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Old 05-03-2009, 03:47 PM   #1
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Need some info from 04-06 4.0L owners

Hello Everyone,
I need some help from any of you all that have a 04-06 4.0L. If you could possibly check to see if you have continuity between fuse 16 (O2 sensor) and fuse 28 (Injectors).
I have had my PCM replaced twice since Easter, blown apart 2 coil packs and it still isnt running.
The Dodge dealer wants 1700 for a new wiring harness and I told them never mind. I have been going thru the wiring harness myself and as of yet I haven't found any broken or frayed wires. But I did find that I have continuity between my O2 sensor fuse and Injector fuse. Not sure if that is correct or not. I wouldn't think so, so therefore I am asking any of you guys to check yours and see if you have it.
I thank you all in advance for helping... I really need to get my Rubicon back on the road, the weather as been awesome I am just sitting here watching the world go by...

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Old 05-03-2009, 03:50 PM   #2
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Since both are probably tied to a common +12v source which may be the reason for the continuity, I would temporarily remove both fuses and then see if the continuity is maintained on the load (not source) side of the fuses.

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Old 05-03-2009, 04:02 PM   #3
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I currently have the battery removed. Didn't want a possible short caused by myself. So I just took it completely out, plus the extra room is nice...
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Old 05-03-2009, 04:18 PM   #4
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I still suggest you remove the fuses since the the wiring that gives them their 12 volts is not affected by the fact the battery has been removed. I'm not suggesting to remove the fuses for safety reasons, I'm suggesting it because the connection you noted between the two circuits may be because they may be tied together where they get their 12 volts from. Removing the fuses would completely isolate them at that side to eliminate that as a possible reason for why the two circuits are showing continuity between them.
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Old 05-03-2009, 05:01 PM   #5
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I pulled the fuse panel off the mounts and checked the wiring of it. Those two share the same colored wire, Blue with 2 red stripes,.
I have the plugs off of the PCM and checked the green wire that comes from it,(white plug in the middle) I get a hit on the injector fuse. Before I checked this same wire at the injectors themselves and was getting hits, now I get nothing after the first second. I have my meter set with the audio on so that I can watch the leads and just listen for it. It hits when I first connect each lead then goes away. I go from injector plug to another injector plug and they all hit, just not at the PCM plug any more.
Also from the Dodge dealer mechanics... They told me that when it first starts that the injector, second one back from the fan, has voltage at first then drops out which is what is causing these issues. Has anyone ever had this issue? Or heard of this issue? If so any ideas what it could be? Or where the issue may be located?
I love my Rubicon but after all these issues and the fact that Dodge is going bankrupt... Well I am not a happy camper at this moment.
Any and all help is much appreciated.
Jerry, Thanks a million for your quick and detailed suggestions.
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Old 05-03-2009, 05:07 PM   #6
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so its a no start? are they making something as simple as a crank sensor over complicated?
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Old 05-03-2009, 05:21 PM   #7
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i think you and the dealer have gotten WAY ahead of yourselves. treat this like any other no start and make sure its getting fuel pressure and spark then go from there. if your getting fuel pressure and spark but no injector pulse spray some starting fluid in it and see if it cranks. sounds more like a crank sensor or an anit-theft problem to me.
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Old 05-03-2009, 05:22 PM   #8
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It starts, it runs, just runs like crap...
After a few minutes it blows the injector fuse... twice it has blown the ignition coil...
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Old 05-03-2009, 05:25 PM   #9
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^good info to have sooner
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Old 05-03-2009, 05:26 PM   #10
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so it blows the coil, give us some more info on that. it runs, then fries the coil? then will not run untill a new coil is installed? then it runs again w/ new coil for a while? is that accurate
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Old 05-03-2009, 05:30 PM   #11
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That is right. I have replaced it three times so far, plus the injector fuse numerous more times.
The mechanics placed a noid light on that injector and it would light up at first then go blank. That why they suggest a new wiring harness. They wont check each wire, dodge wont let them.
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Old 05-03-2009, 05:32 PM   #12
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dodge won't let them? thats funny, but not important.

look near your exhaust very closely anywhere the harness is near it for melted wires, have you had any repairs made recently? or aftermarket junk installed? if so, tell me what it was. definately sounds like a short, if you can find it, repairing it should be next to free if it isn't too far gone.
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Old 05-03-2009, 05:36 PM   #13
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The only mods done before this started was a 2"BB, and I lower the trans cover 1".
Dodge won't let them, I thought that was funny as well.
No engine add ons, or electrical upgrades have been done since I bought it 2 years ago.
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Old 05-03-2009, 05:39 PM   #14
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ok, doesn't sound like anything there could've gotten any wires pinched or anything, just check for wires by the exhaust, crank sensor wires like to end up by the exhaust sometimes and melt causing all sorts of problems.

after that i'd start under the hood and take the harness apart from the injectors and look for breaks, or melts. if you have a wiring diagram you can see what else is on that circuit the fuse blows, that would be helpful.
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Old 05-03-2009, 05:49 PM   #15
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I have taken the harness apart, did that today. Checked all the wires leading to the injectors, all them look really good no kinks frays or hot spots. The common green wire among them leads off into another location. Haven't completely uncovered it yet. Haven't checked by the exhaust yet but will check there tomorrow.
What about the quick hit from the plug to the injectors then nothing? Any idea why I keep losing continuity there?

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