STARTING SYSTEMS

CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
COLD CRANKING TEST . . . . . . . . . . . . . . . . . . . 4
CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . 5
FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . 4
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 8
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
OVERVIEW
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the battery, Group 8B covers the
starti ng system, and Group 8C covers the chargi ng
system. Refer to Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams. We have
separated these systems to make i t easi er to l ocate
the i nformati on you are seeki ng wi thi n thi s Servi ce
Manual . However, when attempti ng to di agnose any
of these systems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods, to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of a i nducti on mi l l i ampere ammeter, vol t/
ohmmeter, battery charger, carbon pi l e rheostat (l oad
tester), and 12-vol t test l amp may be requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See the
On-Board Di agnosti cs Test i n Group 8C - Chargi ng
System for more i nformati on.
INTRODUCTION
The starti ng system consi sts of:
Battery
Starter rel ay
Starter wi th an i ntegral sol enoi d
I gni ti on swi tch
Cl utch pedal posi ti on swi tch (manual transmi ssi on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harness and connecti ons.
Thi s group covers di agnosi s of the compl ete start-
i ng system, except the battery. However, thi s group
onl y covers servi ce procedures for the starter and
starter rel ay. Servi ce procedures for other starti ng
system components can be l ocated as fol l ows:
Battery - refer to Group 8A - Battery for the
di agnosti c and servi ce procedures
I gni ti on swi tch - refer to Group 8D - I gni ti on
Systems for the servi ce procedures
Cl utch pedal posi ti on swi tch - refer to Group 6 -
Cl utch for the servi ce procedures
Park/neutral posi ti on swi tch - refer to Group 21
- Transmi ssi on for the servi ce procedures
Wi re harness and connecti ons - refer to Group
8W - Wi ri ng Di agrams for the servi ce procedures.
DESCRIPTION AND OPERATION
STARTING SYSTEM
The starti ng system components form two separate ci r-
cui ts. A hi gh-amperage feed ci rcui t that feeds the starter
between 150 and 350 amperes, and a l ow-amperage con-
trol ci rcui t that operates on l ess than 20 amperes.
Battery vol tage i s suppl i ed through the l ow-amper-
age control ci rcui t to the coi l battery termi nal of the
starter rel ay when the i gni ti on swi tch i s turned to
the Start posi ti on. The park/neutral posi ti on swi tch
i s i nstal l ed i n seri es between the starter rel ay coi l
ground termi nal and ground. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed unl ess the automati c transmi ssi on gear sel ector
i s i n the Neutral or Park posi ti ons.
ZJ STARTING SYSTEMS 8B - 1
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter. Thi s engages the starter overrun-
ni ng cl utch and pi ni on gear wi th the starter ri ng
gear on the automati c transmi ssi on torque converter
(5.2L/5.9L engi ne), or the automati c transmi ssi on
torque converter dri ve pl ate (4.0L engi ne).
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter from damage by al l owi ng the starter
pi ni on gear to spi n faster than the pi ni on shaft.
When the dri ver rel eases the i gni ti on swi tch to the
On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
STARTER
The starter motor i ncorporates several features to
create a rel i abl e, effi ci ent, compact, and l i ghtwei ght
uni t. A pl anetary gear system (i ntermedi ate trans-
mi ssi on) i s used between the el ectri c motor and the
pi ni on gear. Thi s feature makes i t possi bl e to reduce
the di mensi ons of the starter. At the same ti me, i t
al l ows hi gher armature rotati onal speed and del i vers
i ncreased torque through the pi ni on gear to the
starter ri ng gear on the automati c transmi ssi on
torque converter or torque converter dri ve pl ate, or
on the manual transmi ssi on fl ywheel .
The use of a permanent magnet fi el d al so reduces
the si ze and wei ght of the starter. The permanent
magnet fi el d consi sts of four hi gh-strength perma-
nent magnets. The magnets are al i gned accordi ng to
thei r pol ari ty, and are permanentl y mounted i n the
starter fi el d frame.
The starter motors for al l engi nes are acti vated by
a sol enoi d mounted to the overrunni ng cl utch hous-
i ng. However, the starter motor and sol enoi d are ser-
vi ced onl y as a compl ete assembl y. I f ei ther
component i s faul ty or damaged, the enti re starter
assembl y must be repl aced.
CAUTION:
Permanent magnet starters are highly sensitive
to hammering, shocks, and external pressure. The
permanent magnets may be damaged and the
starter rendered unserviceable, if subjected to any
of these conditions.
The starter motor must not be clamped in a
vise by the starter field frame. Doing so may dam-
age the permanent magnets. The starter should
only be clamped by the mounting flange.
