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XJ
STARTING SYSTEMS
8B - 1
STARTING SYSTEMS
CONTENTS
page
page
DESCRIPTION AND OPERATION
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . .
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR NOISE - 2.5L ENGINE . . . . .
2
3
1
8
8
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 9
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 10
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 13
•
Park/neutral position switch (automatic trans-
mission)
•
Wire harnesses and connections (including the
battery cables).
This group provides complete service information
for the starter motor and the starter relay. Complete
service information for the other starting system
components can be located as follows:
•
Refer to
Battery
in the proper section of Group
8A - Battery for complete service information for the
battery.
•
Refer to
Ignition Switch and Key Lock Cyl-
inder
in the proper section of Group 8D - Ignition
System for complete service information for the igni-
tion switch.
•
Refer to
Clutch Pedal Position Switch
in the
proper section of Group 6 - Clutch for complete ser-
vice information for the clutch pedal position switch.
•
Refer to
Park/Neutral Position Switch
in the
proper section of Group 21 - Transmission for com-
plete service information for the park/neutral posi-
tion switch.
•
Refer to the proper section of
Group 8W - Wir-
ing Diagrams
for complete service information and
circuit diagrams for the starting system wiring com-
ponents.
Group 8A covers the Battery, Group 8B covers the
Starting Systems, and Group 8C covers the Charging
System. We have separated these systems to make it
easier to locate the information you are seeking
within this Service Manual. However, when attempt-
ing to diagnose any of these systems, it is important
that you keep their interdependency in mind.
The battery, starting, and charging systems in the
vehicle operate with one another, and must be tested
as a complete system. In order for the vehicle to start
and charge properly, all of the components that are
used in these systems must perform within specifica-
tions.
DESCRIPTION AND OPERATION
STARTING SYSTEM
DESCRIPTION
An electrically operated engine starting system is
standard factory-installed equipment on this model.
The starting system is designed to provide the vehi-
cle operator with a convenient, efficient and reliable
means of cranking and starting the internal combus-
tion engine used to power the vehicle and all of its
accessory systems from within the safe and secure
confines of the passenger compartment. See the own-
er’s manual in the vehicle glove box for more infor-
mation and instructions on the recommended use
and operation of the factory-installed starting sys-
tem.
NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
service procedures outlined can generally be
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required.
The starting system consists of the following com-
ponents:
•
Battery
•
Starter relay
•
Starter motor (including an integral starter sole-
noid)
•
Ignition switch
•
Clutch pedal position switch (manual transmis-
sion)
8B - 2
STARTING SYSTEMS
XJ
DESCRIPTION AND OPERATION (Continued)
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnos-
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects. Refer to
On-Board Diagnostic Test For Charging System
in the Diagnosis and Testing section of Group 8C -
Charging System for more information.
connect the relay common feed terminal to the relay
normally open terminal. The closed relay contacts
energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls in the sole-
noid plunger. The solenoid plunger pulls the shift
lever in the starter motor. This engages the starter
overrunning clutch and pinion gear with the starter
ring gear on the manual transmission flywheel or on
the automatic transmission torque converter drive
plate.
As the solenoid plunger reaches the end of its
travel, the solenoid contact disc completes the high-
amperage starter feed circuit and energizes the sole-
noid plunger hold-in coil. Current now flows between
the solenoid battery terminal and the starter motor,
energizing the starter.
Once the engine starts, the overrunning clutch pro-
tects the starter motor from damage by allowing the
starter pinion gear to spin faster than the pinion
shaft. When the driver releases the ignition switch to
the On position, the starter relay coil is de-energized.
This causes the relay contacts to open. When the
relay contacts open, the starter solenoid plunger
hold-in coil is de-energized.
When the solenoid plunger hold-in coil is de-ener-
gized, the solenoid plunger return spring returns the
plunger to its relaxed position. This causes the con-
tact disc to open the starter feed circuit, and the shift
lever to disengage the overrunning clutch and pinion
gear from the starter ring gear.
Following are general descriptions of the major
components in the starting system.
OPERATION
The starting system components form two separate
circuits. A high-amperage feed circuit that feeds the
starter motor between 150 and 350 amperes, and a
low-amperage control circuit that operates on less
than 20 amperes. The high-amperage feed circuit
components include the battery, the battery cables,
the contact disc portion of the starter solenoid, and
the starter motor. The low-amperage control circuit
components include the ignition switch, the clutch
pedal position switch (manual transmission), the
park/neutral position switch (automatic transmis-
sion), the starter relay, the electromagnetic windings
of the starter solenoid, and the connecting wire har-
ness components.
