1994 JEEP CHEROKEE torque

²Metal chips are attracted by the magnets and may
not be completely removed from the starter frame.
Chips in the ring gear can lead to failure of the
starter.
2.5L STARTER MOTOR REMOVAL/INSTALLATION
XJÐ2.5L ENGINE
(1) Disconnect negative cable from battery.
(2) Remove exhaust clamp from bracket (Fig. 3).
(3) Remove nut and bolt from forward end of brace
rod (automatic transmission only).
(4) Remove nut from lower end of brace rod (auto-
matic transmission only).
(5) Remove brace rod and bracket (automatic
transmission only).
(6) Remove nut, bolt and bracket from bell housing
(manual transmission only).
(7) Disconnect battery cable and solenoid feed wire
from solenoid (Fig. 4).
(8) Remove starter motor mounting bolts, starter
motor and shims.
Two shim thicknesses are available. One is
0.381 mm (0.015 in.) and the other is 1.143 mm
(0.045 in.). Refer to Group 8A for proper shim se-
lection.
(9) To install starter motor, reverse the removal
procedures and torque mounting hardware as shown.
(10) Connect negative cable to battery.
YJÐ2.5L ENGINE
(1) Disconnect negative cable from battery.
(2) Disconnect battery cable from starter motor
B+ terminal (Fig. 5).(3) Disconnect solenoid feed wire.
(4) Remove starter motor mounting bolts.
(5) Remove starter motor and shims.
Two shim thicknesses are available. One is
0.381 mm (0.015 in.) and the other is 1.143 mm
(0.045 in.). Refer to Group 8A for proper shim se-
lection.
(6) To install starter motor, reverse removal proce-
dures and torque mounting hardware as shown.
(7) Connect negative cable to battery.
Fig. 3 Exhaust Clamp and Brace RemovalÐ2.5L XJ
Fig. 4 Starter Motor Removal/InstallationÐ2.5L XJ
Fig. 5 Starter Motor Removal/InstallationÐ2.5L YJ
JBATTERY/STARTER/GENERATOR SERVICE 8B - 5

4.0L STARTER GENERAL INFORMATION
The Mitsubishi starter motor is a light-weight unit
featuring a planetary gear drive and permanent
magnets for current induction.
The planetary gear drive is splined to both the ar-
mature shaft and overrunning clutch. Starter torque
is transmitted to the overrunning clutch pinion
through the planetary gears which provide higher ro-
tational speeds.
The starter magnetic field is produced by six per-
manent magnets. The magnets are mounted in the
starter frame and positioned according to polarity.
They are permanently attached to the frame and are
not removable.
The starter motor is activated by a solenoid
mounted on the overrunning clutch housing.
This unit is highly sensitive to hammering, shocks,
and external pressure.
CAUTION: The starter motor MUST NOT BE
CLAMPED in a vise by the starter frame. Doing so
may damage the magnets. It may be clamped by the
mounting flange ONLY.
CAUTION: Do not connect the starter motor incor-
rectly when performing tests. The magnets may be
damaged and rendered unserviceable.
²Ensure cleanliness when performing repairs.
²Metal chips are attracted by the magnets and may
not be completely removed from the starter frame.
Chips in the ring gear can lead to failure of the
starter.
4.0L STARTER MOTOR REMOVAL/INSTALLATION
(1) Disconnect negative cable from battery.
(2) Raise and support vehicle.(3) Disconnect battery wire and solenoid feed wire.
(4) Remove starter lower mounting bolt (Fig. 6).
(5) Remove starter upper mounting bolt and re-
move starter.
(6) To install starter motor, reverse the removal
procedures and torque mounting hardware as shown.
(7) Remove vehicle support and lower vehicle.
(8) Install negative cable to battery.
PARK/NEUTRAL POSITION SWITCH
Refer to Group 21 for diagnostic, removal and in-
stallation procedures.
Check linkage adjustment before replacing the
switch.
Fig. 6 Starter Motor Removal/Installation (Typical)
8B - 6 BATTERY/STARTER/GENERATOR SERVICEJ

GENERATOR SERVICE PROCEDURES
GENERAL
The generator is belt-driven by the engine. All en-
gines use serpentine drive. This section will cover
generator removal and installation. The generator is
not serviceable. Information covering on-vehicle test-
ing can be found in Group 8A - Battery/Starting/
Charging Systems Diagnostics.
GENERATOR REPLACEMENTÐLEFT HAND DRIVE
WARNING: FAILURE TO DISCONNECT NEGATIVE
CABLE FROM BATTERY BEFORE DISCONNECTING
RED (OUTPUT) WIRE CONNECTOR FROM GENER-
ATOR CAN RESULT IN INJURY.
ALL YJ AND XJ WITH 2.5L ENGINE
Belt tension is adjusted at the power steering pump
(or idler pulley if not equipped with power steering).
To replace generator:
(1) Disconnect negative cable from battery.
(2) Loosen rear mounting bolts (Fig. 1 or 2).
(3) Loosen power steering pump/idler pulley pivot
bolt and lock nut (Fig. 3 or 4).
(4) Loosen adjusting bolt to remove belt.
(5) Remove generator B+ terminal nut, 2 field ter-
minal nuts, ground and harness holddown nuts (Fig.
5). Remove wire connector assembly.
(6) Remove 2 generator mounting bolts and re-
move generator from vehicle.
(7) Install generator with 2 mounting bolts. Torque
bolts to 55 Nzm (41 ft. lbs.).
(8) Attach generator wires.
CAUTION: Never force a belt over a pulley rim us-
ing a screwdriver as the synthetic fiber may be
damaged.CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in-
stalled incorrectly. Refer to the belt routing label in
engine compartment, or see Group 7 - Belt Sche-
matics.
(9) Place serpentine belt over pulley.
(10) Belt tension adjustment is made at power
steering pump or idler pulley (Figs. 1 or 2).
(11) Turn adjusting bolt until belt has correct ten-
sion. See Belt Tension in Specifications.
Fig. 1 Powering Steering Pump Rear Mounting
BoltsÐExcept XJ With 4.0L
Fig. 2 Idler Pulley Rear Mounting BoltsÐExcept XJ
With 4.0L
Fig. 3 Power Steering Pump Front Mounting
BoltsÐExcept XJ With 4.0L
JBATTERY/STARTER/GENERATOR SERVICE 8B - 7

