Jeep not starting after it's warm

[CJTHING]

My wifes 93 YJ 2.5 160,000 miles is not wanting to start after its warm. Today for example went out to goto a meeting started fine, at meeting 3 hours started fine. Left meeting went to store in for 10 mins wouldn't start. She held the key for about 30 sec and it started. Went to another store in for a few mins wouldn't start. It was doing this last year before winter but parked it for the winter. Replaced starter last week, cleaned the batt terminals and the problem went a way for a week. Batt is 8 years old but it sat the entire winter started the Jeep about once a week and started the Jeep a few months ago for the summer. Any ideas? I'm thinking about replacing the cables and battery. It will aways start you just need to wait about 30mins or just keep holding the key. Almost forgot all the guages light up and work just won't engauge the starter.

[Z28YJ]

Need more info. It sounds like a no cranking issue, correct? When it won't start and she holds the key for 30 seconds, what does it do? Nothing for the first 29 seconds, then crank normally? Crank slowly at first, then fast enough to start the engine? Crank normally the whole 30 seconds and then start? Do the battery cables feel hot to the touch when you are having the issue?

[CJTHING]

Holds the key for 30 sec with nothing but gauges, then it cranks normal. I have never been around when its done it.

[Tommy]

Is the starter solenoid on the fender or starter? Could be getting hot or old. Maybe try to jump the terminals? Could be an internal issure.

[wolfe]

sounds like the starter relay . but more info would be good , auto or stick ?
Tommy just beat me to it so I will just say +1

[Will_M]

Check for loose connections also. Has to be something on the starter circuit.

[CJTHING]

Replaced the starter relay. No change. Starter solenoid is on the starter. I am begining to think its the ingition switch. It's an stick.

[wolfe]

what happens if you jump across the relay ? that would bypass the switch as a test

[v1sion]

I had the exact same problem with my XJ. I ***solved*** it about two years ago.
I cannot remember which Chrysler service bulletin it was.
It was a 50.00 repair at the Heritage Jeep in owings mills.

I will dig around for the actual bulletin tomorrow. If you call Heritage Jeep in Owings Mills, I would imagine the mechanic would understand your problem if you describe it to him.

<edit>
Actually, my 2001 XJ issue would only happen when it was hot out. I am not sure if it was the exact same issue. I will still dig up the service bulletin number and post it here.

<edit>
Ok, here is the bulletin, found it online:

1803103 - 4.0L ROUGH ENGINE IDLE AFTER RESTART FOLLOWING A HOT SOAK
Date: 09/05/03 (supercedes 1802702 dated 09/06/02)
Model Year(s): 1999-2004

Description: NOTE: This bulletin applies to vehicles equipped with a 4.0L engine. This bulletin involves the installation of a fuel injector insulator sleeve.

Details: Customers may describe a 20 to 30 second rough idle following the restart of a heat soaked engine. This condition may be most noticeable when the engine is restarted following a prior 10 to 20 minute heat soak in hot ambient conditions of approximately 32 C (90ºF) or higher. This condition may be consistent with short city stop-and-go driving trips and can be aggravated by the use of fuel with a high ethanol content. Depending upon various conditions a MIL may occur due to DTC P0303 - Cylinder #3 Misfire.

This condition may be caused by heat from the exhaust manifold that following engine shut down migrates to the area around injector #3 and causes fuel vapor to form within the injector. This in turn may cause a momentary misfire of cylinder #3 until the fuel vapor is cleared of injector #3. The insulator sleeve lowers the injector #3 temperature to a point below which the fuel will not normally vaporize.

If vehicle exhibits a rough idle, and if a misfire of cylinder #3 is observed following a 10 to 20 minute hot soak, perform the Repair Procedure.

Parts required:
56028371AA Ignition Wire Shield

Repair procedure:
1. Cut insulator sleeve, p/n 56028371AA, to make two (2) insulator sleeves about 25-30 mm (1 in.) in length. See diagram.
2. Install one sleeve around injector #3, with the slit on the upward facing side of the injector. Install the other sleeve with the slit on the downward facing side of the injector.
3. Confirm sleeve is flush to intake manifold surface around injector.
4. Check injector #3 wire and ensure that the injector is rotated to a 2 o'clock position (from driver?s side of vehicle).

Hope it helps.

[CJTHING]

Found the problem. Wife bought the Jeep used in 96 and PO had an alarm installed. She/we didn't know. Started to pull the dash apart to check the conections on the steering column and found the alarm brain box. Removed it soldered all the wires back together and so far no more starting issues.