Hello,
I have a 1997 D1 (NAS, 4.0 with Advanced Evap Loss), that I purchased in a non-running condition. Upon receiving the vehicle, it presented a crank but no start situation. I have a 96 D1 (also 4.0, but without AEL) that I have been borrowing parts off of to help with diagnostics. Here is what I did:

1. Verify spark, bright and blue. Replaced spark plugs and wires as precautionary. Swapped out coil with known good unit, same issue.

2. Verify fuel - plenty of fuel at rail, pump comes on as should, plugs wet with fuel, injectors pulse (tested with noid light). Starting fluid does not help. Fresh gas in tank.

3. Verify crank signal via OBD tool, can see that the engine cranks between 75-125rpm. Swapped out CPS with known working unit, same issue.

4. Found no check engine light when key is in position II. Removed ECU, cleaned board and put dielectric grease on connectors

5. Still no CEL, removed cluster and found burnt bulb. Replaced bulb and now CEL works INTERMITTENTLY when in position II, and does not illuminate when cranking

6. Swapped ECU with unit from my running 96, same issue

7. Checked ALL fuses. When fuse is removed for fuel injectors, the rig cranks differently than when the fuse is in place. Again, the plus are wet and the injectors are operations correctly.

With all of this, the rig actually started one morning but was only running on what felt like 1 cylinder. At this point I was sure there was mechanical issues, so I started tearing it down. After removing the valley pan gasket, i found a BROKEN PUSHROD for the exhaust valve on cylinder #3. I then took the heads off, got them rebuilt, replaced push rod and lifter and reassembled. I also replaced the fuel injector on cylinder #3. Tried to start it, and same issue. Compression is good. No pending faults. I can see all data values on scan tool, along with engine speed when cranking.

I have exhausted the forums trying to find any solutions. I am really getting near the end of my rope with this rig. If anyone has any advice, I would appreciate it! I really don't want to part this rig out, but it seems to not want to be alive anymore! I am sure I am forgetting things, I will update as I can.

 

Did you verify spark on all cylinders? Could be the Cam Position Sensor or wiring to it (Mounted on front cover just below water pump & above harmonic balancer). The crank & cam sensor combine signals to the ECU.

 

Hi Best4x4,

I have a strong bright and blue spark on all cylinders, the spark is consistent intervals as well. I have not checked the cam position sensor / connections, I will try that tonight and report back.

 

Well,

Removed connector for cam sensor and found it coated in oil / sludge. Cleaned connector and installed, same issues. Any other ideas???? I should mention there is no faults pending but I can communicate with ECU to see cranking speed / temp values.

 

You maybe tried this already. Swap cam sensor?

 

Are the plug wires correct?