Hello everyone,
I’m in the process of trying to figure out why my ‘92 FJ80 won’t crank and killed my battery simultaneously?!
While driving around a few days ago I smelled a burning plastic smell coming from the truck.
When I parked, turned off the engine for a minute, then tried to start truck again.. Nothing! No crank no noises.
I had a similar issue when I first purchased the truck and it was the fusible link(which was replaced).
I also replaced the EFI relay a while back and I’m aware of the overheating issue. I tried replacing the EFI relay during this issue thinking it was an overheated relay with no success.
I was able to limp the truck home after about twenty minutes of cooling down.
Seems like an intermittent short???
The following morning when it was cold out I tried to crank the engine and same
Symptoms persisted no crank no noises. Battery also seemed sluggish. The battery died later that day without ever turning the engine over.
I have been trying to isolate any bad wires with regard to the ignition system. I’ve looked for signs of burning or overheated wiring. No smoking guns yet.
I’ve tested the starter motor wires for continuity and the fusible link wiring for the same.
So far nothing is jumping out at me. I removed the ignition switch to inspect… slight smell of burning wire however no visible damage. Same with the engine bay starter motor wire black with red strip smelled the same… burnt but no visible or palpable damage. No visible damage and continuity was tested and passed.
What else should I do before putting back together with new ignition switch?
I also found a ground wire wrapped in another wire and I don’t know where the other wire goes? It appears as if one inner wire was wrapped around another wire with sheathing? I know one of the connector goes to the engine so I’m assuming it’s a ground?
Pictures below…
I’m in the process of trying to figure out why my ‘92 FJ80 won’t crank and killed my battery simultaneously?!
While driving around a few days ago I smelled a burning plastic smell coming from the truck.
When I parked, turned off the engine for a minute, then tried to start truck again.. Nothing! No crank no noises.
I had a similar issue when I first purchased the truck and it was the fusible link(which was replaced).
I also replaced the EFI relay a while back and I’m aware of the overheating issue. I tried replacing the EFI relay during this issue thinking it was an overheated relay with no success.
I was able to limp the truck home after about twenty minutes of cooling down.
Seems like an intermittent short???
The following morning when it was cold out I tried to crank the engine and same
Symptoms persisted no crank no noises. Battery also seemed sluggish. The battery died later that day without ever turning the engine over.
I have been trying to isolate any bad wires with regard to the ignition system. I’ve looked for signs of burning or overheated wiring. No smoking guns yet.
I’ve tested the starter motor wires for continuity and the fusible link wiring for the same.
So far nothing is jumping out at me. I removed the ignition switch to inspect… slight smell of burning wire however no visible damage. Same with the engine bay starter motor wire black with red strip smelled the same… burnt but no visible or palpable damage. No visible damage and continuity was tested and passed.
What else should I do before putting back together with new ignition switch?
I also found a ground wire wrapped in another wire and I don’t know where the other wire goes? It appears as if one inner wire was wrapped around another wire with sheathing? I know one of the connector goes to the engine so I’m assuming it’s a ground?
Pictures below…