(12) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 Nzm (20 ft. lbs.) torque.
(13) Connect negative cable to battery.
XJ WITH 4.0L ENGINE
Belt tension is adjusted at the power steering
pump.
To replace generator:
(1) Disconnect negative cable from battery.
(2) Loosen rear mounting bolts (Fig. 6).
(3) Loosen power steering pump pivot bolt and lock
nut (Fig. 7).
(4) Loosen adjusting bolt to remove belt.
(5) Raise and support vehicle.(6) Remove generator B+ terminal nut, 2 field ter-
minal nuts, ground and harness holddown nuts (Fig.
5). Remove wire connector assembly.
(7) Remove 2 generator mounting bolts and re-
move generator from vehicle.
(8) Install generator with two mounting bolts.
Torque bolts to 55 Nzm (41 ft. lbs.).
(9) Attach generator wires.
Fig. 4 Idler Pulley Front Mounting BoltsÐExcept XJ
With 4.0L
Fig. 5 Remove or Install Connector Assembly
Fig. 6 Powering Steering Pump Rear Mounting
BoltsÐXJ With 4.0L
Fig. 7 Powering Steering Pump Front Mounting
BoltsÐXJ With 4.0L
8B - 8 BATTERY/STARTER/GENERATOR SERVICEJ

CAUTION: Never force a belt over a pulley rim us-
ing a screwdriver as the synthetic fiber may be
damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in-
stalled incorrectly. Refer to the belt routing label in
engine compartment, or see Group 7 - Belt Sche-
matics.
(10) Place serpentine belt over pulley.
(11) Belt tension adjustment is made at power
steering pump (Fig. 6).
(12) Turn adjusting bolt until belt has correct ten-
sion. See Belt Tension in Specifications.
(13) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 Nzm (20 ft. lbs.) torque.
(14) Remove support and lower vehicle.
(15) Connect negative cable to battery.
GENERATOR REPLACEMENTÐRIGHT HAND DRIVE
The generator used on the right hand drive is the
same as used on left hand drive. However, the
mounting and accessory drive belt installation are
different.
WARNING: FAILURE TO DISCONNECT NEGATIVE
CABLE FROM BATTERY BEFORE DISCONNECTING
RED (OUTPUT) WIRE CONNECTOR FROM GENER-
ATOR CAN RESULT IN INJURY.
(1) Remove negative cable from battery.
(2) Remove 2 screws holding electric cooling fan
(Fig. 8).
(3) Unplug electric cooling fan connector.
(4) Pull fan up and out of vehicle.
(5) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(6) Remove generator mounting bolts.
(7) Position generator to gain access to all of the
wire connectors.(8) Remove B+ terminal nut, 2 field terminal
nuts, ground and harness holddown nuts (Fig. 9). Re-
move wire connector assembly.
(9) Remove generator from vehicle.
(10) To install generator, reverse the removal pro-
cedures. Refer to Group 7 for belt installation.
(11) Tighten battery cable bolts to 10-20 Nzm (90-
178 in. lbs.).
Fig. 8 Electric Cooling Fan Removal/Installation
Fig. 9 Remove or Install Connector Assembly
JBATTERY/STARTER/GENERATOR SERVICE 8B - 9

SPECIFICATIONS
BATTERY CLASSIFICATIONS AND
RATINGSÐLEFT HAND DRIVE
BATTERY CLASSIFICATIONS AND
RATINGSÐRIGHT HAND DRIVE
BATTERY TORQUE SPECIFICATIONS
BELT TENSION
8B - 10 BATTERY/STARTER/GENERATOR SERVICEJ

4.0L ENGINES 2.5L ENGINES
4.0L STARTER MOTOR AND SOLENOID
TESTING SPECIFICATIONS
STARTING SYSTEM COLD CRANKING
SPECIFICATIONS
STARTER MOTOR TORQUE SPECIFICATIONS
2.5L STARTER MOTOR SPECIFICATIONS
STARTING SYSTEM COLD CRANKING
SPECIFICATIONS
STARTER MOTOR TORQUE SPECIFICATIONS
JBATTERY/STARTER/GENERATOR SERVICE 8B - 11

GENERATOR SPECIFICATIONS
TORQUE SPECIFICATIONS
OUTPUT VOLTAGE SPECIFICATIONS
8B - 12 BATTERY/STARTER/GENERATOR SERVICEJ