1) Has the Jeep ever started with the key since the swap?
2) Did you take the 10-pin dash connector apart to check whether you have wires on both sides of the connector in slot 7 and try putting 12V to the yellow wire to see if it will crank?
3) When you had the switch apart did you accidentally ground the prong or put 12V on it?
Bonus question: what mods were done to the engine harness and bulkhead connector on the firewall, if any?
1) No the engine hasn't turned over with the key since the motor swap.
2) No I missed that step. Didn't take that apart, where did you say it was located??
3) No, not that I know of. I pulled it off the column still hooked to the plug ins. and tested it that way. Was that ok or was it wrong? I used a screwdriver to push the acuator to the start position. Didn't have 12v to it until I did that.
Bonus...no mods were done to the harness and connector that I know of. Thanks again!!!
The dash connector comes through the firewall right above the transmission tunnel and looks like this
The numbers are stamped on the top of the connector and the yellow wire (slot 7) is the feed to your PDC start relay. Take the connector apart and hook your test light to battery positive, stick the tip in slot 7 on the side heading out to the engine and it should crank with the key in the "on" position. At the very least you should hear the starter relay click.
While you're there recheck the green wire for 12V in start like you said you did already, then check for 12V in start at the pin that goes into slot 7 in the dash connector. The wire to this pin isn't green, I'm thinking it might be white w/ orange trace but I'm not sure.
Ok, I will check that tomorrow morning after I get home from doing chores. Thanks for the pic. Very helpful. I assume that the other end going out of the firewall to the engine compartment is another plug? What happens if it doesn't turn over??
The other end is just a bundle of ten wires that join up with about twenty more in the engine wiring harness. This is just a branch off from the main harness between the firewall bulkhead connector and the PDC, battery, starter, etc., etc.
If power to the yellow wire with the key in "run" doesn't engage the starter (or at least activate the relay) the next step is to troubleshoot the PDC. The yellow wire connects to contact #26 on the starter relay.
Make sure you check the green wire to dash connector circuit too while you're right there.
I will check that as well. Now if I have my relay out and my voltage meter hooked up, I will only have 12v to only one slot where the relay goes with the key off? I am just trying to gather this information, to eliminate a lot of back and forth if I can. Now if I do this and touch the slot 7 and it does turn the engine over, what is my next step sir? I really appreciate all the help. This has been plaguing me for months and months.....
Ok, I found the connector, took it apart, couldn't find my test light, so I used a jumper wire from the positive post on the battery, stuck it in SLOT 7 didn't do anything. Will that jumper wire do the same as the test light?? If not I will go grab one and try again. Thanks. Brentd
Did you also check to see if you had 12V in START from the green wire on the column you checked before to the corresponding wire (actually you'll see a pin) that goes into slot 7 (yellow) on the dash connector? See my post with the photo of the connector.
On my Jeep someone had bypassed the dash connector and ran the green start wire to the bulkhead, then to the PDC instead of through the dash connector. The pin in slot 7 had been removed.
If you had the key in run and put 12V off the battery to the yellow wire and it didn't crank (or even cause the relay to click) I see several possibilities.
1) The yellow isn't connected to the base of the relay in the PDC
2) The relay is bad
3) The ground or 12V constant at the relay is bad
If you confirm you have power in start from green to yellow, take the PDC out of the bracket, flip it over and take the bottom cover off so you can see where the yellow wire terminates under the starter relay on terminal #26 (tiny numbers are stamped where the wires terminate). Check continuity between green and slot 26 (with the dash connector back together) with your meter. That will show whether you have a complete path from key to relay.
No I didn't check that green wire again. Now, I check that with the plug disconnected?? And if I do have 12v to that wire, then there might be a problem in the PDC? After all that what happens if there isn't anything wrong with the PDC? By the way, I don't have brake lights or blinkers either. Just throwing that out there.
They aren't around anymore, they stopped after they found the motor wouldn't turn over. No I haven't checked all the grounds completely. I have infact checked all the fuses, everything seems to be working like they should. Besides the starter and the fuel pump not coming on, just the brake lights and blinkers. Have tail lights, headlights, fog lights, dash lights, blower motor works, heat, wipers, you name it, its all there.
You're gonna have to find someone that can trace circuits. I can tell you more that I would do to track down the weak link(s) in your wiring but I don't want to cause any injury to you or the Jeep.
I will tell you that on the bottom side of the starter relay in the PDC you should see 4 wires, red, yellow, brown and brown/black (I think). The red should have 12V on it all the time, the yellow is the starter feed from the ignition, the brown is the 12V feed to the starter, and the BR/BK is ground. You need an energized relay (red), a 12V start signal (yellow), a feed to the starter (brown) and a good ground (brown/black). With a little help you should be able to figure out from here why it won't crank with the key.
I just did a SM420 transmission conversion on my 94 2.5 and after completing the conversion had the exact same problem. Was freaking out after all that work, turned out all it was there is a connector on the AX-5 (piece of $hit transmission!) that has a loop back wire (I think it was a white wire) coming out of the connector and going back in. Think my buddy referred to it as the neutral safety switch or something. All I had to do was to unplug that off the P.O.S! and plug it in and Voila! Hope this doesn't send you on a wild goose chase but sometimes the hardest problems have the easiest solutions. If that was unplugged and left off after the engine swap it will not crank turnover, nada nothing, or at least mine wouldn't.
Well I am scheduled to take the Jeep into a mechanic next Friday morning. I am going to continue to see if I can track down the problem, and if I get it figured out before then that's great! But talked to him, and he said that it has to be something simple considering it was just a simple engine swap. Hopefully that will be the case. Checked all my grounds last night and everything seems to be in place. So more to come.......
Everyone will be happy to know that the ol girl is up and running again. Took it to the shop this morning, guy called me about 5 and said he had it going. Not real sure how i was getting power to anything really. I guess there was grounds hooked to positives, and positives hooked to the grounds. Said he was surprised that it didnt burn down. Starter was wired wrong or something like that. I was all over that thing and didn't see that. Crank sensor was pulled apart, just what he told me on the phone. We have a better idea when I get the bill. Thanks to all that helped out with this, it is very much appreciated!
Yeah, that's what he said, but I will find out more details when I got to pick it up monday or tuesday. I was shocked also, never heard of a starter being wired wrong either. We will see I guess. Glad it is finally running also, been a long time!