Hi guys, I'm hoping to get some help troubleshooting my no start situation on my '93 XJ 4WD with the 2.5L and 5-speed manual transmission.

So a few weeks ago my wife were out and about in the XJ and it was driving normally. We parked it, and when we got back into it the engine would not start. The battery is good (just replaced it in December), the lights and dash work, but when we turned the key nothing happened. The engine did not turn over, no click from the starter solenoid, nothing. Here's the weird part: my wife fiddled with the key while I looked hopelessly under the hood. After trying the key several times to no avail, it finally just started randomly. We immediately drove home and it has sat in the garage ever since.

I have replaced a ballast resistor, the ignition coil, the ignition switch, and the starter. The resistor I knew was going bad so that was the first thing I tried. Nothing changed. A friend suggested I try the coil. I don't like throwing parts at a vehicle instead of diagnosing the problem, but I understand the coil is tricky to test and so I bit the bullet and just swapped it out. No change. Another friend suggested the ignition switch. Same issue, I wasn't sure how to test it so I just replaced it. Again, this made no difference. A friend and I attempted to jump the solenoid (not sure if that's the proper terminology - we did the trick with the screwdriver) and nothing happened. In a bit of frustration, I went ahead and removed the starter and brought it to O'Reilly's where they bench tested it and said it was bad. So I replaced it. Still nothing.

I am not much of a mechanic, just a kid with a socket set. I am clueless as to what to do next. Any and all ideas or advice are appreciated.

 

You ever refresh your grounds? That's where I'd be looking first. I had similar symptoms from that.

 

I think there is a starter relay (or fuse) in the relay box under the hood might want to check that out, look in your owner's manual it will show you which one idk if that could be the problem just thought I'd throw it out there

 

Yes,all grounds & fuses.

 

I have not refreshed my grounds. Sorry if this is a noob question, but how do I do that? I've searched the forum/google and all I've really found are these diagrams:











Do I go through these one by one and clean them?

Thanks for the tip. I did test the starter relay and (assuming I did the test correctly) it is okay.

 

There are three terminals on the starter. Two larger ones (battery, starter motor) and a smaller (usually green) wire.
If you short the two large terminals with a screwdriver, does the starter crank the engine?
(Do this in Neutral with the parking brake ON, wheels chocked and the key OFF)

If it does not, the problem is in the starter, the battery, the battery cables or the battery cable connections.
If the starter does crank- check the small, third green wire. It should show +12V when the key is turned to "start".
(disconnect it from the starter first, measure between the disconnected wire and chassis ground).
If it does not, there is a problem in the start circuit: ignition switch, fuses, relay, Park or Neutral Interlock Switch.

"refreshing grounds" means taking each ground connection apart, cleaning it up and re-assembling. The main (-) battery cable, chassis and engine block grounds, IIRC there are some ground studs near the coil as well.

 

Well stated Chuck, (as usual). That pretty much nails it down. I didn't read the whole tread, but the "ground gang" on the dipstick tube mount, grounds EVERYTHING. Both the Puters', sensors, and more. Later models might not be exactly on that stud, but still on the block near it...I don't know for sure there.

 

Thanks Radi. When I short the two terminals with a screwdriver, the starter motor whirs but the engine does not crank. You said if this happens, the problem is in the starter, the battery, the battery cables, or battery cable connections. Now I am really confused as I replaced the battery and battery terminals in December and I just replaced the starter a few days ago.

 

Some starters have a mechanical link/pivot that engages the gear on the flywheel when the solenoid is powered. Ours just use the drive of the starter motor to force that Bendix out to engage with the teeth.

Myself, before spending $ on a replacement, (and giving them my good starter), I might lube and bench test that Bendix. Also it might be free to have it checked.

Shop rates are too high now. It use to be common to just replace the bad part. Napa might still list a solenoid, but the Bendix you might need, IDK.

 

There are 2 reasons the starter motor will turn but not engage the flywheel, either it can't draw enough current, or the starter is bad. I'd make sure your (-) battery cable is clean & tight where it attaches to the engine block. If that's good, have the starter bench tested. It isn't that unusual to get a flaky rebuild.

 

For anyone following this thread, everything is sorted out. The Jeep is running and back in action!

I am both relieved and frustrated. It turns out that the bad starter I replaced was the original issue. When I removed the old starter, there were a couple of metal shims between the starter and where it mounted. During installation of the new starter, I assumed these shims needed to be put back in. I was wrong. The reason the new starter was not turning the flywheel is because of those shims - it wasn't touching anything!

I also installed the ignition switch incorrectly, thus creating a new problem. It is fixed now. I am rather embarrassed and frustrated with myself that I installed those parts incorrectly, but that's how you learn I guess!

 

4banger,do not be embarrassed.
We have all done things that need to be re-done or fixed.
That's the great thing about Cherokee Forum.
The people here help you thru the tough patches.

 

Hey thanks Marty, I appreciate it!

 

I had an issue like this once and the wires were corroded that plug into the starter. I cleaned them up and it was good to go.