Do not connect the starter motor incorrectly
when testing. Reverse polarity may damage the per-
manent magnets and render the starter unservice-
able.
STARTER RELAY
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) mi cro-rel ay. The termi nal desi g-
nati ons and functi ons are the same as a conventi onal
I SO rel ay. However, the mi cro-rel ay termi nal ori enta-
ti on (or footpri nt) i s di fferent, the current capaci ty i s
l ower, and the rel ay case di mensi ons are smal l er
than those of the conventi onal I SO rel ay.
The starter rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when the i gni ti on swi tch i s turned to
the Start posi ti on. See the Di agnosi s and Testi ng sec-
ti on of thi s group for more i nformati on on the opera-
ti on of the starter rel ay.
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC), i n the engi ne compartment. Refer
to the PDC l abel for rel ay i denti fi cati on and l ocati on.
The starter rel ay cannot be repai red and, i f faul ty
or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
STARTING SYSTEM
For ci rcui t descri pti ons and di agrams, refer to
8W-21 - Starti ng System i n Group 8W - Wi ri ng Di a-
grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
8B - 2 STARTING SYSTEMS ZJ
DESCRIPTION AND OPERATION (Continued)
INSPECTION
Before removi ng any uni t from the starti ng system
for repai r or di agnosi s, perform the fol l owi ng i nspec-
ti ons:
Battery - Vi sual l y i nspect the battery for i ndi -
cati ons of physi cal damage and l oose or corroded
cabl e connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of the battery. Charge or repl ace
the battery, i f requi red. Refer to Group 8A - Battery
for more i nformati on.
Ignition Switch - Vi sual l y i nspect the i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Park/Neutral Position Switch - Vi sual l y
i nspect the park/neutral posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons.
Starter Relay - Vi sual l y i nspect the starter
rel ay for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Starter - Vi sual l y i nspect the starter for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons.
Starter Solenoid - Vi sual l y i nspect the starter
sol enoi d for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect the wi re harness for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red.
Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
ENGAGE.
1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position switch
(auto trans) faulty or
misadjusted.
6. Starter solenoid faulty.
7. Starter assembly faulty.
1. Refer to Group 8A - Battery. Charge or
replace battery, if required.
2. See Cold Cranking Test, in this group. Test and
repair feed and/or control circuits, if required.
3. See Relay Test, in this group. Replace relay, if
required.
4. See Ignition Switch Test, in this group. Replace
switch, if required.
5. See Park/Neutral Position Switch Test, in this
group. Replace switch, if required.
6. See Solenoid Test, in this Group. Replace
starter assembly, if required.
7. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER ENGAGES, FAILS
TO TURN ENGINE.
1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter assembly faulty.
4. Engine seized.
1. Refer to Group 8A - Battery. Charge or
replace battery, if required.
2. See Cold Cranking Test, in this group. Test
and repair feed and/or control circuits, if
required.
3. If all other starting system components and
circuits check OK, replace starter assembly.
4. Refer to Group 9 - Engine, for diagnostic
and service procedures.
STARTER ENGAGES, SPINS
OUT BEFORE ENGINE
STARTS.
1. Broken teeth on starter ring
gear.
2. Starter assembly faulty.
1. Remove starter as described in this group.
Inspect ring gear and replace, if required.
2. If all other starting system components and
circuits check OK, replace starter assembly.
STARTER DOES NOT
DISENGAGE.
1. Starter improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter assembly faulty.
1. Install starter as described in this group.
Tighten starter mounting hardware to correct
torque specifications.
2. See Relay Test, in this group. Replace relay,
if required.
3. See Ignition Switch Test, in this group.
Replace switch, if required.
4. If all other starting system components and
circuits check OK, replace starter assembly.
ZJ STARTING SYSTEMS 8B - 3
DIAGNOSIS AND TESTING (Continued)
COLD CRANKING TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-21 - Starti ng System i n Group 8W - Wi ri ng Di a-
grams. The battery must be ful l y-charged and l oad-
tested before proceedi ng. Refer to Group 8A - Battery
for more i nformati on.
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 1). Refer to the operati ng
i nstructi ons provi ded wi th the tester bei ng used.
(2) Ful l y engage the parki ng brake.
(3) Pl ace the automati c transmi ssi on gearshi ft
sel ector l ever i n the Park posi ti on.
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent the engi ne from starti ng, unpl ug
the Automati c ShutDown (ASD) rel ay. The ASD rel ay
i s l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC l abel for rel ay i denti fi cati on and
l ocati on.
(6) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw.
(a) I f the vol tage reads bel ow 9.6 vol ts, remove
the starter for bench testi ng. I f the starter bench
test i s OK, refer to Group 9 - Engi ne for further
di agnosi s of the engi ne. I f the starter bench test i s
not OK, repl ace the faul ty starter.
