Hello all, I'm stuck. If you have any ideas, please do let me know.

Issue ← 99 XJ starts in the morning every time, no issues. After it warms up, it will not start again. I hear the relay and the starter solenoid both click, and nothing happens.

History ← I started having weak starts; my battery tested bad. Battery was replaced. Soon after, my starter died. I replaced the starter, and it lasted for several months, then seemingly, it went bad again. I returned the re-manufactured part to NAPA and got a replacement. That one worked for almost a week until it went bad (I thought). When the tow truck brought my XJ home hours later, it started right up. I talked to NAPA and they gave me a brand new starter, not a re-manufactured part. The same issue remains.

Replaced ← Battery & Cables, Starter, Ignition Cylinder, Ignition Switch, NSS.

Troubleshooting ← grounds tested with meter, voltage at starter tested with meter.

 

I replaced the CPS today and I still have the same issue. No dice. Anyone have an idea of what it could be?

 

sounds like you have a bad ground somewhere. Did you check the power distribution box terminals? and double check the grounds? sometimes you have to remove the grounds and clean the area, then re - install the ground.

also I remember someone having a similar issue and I think it was the ignition switch--maybe someone else will chime in

 

starting problems should always clearly state if/if not the starter cranks/rotates. if it can be jumped to crank.
does the starter rotate the engine AND the engine dont run on its own...

 

I can jump the solenoid with a screwdriver and it'll start every time. The engine runs fine on its own once started. Also, yesterday was the first time it wouldn't initially start with the key.

 

i had a similar prob with a reman starter. i could jump it like you do. i was tempted to add a pushbutton jumper on the dash!!
new, NEW starter fixed it

 

I'm thinking it's a bad solenoid. I ordered a replacement; I'll install it Tuesday.

 

I did a little more testing today. I checked voltage on the trigger wire at the solenoid while the key was being turned to start and I have 10v. Should I be getting 12v here?

 

Good! That beats repeatedly firing the parts cannon.




Hmmm. Not sure that's a problem. Since you are loading the circuit, I would expect a voltage drop, but maybe not that much. I'm guessing here as I have not made that measurement myself (haven't had a reason to).

I'd be tracing that circuit back and looking for corroded connections or frayed wiring. CRC Contact Cleaner is your friend.

 

jump batt cable to trigger wire,screwdriver jump. see if it cranks.'i had a sticky reman ttarter. i know....