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XJ
REMOVAL AND INSTALLATION (Continued)
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 transmis-
sion 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 termi-
nal 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 har-
ness.
(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 test-
ing 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 trans-
mission 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 termi-
nal onto the starter solenoid B(+) terminal stud.
STARTING SYSTEMS
Always support the starter motor during this process.
Do not let the starter motor hang from the wire har-
ness.
(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 trans-
mission 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 con-
verter 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 con-
verter 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 iden-
tification 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 recep-
tacle in the PDC.
(3) Align the starter relay terminals with the ter-
minal 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.
8B - 13
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Troubleshooting
