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Unread 03-09-2011, 09:14 AM   #1
Registered User
1996 ZJ 
Join Date: Mar 2011
Location: Harpers Ferry, West Virginia
Posts: 2
96 JGC Ltd - Electrical Issue - HELP!

Long story, but PLS -give me your input as I am out of ideas! Thanks

Owned this since early 2010. Later that year in the fall season, the Jeep started having issues; After being parked for a week or so, got in to start/warm engine, ran fine... put in reverse, soon as I gave it gas, engine died. Showed signs of what seemed to be a dead alternator. Replaced alternator, same issues only now, would not hold idle on its own, ran very rough when kept running by giving it gas...

Went to repair shop #1: Was told it was a bad battery connection - they replaced battery (it was old) along w/ positive terminal wiring. Died 15 min. after leaving shop, same symptoms as had originally. Went back to same shop. After a week of "diagnostics", I was informed it was the Crankshaft Position Sensor, and parts+labor would be $400~. I thought this was high, got the part myself, installed successfully. (actually was fairly difficult due to where the part was located).
Now the Jeep won't start at all.

Off to Shop #2... After more detailed diagnosing, they determine the issue is a bad PCM, as well as junction box that is causing a 20 fuse to blow every 10 min. or so, causing engine to die. Was advised that PCM can only be done by dealer. Off to dealer. $650 later, picked up, drove for around a total of 2 hrs, died again/blew fuse. Since they didn't provide the diagnosis, they didn't assume any responsibility for the issue, Went back to shop #2 for answers, they tell me must be the junction box...

Assuming the PCM was a necessary fix, and I now just needed to replace junction box, I found one at a junkyard and installed in the Jeep. After replacing, I used a 25 fuse in place of the 20 and had a successful test drive that lasted a couple hours..... Fuse blew again, back in the garage...

I have a Haynes manual and the owners manual, neither specifies specifically what this (MINI 20) fuse is linked to.

I'm not the most mechanically-inclined, but really want to avoid taking this to a shop again, so I'm anxious to find a good DIY fix.

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Unread 03-09-2011, 09:29 AM   #2
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1993 ZJ 
Join Date: Jan 2011
Location: chesapeake, VA
Posts: 3,562
take a pic of location of said fuse
I see youre new...WELCOME
you will need to put pics on an online album and link to them (photoucket,flickr...etc.

i know alot have had problems of loose connections/harnesses to the PCM
i went through a period where mine would just die, no sputtering choking or struggling of any type
i got frustrated and beat the battery terminal with a wrench and it started
the small line coming from the negative side was loose, but you said your terminals have been redone
i would start checking harnesses for bad connections and putting electric grease on all fittings
V8 zj at 6" . Double tri rear and true 3 link front. Stretched to 108"
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Unread 03-09-2011, 09:33 AM   #3
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1997 ZJ 
Join Date: Dec 2008
Location: Virginia Beach, Virginia
Posts: 77
I would start by checking ALL your ground wires. I dont know how many electrical problems ive had and it turns out to be a loose or detached ground wire.
Friday128 is offline   Reply With Quote Quick reply to this message
Unread 03-09-2011, 10:25 AM   #4
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1996 ZJ 
Join Date: Mar 2011
Location: Harpers Ferry, West Virginia
Posts: 2
Thanks guys ---

here is the location of fuse. -ITS NOT the relay where the finger is pointing, but the BOTTOM-MIDDLE MINI 20 in the section just below the pointed finger.


I can start the Jeep by taking out the fuse, sticking a wire in there. I'd be tempted to do that and leave it running to find out what it's linked to, just don't wanna fry an expensive part. Especially that PCM that was just replaced. Guess I could also start a fire...

I guess the next steps then will be to back out those torx on the PCM (saw that on some other threads earlier) and check those grounds. I really don't know where else to check grounds aside from the other/main going to frame/undercarriage(?) -May try a local Jeep dealer to see if I can get some detailed wiring diagrams/layouts.......
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