If the vehicle is equipped with a manual transmis-
sion, it has a clutch pedal position switch installed in
series between the ignition switch and the coil bat-
tery terminal of the starter relay. This normally open
switch prevents the starter relay from being ener-
gized when the ignition switch is turned to the
momentary Start position, unless the clutch pedal is
depressed. This feature prevents starter motor oper-
ation while the clutch disc and the flywheel are
engaged. The starter relay coil ground terminal is
always grounded on vehicles with a manual trans-
mission.
If the vehicle is equipped with an automatic trans-
mission, battery voltage is supplied through the low-
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is
turned to the momentary Start position. The park/
neutral position switch is installed in series between
the starter relay coil ground terminal and ground.
This normally open switch prevents the starter relay
from being energized and the starter motor from
operating unless the automatic transmission gear
selector is in the Neutral or Park positions.
When the starter relay coil is energized, the nor-
mally open relay contacts close. The relay contacts
STARTER MOTOR
DESCRIPTION
The starter motors used for both the 2.5L and the
4.0L engines available in this model are not inter-
changeable. Both starter motors are mounted with
two screws, but the 2.5L starter motor is mounted to
the right rear corner of the engine block, while the
4.0L starter motor is mounted to the manual trans-
mission clutch housing or automatic transmission
torque converter housing on the right side of the
engine.
Each of these starter motors incorporates several
of the same features to create a reliable, efficient,
compact, lightweight and powerful unit. The electric
motors of both starters have four brushes contacting
the motor commutator. The 2.5L starter motor uses
four permanent magnets for the field poles, while the
4.0L starter motor features four electromagnetic field
coils wound around four pole shoes. The 2.5L starter
motor is rated at 1.2 kilowatts (about 1.6 horse-
power) output at 12 volts, while the 4.0L starter
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DESCRIPTION AND OPERATION (Continued)
motor is rated at 1.4 kilowatts (about 1.9 horse-
power) output at 12 volts.
Both of these starter motors are serviced only as a
unit with their starter solenoids, and cannot be
repaired. If either component is faulty or damaged,
the entire starter motor and starter solenoid unit
must be replaced.
STARTING SYSTEMS
8B - 3
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
OPERATION
These starter motors are equipped with a plane-
tary gear reduction (intermediate transmission) sys-
tem. The planetary gear reduction system consists of
a gear that is integral to the output end of the elec-
tric motor armature shaft that is in continual
engagement with a larger gear that is splined to the
input end of the starter pinion gear shaft. This fea-
ture makes it possible to reduce the dimensions of
the starter. At the same time, it allows higher arma-
ture rotational speed and delivers increased torque
through the starter pinion gear to the starter ring
gear.
The starter motors for both engines are activated
by an integral heavy duty starter solenoid switch
mounted to the overrunning clutch housing. This
electromechanical switch connects and disconnects
the feed of battery voltage to the starter motor and
actuates a shift fork that engages and disengages the
starter pinion gear with the starter ring gear.
Both starter motors use an overrunning clutch and
starter pinion gear unit to engage and drive a starter
ring gear that is integral to the flywheel (manual
transmission) or torque converter drive plate (auto-
matic transmission) mounted on the rear crankshaft
flange. Shims are available and can be used to adjust
the 2.5L starter motor mounting position to correct
for improper starter pinion gear to starter ring gear
engagement.
DIAGNOSIS AND TESTING
STARTING SYSTEM
DIAGNOSIS
The battery, starting, and charging systems oper-
ate with one another, and must be tested as a com-
plete system. In order for the vehicle to start and
charge properly, all of the components involved in
these systems must perform within specifications.
Group 8A covers the Battery, Group 8B covers the
Starting Systems, and Group 8C covers the Charging
System. We have separated these systems to make it
easier to locate the information you are seeking
within this Service Manual. However, when attempt-
ing to diagnose any of these systems, it is important
that you keep their interdependency in mind.
The diagnostic procedures used in these groups
include the most basic conventional diagnostic meth-
ods, to the more sophisticated On-Board Diagnostics
(OBD) built into the Powertrain Control Module
(PCM). Use of an induction-type milliampere amme-
ter, volt/ohmmeter, battery charger, carbon pile rheo-
stat (load tester), and 12-volt test lamp may be
required.
All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnos-
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects. Refer to
On-Board Diagnostic Test For Charging System
in the Diagnosis and Testing section of Group 8C -
Charging System for more information.
