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Old 07-12-2009, 06:47 PM   #1
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1990 jeep wrangler 2.5 electrical problems.

got a 90 jeep wrangler with a 2.5 TBI and yesterday it rained bad but didnt seem to be the problem it was fine up until i changed the master cyl because there was no brakes, anyways i didnt lose any brake fluid i sucked it all out and also put rags down to make sure if any came out it wouldnt make a mess.

since that happened the jeep wasent happy.

first it was fine i took it out for a drive then some sudden stops to make sure it was gonna stop properly.
it stalled out a few times but seemed ok other wise.

after the night was over after trying to install a new front wheel bearing and after i got it on and tire back on only to find out it was the wrong bearing since the tire didnt move then having to put the old beat bearing back on. the thing didnt run right kept stalling out under any type of driving but being that it was late and i wasent in the mood i tried to push it and it didnt wanna go.
i stopped several times, playing with wires, vacuum lines and anything i could find that might be a problem including the injector in the TBI setup which had the 2 tq screws loose... nothing seemed to change the way it acted.

finally got it happy enough to drive back after using 3/4 a tank for a 70 mile trip which it normally only uses at most 1/4 tank.
i knew it was running rich real rich the exhaust fumes burnt my eyes and there was fuel puddling inside the intake.

got up this morning got some things around to try and help the problem.

so far i cleaned every plug with electrical cleaner and then using dielectric grease in every plug.
removed checked and double checked every vacuum line none leaking or crushed shut.

removed the injector cleaned it out reinstalled.

the thing has almost everything replaced for normal upkeep.
wires plugs (had to change them again got fouled out from being so rich)
cap, etc
fuel filter, injector cleaner etc...
air filter as well...
all but the o2 i wanted to replace yet.
the coil looks like it was on the jeep from its birth.


anyways heres the funny part.
at first it seemed to stall from the brakes being used like the vacuum was causing the problem but during the drive last night it seemed to get back when you used the lights, switched the high beams on and off would cause it to hiccup.
today after cleaned checking and greasing all the wiring etc. it seemed to be ok idling on its on with a slight miss on and off nothing that bothered me enough as it did last night.
anyways when i took it out for the drive i had to use some throttle to start it which its always been a little rough to start from time to time which i figured out coil since that and o2 havent been replaced but when i had it out driving it seemed like it was ok until i turned the headlights on where it got a good miss then switching between high and low beams cause some issues nothing major until i went to switch from high to low beams and held the switch back to make both high and low come on at the same time... it stalled right away with no warning or anything until i left it go since i was still it gear it started running again. so i tried it again same thing each time.

i dont know if maybe someone went threw this before or something and might be able to chime in.

it seems to be power related so i also checked the voltage and its putting out 14v running and battery checks out fine but i didnt do a load test on the battery.
my guess right now it the coil might be getting weak is the only thing i came up with thus far.

like i said i cant get it to get upset by messing with wiring or vacuum lines etc, i could find any leaks intake or anything.
only time i can get it to really get upset it by holding the high/low headlight switch in which kills it right away.
none of this happened until i did the brake master cly.

thanks for the time

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Old 07-24-2009, 10:55 PM   #2
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Did you check to see if maybe you just accidentally unplugged a some wire or hose when you did the Master cylinder?

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Old 07-25-2009, 05:07 PM   #3
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my 89 yj had the same problem ,check alternator for over voltage mine had a bad regulator and diode .
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Old 07-25-2009, 07:35 PM   #4
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you covered a lot of bases already, good job on all that. another simple possibility is battery terminals, the clamps on the battery are notorious for being a little loose, causing all sorts of stupid problems. i'd take them off, clean and retighten the terminal ends.
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