ignition Switch and Key Lock Cyl-
inder for ignition switch diagnosis and testing proce-
dures.
Clutch Pedal Position Switch
• If the vehicle is equipped with a manual trans-
mission, refer to Clutch Pedal Position Switch for
clutch pedal position switch diagnosis and testing
procedures.
Park/Neutral Position Switch
• If the vehicle is equipped with an automatic
transmission,
refer
to
Park/Neutral
Position
Switch for park/neutral position switch diagnosis
and testing procedures.
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
• Visually 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
to Battery for battery cleaning and inspection proce-
dures.
Ignition Switch
• Visually inspect ignition switch for indications of
physical damage and loose or corroded wire harness
connections. Clean corroded connections as required.
Refer to Wiring Diagrams. Refer to Ignition
Switch and Key Lock Cylinder for ignition switch
service procedures.
Clutch Pedal Position Switch
• If vehicle is equipped with a manual transmis-
sion, visually inspect clutch pedal position switch for
indications of physical damage and loose or corroded
wire harness connections. Clean corroded connections
as required. Refer to Clutch Hydraulic Linkage for
clutch pedal position switch service procedures.
Park/Neutral Position Switch
• If vehicle is equipped with an automatic trans-
mission, visually inspect park/neutral position switch
for indications of physical damage and loose or cor-
roded wire harness connections. Clean corroded con-
nections
as
required.
Refer
to
Park/Neutral
Position Switch for park/neutral position switch
service procedures.
Starter Relay
• Visually inspect starter relay for indications of
physical damage and loose or corroded wire harness
connections. Clean corroded connections as required.
Refer to Starter Relay for starter relay service pro-
cedures.
Starter Motor
• Visually inspect starter motor for indications of
physical damage and loose or corroded wire harness
connections. Clean corroded connections as required.
If problem being diagnosed involves improper starter
engagement, disengagement or noise complaints,
starter motor should be removed. With starter motor
removed, inspect starter pinion and ring gears for
damaged or missing teeth. Replace faulty compo-
nents as required. Refer to Starter Motor for
removal/installation procedures.
Starter Solenoid
• Visually inspect starter solenoid for indications
of physical damage and loose or corroded wire har-
ness connections. Clean corroded connections as
required. Refer to Starter Motor for starter solenoid
service procedures.
Wiring
• Visually inspect starting system wire harnesses
for indications of physical damage. Repair or replace
any faulty wiring, as required. Refer to Wiring Dia-
grams for repair or connector and terminal service
procedures.
8F - 36
STARTING
TJ
STARTING (Continued)
SPECIFICATIONS
STARTER
Starter Motor and Solenoid
Manufacturer
Mitsubishi
Engine Application
2.4L, 4.0L
Power Rating
2.4L - 1.4 Kilowatt (1.9 Horsepower)
4.0L - 1.4 Kilowatt (1.9 Horsepower)
Voltage
12 Volts
** Number of Permanent Magnets
6
Number of Brushes
4
Drive Type
Planetary Gear Reduction
Free Running Test Voltage
11.2 Volts
Free Running Test Maximum Amperage Draw
90 Amperes
Free Running Test Minimum Speed
2.4L - 24400 rpm
4.0L - 2500 rpm
Solenoid Closing Maximum Voltage Required
7.8 Volts
*Cranking Amperage Draw Test
2.4L - 160 Amperes
4.0L - 160 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
** The starter is equipped with permanent magnets. Never strike the starter case to attempt to loosen a sticking/
stuck armature as permanent magnets may crack or break.
TORQUE
DESCRIPTION
N-m
Ft. Lbs.
In. Lbs.
Starter Solenoid B+
Terminal Nut
11.3
-
100
Starter Mounting Bolts
(2.4L)
54
40
-
Starter Heat Shield
Mounting Bolts
6
-
55
Starter Mounting Bolt
(forward facing 4.0L)
41
30
-
Starter Mounting Bolt
(rearward facing 4.0L)
48
35
-
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR/SOLENOID
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with starter motor
removed from vehicle. Refer to starter motor specifi-
cations.
CAUTION: Permanent magnets are used in the
starter. Permanent magnet starters are highly sensi-
tive to hammering, shocks, external pressure and
reverse polarity. This starter motor must never be
clamped in a vise by starter field frame. The starter
should only be clamped by mounting flange. Do not
reverse battery cable connections to starter motor
when testing. The permanent magnets may be dam-
aged and starter rendered unserviceable if it is sub-
jected to any of these conditions.
TJ
STARTING
8F - 37
STARTING (Continued)
STARTER MOTOR TESTING
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal / Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect a suitable volt-ampere tester and12-
volt battery to starter motor in series, and set amme-
ter to 100 ampere scale. See instructions provided by
manufacturer of volt-ampere tester being used.
(4) Install a jumper wire from solenoid terminal to
solenoid B(+) terminal stud. The starter motor should
operate. If starter motor fails to operate, replace
faulty starter motor.
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to starter motor free run-
ning test voltage specifications.
(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to starter motor free running test maximum amper-
age draw specifications.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor.
STARTER SOLENOID TESTING
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor from vehicle. Refer to
Starter Motor for removal/installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with a continuity
tester (Fig. 7). There should be continuity. If OK, go
to Step 4. If not OK, replace faulty starter motor.
(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 8). There should be continuity.
If not OK, replace faulty starter motor.
REMOVAL
2.4L
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) While supporting starter motor, remove two
bolts securing starter motor to transmission (Fig. 9).
(4) Lower starter motor far enough to access and
remove nut securing battery cable to starter solenoid
B(+) terminal stud (Fig. 10). Always support starter
motor during this process. Do not let starter motor
hang from wire harness.
(5) Remove battery cable at starter.
(6) Disconnect solenoid terminal wire harness con-
nector from starter solenoid.
(7) Remove starter motor.
Fig. 7 CONTINUITY TEST BETWEEN SOLENOID
TERMINAL AND FIELD COIL TERMINAL
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
Fig. 8 CONTINUITY TEST BETWEEN SOLENOID
TERMINAL AND SOLENOID CASE - TYPICAL
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
Fig. 9 STARTER - 2.4L
1 - STARTER
2 - MOUNTING BOLTS (2)
8F - 38
STARTING
TJ
STARTER MOTOR (Continued)
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