STARTER RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when the ignition switch is turned to
the Start position. The starter relay is located in the
Power Distribution Center (PDC), in the engine com-
partment. See the fuse and relay layout label affixed
to the inside surface of the PDC cover for starter
relay identification and location.
The starter relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
8B - 4
STARTING SYSTEMS
XJ
DIAGNOSIS AND TESTING (Continued)
Starting System Diagnosis
CONDITION
STARTER FAILS TO
OPERATE.
POSSIBLE CAUSE
1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Clutch pedal position
switch faulty.
6. Park/Neutral position
switch faulty or
misadjusted.
7. Starter solenoid faulty.
8. Starter motor faulty.
CORRECTION
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
4. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
5. Refer to Clutch Pedal Position Switch in the Diagnosis
and Testing section of Group 6 - Clutch.
6. Refer to Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission. Replace
the park/neutral position switch, if required.
7. Refer to Starter Motor in the Diagnosis and Testing
section of this group. Replace the starter motor assembly,
if required.
8. If all other starting system components and circuits test
OK, replace the starter motor assembly.
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. If all other starting system components and circuits test
OK, replace the starter motor assembly.
4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Remove the starter motor to inspect
the starter ring gear. Replace the starter ring gear, if
required.
2. If all other starting system components and circuits test
OK, replace the starter motor assembly.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.
2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
3. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
4. If all other starting system components and circuits test
OK, replace the starter motor assembly.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter motor faulty.
4. Engine seized.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. Starter ring gear faulty.
2. Starter motor faulty.
STARTER DOES NOT
DISENGAGE.
1. Starter motor
improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
XJ
DIAGNOSIS AND TESTING (Continued)
INSPECTION
For complete circuit diagrams, refer to
Starting
System
in the Contents of Group 8W - Wiring Dia-
grams. Before removing any unit from the starting
system for repair or diagnosis, perform the following
inspections:
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.
•
Battery
- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to
Battery
in the
proper section of Group 8A - Battery for complete ser-
vice information for the battery.
•
Ignition Switch
- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections. Refer to
Igni-
tion Switch and Key Lock Cylinder
in the proper
section of Group 8D - Ignition System for complete
service information for the ignition switch.
•
Clutch Pedal Position Switch
- If the vehicle
is equipped with a manual transmission, visually
inspect the clutch pedal position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Refer to
Clutch Pedal Posi-
tion Switch
in the proper section of Group 6 -
Clutch for complete service information for the clutch
pedal position switch.
•
Park/Neutral Position Switch
- If the vehicle
is equipped with an automatic transmission, visually
inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Refer to
Park/Neutral Posi-
tion Switch
in the proper section of Group 21 -
Transmission for complete service information for the
park/neutral position switch.
•
Starter Relay
- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
•
Starter Motor
- Visually inspect the starter
motor for indications of physical damage and loose or
corroded wire harness connections.
•
Starter Solenoid
- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
•
Wiring
- Visually inspect the wire harnesses for
damage. Repair or replace any faulty wiring, as
STARTING SYSTEMS
8B - 5
required. Refer to the proper section of
Group 8W -
Wiring Diagrams
for complete service information
and circuit diagrams for the starting system wiring
components.
TESTING
COLD CRANKING TEST
For complete circuit diagrams, refer to
Starting
System
in the Contents of Group 8W - Wiring Dia-
grams. The battery must be fully-charged and load-
tested before proceeding. Refer to
Battery
in the
Diagnosis and Testing section of Group 8A - Battery
for the procedures.
(1) Connect a suitable volt-ampere tester to the
battery terminals (Fig. 1). See the instructions pro-
vided by the manufacturer of the volt-ampere tester
being used.
Fig. 1 Volts-Amps Tester Connections - Typical
(2) Fully engage the parking brake.
(3) If the vehicle is equipped with a manual trans-
mission, place the gearshift selector lever in the Neu-
tral position and block the clutch pedal in the fully
depressed position. If the vehicle is equipped with an
automatic transmission, place the gearshift selector
lever in the Park position.
(4) Verify that all lamps and accessories are
turned off.
(5) To prevent the engine from starting, remove
the Automatic ShutDown (ASD) relay. The ASD relay
is located in the Power Distribution Center (PDC), in
the engine compartment. Refer to the fuse and relay
layout label affixed to the underside of the PDC cover
for ASD relay identification and location.
(6) Rotate and hold the ignition switch in the Start
position. Note the cranking voltage and current
(amperage) draw readings shown on the volt-ampere
tester.
(a) If the voltage reads below 9.6 volts, refer to
Starter Motor
in the Diagnosis and Testing sec-
tion of this group. If the starter motor is OK, refer

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