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, see the Feed Ci rcui t Test procedures i n thi s
group.
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter does not turn, see the Control Ci rcui t
Test procedures i n thi s group.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter turns very sl owl y, see the Feed Ci rcui t
Test procedures i n thi s group.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage ci rcui t. For ci rcui t descri pti ons and
di agrams, refer to 8W-21 - Starti ng System i n Group
8W - Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that the vol tage drop i s gi vi ng an i ndi ca-
ti on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n that the fol l owi ng procedures are
accompl i shed:
Battery i s ful l y-charged. Refer to Group 8A -
Battery for more i nformati on.
Ful l y engage the parki ng brake.
Pl ace the automati c transmi ssi on gearshi ft sel ec-
tor l ever i n the Park posi ti on.
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent the engi ne from starti ng. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC l abel for ASD rel ay i denti fi cati on
and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 2). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
Fig. 1 Volts-Amps Tester Connections - Typical
Fig. 2 Test Battery Negative Connection Resistance
- Typical
8B - 4 STARTING SYSTEMS ZJ
DIAGNOSIS AND TESTING (Continued)
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 3). Rotate and hol d the i gni ti on swi tch i n
the Start posi ti on. Observe the vol tmeter. I f vol tage
i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 4). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 5). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
(5) Connect the posi ti ve l ead of the vol tmeter to
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
6). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, remove the starter and see the Sol enoi d Test
procedure i n thi s group.
CONTROL CIRCUIT TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-21 - Starti ng System i n Group 8W - Wi ri ng Di a-
grams. The starter control ci rcui t consi sts of:
Battery
Starter rel ay
Starter sol enoi d
I gni ti on swi tch
Fig. 3 Test Battery Positive Connection Resistance -
Typical
Fig. 4 Test Battery Positive Cable Resistance -
Typical
Fig. 5 Test Ground Circuit Resistance - Typical
Fig. 6 Test Starter Ground - Typical
ZJ STARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)
Park/neutral posi ti on swi tch
Wi re harness and connecti ons.
Test procedures for these components shoul d be
performed i n the order i n whi ch they are l i sted, as
fol l ows:
SOLENOID TEST
Remove the starter as descri bed i n thi s group.
Then proceed as fol l ows:
(1) Remove the wi re from the sol enoi d fi el d coi l
termi nal .
(2) Check for conti nui ty between the sol enoi d ter-
mi nal and fi el d coi l termi nal wi th a conti nui ty tester
(Fi g. 7). There shoul d be conti nui ty. I f OK, go to Step
3. I f not OK, repl ace the faul ty starter assembl y.
(3) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d case (Fi g. 8). There shoul d be
conti nui ty. I f OK, go to Step 4. I f not OK, repl ace the
faul ty starter assembl y.
(4) Connect the sol enoi d fi el d coi l wi re to the fi el d
coi l termi nal .
(5) I nstal l the starter as descri bed i n thi s group.
RELAY TEST
The starter rel ay (Fi g. 9) i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
Remove the starter rel ay from the PDC as
descri bed i n thi s group to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the starter sol enoi d fi el d coi l s. There shoul d be
conti nui ty between the cavi ty for rel ay termi nal 87
and the starter sol enoi d termi nal at al l ti mes. I f OK,
go to Step 4. I f not OK, repai r the open ci rcui t to the
starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on.
Check for battery vol tage at the cavi ty for rel ay ter-
mi nal 86 wi th the i gni ti on swi tch i n the Start posi -
ti on, and no vol tage when the i gni ti on swi tch i s
rel eased to the On posi ti on. I f OK, go to Step 5. I f
not OK, check for an open or short ci rcui t to the i gni -
ti on swi tch and repai r, i f requi red. I f the ci rcui t to
the i gni ti on swi tch i s OK, see the I gni ti on Swi tch
Test procedure i n thi s group.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s grounded
through the park/neutral posi ti on swi tch onl y when
the gearshi ft sel ector l ever i s i n the Park or Neutral
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal
Fig. 8 Continuity Test Between Solenoid Terminal
and Solenoid Case
Fig. 9 Starter Relay
8B - 6 STARTING SYSTEMS ZJ
DIAGNOSIS AND TESTING (Continued)
posi ti ons. Check for conti nui ty to ground at the cav-
i ty for rel ay termi nal 85. I f not OK, check for an
open or short ci rcui t to the park/neutral posi ti on
swi tch and repai r, i f requi red. I f the ci rcui t i s OK,
see the Park/Neutral Posi ti on Swi tch Test procedure
i n thi s group.
PARK/NEUTRAL POSITION SWITCH TEST
(1) Pl ace the transmi ssi on gear sel ector l ever i n
the Park posi ti on.
