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Unread Today, 04:53 AM   #1
mvd1968
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1977 CJ7 
 
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Solenoid CJ7 wire red/green is getting smoking hot HELP

Hi

Noticed my red/green wire to the solenoid is getting smoking hot. I did some rewiring but never noticed this and did not changed anything to the iginition wires

How can i test this wire? Even with the coil feed disabled it is getting hot.
I saw the wire diagramm that wire 138 has an resistance?

1977 CJ7
Engine amc 258 1986

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Unread Today, 05:12 AM   #2
Mike Romain
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1986 CJ7 
 
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Key on or key off? Engine on or engine off?
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86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
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Unread Today, 05:21 AM   #3
mvd1968
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1977 CJ7 
 
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Quote:
Originally Posted by Mike Romain View Post
Key on or key off? Engine on or engine off?
With the key in on and engine off getting hot

Thinks somewhere i get an short beacuse when meassering the I terminal with an ohm meter it is connected with ground.

How is this wire routed to the ignition key? Thru the bulkhead connector?
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Unread Today, 05:27 AM   #4
Mike Romain
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Quote:
Originally Posted by mvd1968 View Post

With the key in on and engine off getting hot
At the same time, your ignition module is melting too. The ignition is energised with the key on which overheats the circuits. That is the fastest way to kill an ignition module. They get hot enough to melt the potting goo out.
The coil will eventually get cherry red too.
The next connection on that wire to the solenoid is a crimp connector that uses high heat duct tape for protection because black tape's glue will melt out.
If it gets real hot with the engine running, you have issues.
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86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
Some Canadian Bush Jeep Runs and Build Photos: http://mikeromainjeeptrips.shutterfly.com (10 new albums added Sept 16/10)
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Unread Today, 05:33 AM   #5
mvd1968
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Quote:
Originally Posted by Mike Romain View Post
At the same time, your ignition module is melting too. The ignition is energised with the key on which overheats the circuits. That is the fastest way to kill an ignition module. They get hot enough to melt the potting goo out.
The coil will eventually get cherry red too.
The next connection on that wire to the solenoid is a crimp connector that uses high heat duct tape for protection because black tape's glue will melt out.
If it gets real hot with the engine running, you have issues.
I have installed an HEI ignition an rewired and use relays. Removed the ignition module
When measuring terminal I should it be connected to ground?
How can i determine if i got an short on red/green wire?
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Unread Today, 05:39 AM   #6
Mike Romain
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Quote:
Originally Posted by mvd1968 View Post

I have installed an HEI ignition an rewired and use relays. Removed the ignition module
When measuring terminal I should it be connected to ground?
How can i determin if i got an short on red/green wire?
Lest be sure we are talking the same wire without me having to dig out my books. This wire goes to the small side terminal of the solenoid? If so it feeds power to the stock coil when the starter is turning. It hooks to the stock ignition wires.
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86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
Some Canadian Bush Jeep Runs and Build Photos: http://mikeromainjeeptrips.shutterfly.com (10 new albums added Sept 16/10)
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Unread Today, 05:46 AM   #7
mvd1968
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Yes

Its the I terminal. Book says it schould be HOT switching to on and start
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Unread Today, 06:08 AM   #8
mvd1968
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when connecting a testlight to terminal i and s and with the 12v it lights up. So I and S are connected to ground.
Thought that these I and S wires should be hot when going to IGNITION on and START?

Before i tear down my dashboard can someone explain me how this solenoid works?
Is power going to the i and s teminal or coming from it?

I followed the wire to the firewall connector and when checking ground on the red/white 13B the testlight lights. So i put one end to the battery + and one end to the 13B and the light burns weak

is this correct??
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Unread Today, 06:44 AM   #9
Mike Romain
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Quote:
Originally Posted by mvd1968 View Post
when connecting a testlight to terminal i and s and with the 12v it lights up. So I and S are connected to ground.
Thought that these I and S wires should be hot when going to IGNITION on and START?
You need to check the wires going to I and S. The S post grounds because it is a magnetic producing coil that needs a circuit. The I post grounds through the starter brushes.
S wire only gets power when the key is in start.
I gets power when the key is in run and start. 9 and 12 volts respectively.
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86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
Some Canadian Bush Jeep Runs and Build Photos: http://mikeromainjeeptrips.shutterfly.com (10 new albums added Sept 16/10)
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Unread Today, 08:39 AM   #10
CrashOdle
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There is no ground connected to the solenoid. It gets its ground through its case (mounted to the fender). You should have a blue wire from your ignition switch to the "S" terminal to close the solenoid and pass batt power to the starter. That in turn energizes the "I" terminal during start and sends power to the ign module. Once you release the key to run, power quits on the "I" terminal and the the module now get run 12v on a different wire. It has two circuits that's allows for a different timing curve for starts and run if I'm not mistaken.
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Unread Today, 08:44 AM   #11
mvd1968
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Quote:
Originally Posted by Mike Romain View Post
You need to check the wires going to I and S. The S post grounds because it is a magnetic producing coil that needs a circuit. The I post grounds through the starter brushes.
S wire only gets power when the key is in start.
I gets power when the key is in run and start. 9 and 12 volts respectively.
This is both correct. Replaced the red/green wire to I with a new wire from the firewall connector. Used an AWG 13.
now. Wire gets a little warm no with ignition on, but i read that is normal. Happy now

What can be the reason my wire got so hot? Is it because it was hardened due oil/gas and was very old?
Assume this harness is form 1977

Thanks to Mike for the quick answers and to Crash for the solenoid explanation (tu)
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Unread Today, 09:37 AM   #12
Mike Romain
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Location: Off the Grid in Chester Grant, Nova Scotia, Canada
Posts: 16,154
Quote:
Originally Posted by mvd1968 View Post

This is both correct. Replaced the red/green wire to I with a new wire from the firewall connector. Used an AWG 13.
now. Wire gets a little warm no with ignition on, but i read that is normal. Happy now

What can be the reason my wire got so hot? Is it because it was hardened due oil/gas and was very old?
Assume this harness is form 1977

Thanks to Mike for the quick answers and to Crash for the solenoid explanation (tu)
The I terminal "provides" power to the coil when the starter is turning. You do not want it hooked direct to the bulkhead connector, that is a short, you want it hooked to a stock coil only. In stock form it powers the coil, then once running the coil gets its power through a ballast resistor.
It should be disconnected for an hei setup.
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86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
Some Canadian Bush Jeep Runs and Build Photos: http://mikeromainjeeptrips.shutterfly.com (10 new albums added Sept 16/10)
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