99 xj is having problems. I cant get it to crank from the key, if i use a power wire on the starter i can get it to crank but still no start. I have checked grounds, relays, fuses. Also has new plugs, wires and distributer. Cps is also new, along with ignition switch. Any info or ideas are greatly appreciated.
Loose/dirty wire connections or corroded wires will cause that.
I would say you have a low voltage issue from:
• a failing battery
• a failing alternator
• dirty, corroded, or loose wire connections
• internally corroded battery wires
Perform routine maintenance of the start and charge systems. Remove, clean, and firmly reconnect all the wires and cables to the battery, starter, and alternator. Look for corroded or damaged cables or connectors and replace as needed. Copper wires should be copper color, not black or green. Do the same for the grounding wires from the starter to engine block, the ground wires at the coil, and the ground wires from the battery and engine to the Jeep's frame/body. You must remove, scrape, and clean until shiny, the cable/wire ends, and whatever they bolt to. Jeeps do not tolerate low voltage, bad connections, or poor grounds.
Place your DVOM (Digital Volt Ohm Multi-Meter) on the 20 volt scale. First check battery voltage by placing your multi-meter's positive lead on the battery's positive post ( the actual post, not the clamp ) and the negative lead on the negative post. You need a minimum of 12 volts to continue testing.Next, leave your meter connected and take a reading while the engine is cranking. Record this voltage reading. Now connect your positive lead to the battery terminal stud on the starter and the negative lead to the starter housing. Again, crank the engine and record the voltage reading. If the voltage reading at the starter is not within 1 volt of battery voltage then you have excessive voltage drop in the starter circuit.
Typical voltage drop maximums:
• starter circuit (including starter solenoid) = 0.60 volt
• battery post to battery terminal end = zero volts
• battery main cable (measured end to end) 0.20 volt
• starter solenoid = 0.20 volt
• battery negative post to alternator metal frame = 0.20 volt
• negative main cable to engine block = 0.20 volt
• negative battery post to starter metal frame = 0.30
• battery positive post to alternator b+stud = 0.5 volt with maximum charging load applied (all accessories turned on)
Test the output at the alternator with your volts/ohms multi-meter. You should be measuring 13.8-14.4 volts. Load testing the alternator is still recommended.
Exchange the ASD relay with the Starter relay in the fuse box under the hood near the battery.
Have your helper turn the ignition key to START while you tap on the starter with a hammer. If the engine starts, you probably need a new starter.
Have the battery, starter, and the alternator Load Tested for proper function in a test machine that applies a simulated work load. Handheld testers are inaccurate and will often pass faulty parts
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Which of those would most likely be the cause of the key not cranking it. The starter is new, and i just dont understand why i can get it to crank manually, but the key wont make it crank. All guages lights power everything works as it should. What about asd related issues? Ive never came across anything so frustrating, i have looked over and cleaned up all of the connections you sugested prior to starting this thread.