(2) Di sconnect and i sol ate the battery negati ve
cabl e.
(3) Rai se and support the vehi cl e.
(4) Unpl ug the park/neutral posi ti on swi tch wi re
harness connector.
(5) Check for conti nui ty between the center swi tch
termi nal and a good chassi s ground. There shoul d be
conti nui ty. I f OK, go to Step 6. I f not OK, repl ace the
faul ty swi tch.
(6) Move the transmi ssi on gear sel ector to the
Reverse posi ti on and check for conti nui ty between
the center swi tch termi nal and a good chassi s
ground. There shoul d be no conti nui ty. I f not OK,
repl ace the faul ty swi tch.
IGNITION SWITCH TEST
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn shrouds and
unpl ug the i gni ti on swi tch wi re harness connector.
Refer to Group 8D - I gni ti on Systems for the proce-
dures.
(3) Wi th the i gni ti on swi tch i n the On posi ti on,
check for conti nui ty between the i gni ti on swi tch ter-
mi nal s 1 and 7. These are the termi nal s at each end
of the swi tch connector. There shoul d be no conti nu-
i ty. I f OK, go to Step 4. I f not OK, repl ace the faul ty
swi tch.
(4) Wi th the i gni ti on swi tch hel d i n the Start posi -
ti on, check for conti nui ty between the i gni ti on swi tch
termi nal s 1 and 7 agai n. There shoul d now be conti -
nui ty. I f not OK, repl ace the faul ty swi tch.
REMOVAL AND INSTALLATION
STARTER
4.0L ENGINE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Di sconnect the battery cabl e and sol enoi d feed
wi re from the starter sol enoi d (Fi g. 10).
(4) Remove the front starter mounti ng bol t and the
automati c transmi ssi on oi l cool er l i ne bracket (Fi g.
11).
Fig. 10 Starter Wire Harness Remove/Install -
Typical
Fig. 11 Starter Remove/Install - 4.0L Engine
ZJ STARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)
(5) Remove the rear starter mounti ng bol t and
l ower the starter.
(6) Reverse the removal procedures to i nstal l .
Ti ghten the starter hardware as fol l ows:
Upper mounti ng bol t - 55 Nm (40 ft. l bs.)
Lower mounti ng bol t - 41 Nm (30 ft. l bs.)
Sol enoi d battery cabl e nut - 10 Nm (90 i n. l bs.)
Sol enoi d termi nal nut - 6 Nm (55 i n. l bs.).
5.2L AND 5.9L ENGINE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Di sconnect the battery cabl e and sol enoi d feed
wi re from the starter sol enoi d (Fi g. 10).
(4) Remove the l ower starter mounti ng bol t and
the exhaust brace (Fi g. 12).
(5) Remove the upper starter mounti ng nut, l ock
washer, and automati c transmi ssi on oi l cool er l i ne
bracket.
(6) Move the starter towards the front of the vehi -
cl e unti l the starter gear housi ng nose cl ears the bel l -
housi ng. Then ti l t the starter nose downwards past
the exhaust pi pe.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the starter hardware as fol l ows:
Lower mounti ng bol t - 68 Nm (50 ft. l bs.)
Upper mounti ng nut - 68 Nm (50 ft. l bs.)
Sol enoi d battery cabl e nut - 10 Nm (90 i n. l bs.)
Sol enoi d termi nal nut - 6 Nm (55 i n. l bs.).
STARTER RELAY
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 13).
(3) Refer to the l abel on the PDC for starter rel ay
i denti fi cati on and l ocati on.
(4) Unpl ug the starter rel ay from the PDC.
(5) I nstal l the starter rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the PDC and pushi ng
the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(7) Connect the battery negati ve cabl e.
(8) Test the rel ay operati on.
Fig. 12 Starter Remove/Install - 5.2L and 5.9L
Engine
Fig. 13 Power Distribution Center
8B - 8 STARTING SYSTEMS ZJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
STARTING SYSTEM
Starter and Solenoid
Manufacturer Mitsubishi Mitsubishi
Engine Application 4.0L 5.2L/5.9L
Power Rating 1.4 Kilowatt 1.4 Kilowatt
Voltage 12 Volts 12 Volts
Number of Fields 4 4
Number of Poles 4 4
Number of Brushes 4 4
Drive Type Planetary Gear Reduction Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts 11.2 Volts
Free Running Test Maximum
Amperage Draw
80 Amperes 80 Amperes
Free Running Test Minimum Speed 2500 rpm 2500 rpm
Solenoid Closing Maximum Voltage 7.8 Volts 7.8 Volts
*Cranking Amperage Draw Test 160 Amperes 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
ZJ STARTING SYSTEMS 8B - 9