The Problem
First, the area that typically gets fried sits around a 5volt regulator which is highlighted with a white arrow in the picture below. From what I am seeing, the cause of failure always seems to be one (or all) of the electrolytic capacitors highlighted in the blue boxes. This makes sense because electrolytic capacitors tend to last a LONG time but what can kill them is heat and sitting next to the roof of an XJ for 20 years is a pretty sure way to accelerate their demise. The problem is that when they blow, they take other components (and traces) with them. The 3 small ceramic capacitor to the right of the voltage regulator (numbered 1-3 in orange)are prime targets for this. These 3 capacitors can actually be removed since they aren't really needed in this circuit but I will include a section below on how to change them out if you prefer.
Power Circuit
The real issue is that when the electrolytic capacitor blows, these little caps get really hot and often cause some of the traces to break. The one highlighted in red is often bad and this one is very important since it is what provides the ground signal to two of the electrolytic capacitors. To test this, turn the board over and connect a mult-imeter (set to ohms) between pin 3 of the regulator and the negative pole of each capacitor (marked with the white bar and a "-" sign on the sides of the capacitors). When you connect your meter to these points, each should read close to 0 ohms.
CPU Reset Circuit
The other trace that tends to get burned up is the one that connects pin 2 of the regulator to the CPU. This pin provides a 4.6-4.7v reset signal to the CPU and if it is broken, the CPU won't turn on. The best way to check this trace is to use your multi-meter again (still on the ohms setting) between pin 2 of the regulator and pin 5 of the CPU (both ends highlighted with the yellow arrow). When you connect to these you should also get a reading of close to 0 ohms.
The Fix
If both of your multi-meter tests are good, you should be able to simply replace these three capacitors. All 3 are 100uF 35V capacitors and are available online or from places like Fry's Electronics. Typical cost is ~$1.50 each (3 needed).
Power Circuit fix
If you found a broken trace between pin 3 and the negative poles of the electrolytic capacitors, the easiest fix is to turn the board over and solder a wire between pin 3 (ground) of the regulator and the negative pole on one of the new electrolytic capacitors. This essentially re-attaches the connection I highlighted with the red line in the pic. Here is an easy trick: rather than looking for small wire, simply use some of the excess wire you will cut off the bottom of the capacitors and slide some heat shrink tubing over it. This will insulate the wire to keep it from touching any other part of the circuit.
CPU Reset Circuit fix
If you found a broken trace when you checked the connection between pin 2 of the regulator and pin 5 of the CPU, the fix is a little harder. The break is usually on a small trace that runs right between the orange 2 and 3 in the pic. If you look closely at the pic, there is a small solder spot directly under the orange number 3. What this hole does is connect the trace on the top of the board to another trace on the bottom of the board. If you connect your multi-meter between this solder blob and pin 5 of the CPU, it should read 0 ohms and if so, I typically turn the board over, heat up this blob and feed a small wire through it. I then attach the other end of the wire to pin 2 of the regulator (using heat shrink insulator again).
Burned up ceramic capacitor fix
This fix isn't really necessary since the board will work perfectly without these capacitors but if anyone wants to change them out, they are all 100nF and can be replaced on the backside of the board with traditional ceramic capacitors. These cap's are simply used to try to protect the voltage regulator when something goes wrong. I have numbered them in the pic and the connect as follows:
#1 - connects between pin 2 of the regulator and the positive side (opposite of the side marked with the white bar and "-" sign) of the middle electrolytic capacitor.
#2 - connects between pin 2 and pin 3 of the regulator
#3 - connects between pin 3 of the regulator and the
positive side (opposite of the side marked with the white bar and "-" sign) of the right-most electrolytic capacitor.
I know that this is an old thread but I have now fixed a bunch of these things and thought I should update with more detail.
Electrolytic Capacitor failures. This is the big one and has been covered extensively in this post but I want to add that I have been using the high temperature capacitors at this link with better long term success:
http://www.mouser.com/Search/ProductDetail.aspx?qs=9rQVDmoPMIQrjoUI1ogLLg%3d%3d
The isolating capacitors are available at this link:
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http://www.mouser.com/ProductDetail...=sGAEpiMZZMuMW9TJLBQkXsjX9hJVC7r9GotYpTs8phg=
2) Clock issues. I am finding that the later rev's of the board use a different clock as shown in the pics below. The newer ones (blue in the pic) fail VERY easily so I recommend replacing them with a standard 4MHz crystal as I have done in the second pic below.
[FONT="]Note: the old crystal has three pi[FONT="]ns w[FONT="]hile the new one only has two but don't worry about it, just connect the new one to the two outer holes and leave t[FONT="]he center one ([FONT="]ground as Karsten noted[FONT="] earl[FONT="]ier) disconnected.[/FONT][/FONT][/FONT][/FONT][/FONT][/FONT][/FONT]
The new Crystal is available at the link below:
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http://www.mouser.com/ProductDetail...=sGAEpiMZZMsBj6bBr9Q9aew7Ki0pGAG0ES4bPHSHRXY=
When you go to replace the capacitors, I find it easier to connect the isolating capacitors from the bottom as shown in this pic (I use some shrink tubing on [FONT="]leads that could contact other solder join[FONT="]ts)[/FONT][/FONT]:
Also check:
1) the trace that connects the CPU to the display chip runs through the "hot zone" and often breaks. You can easily check it from the backside with a meter by testing the the points where I have connected the blue wire. If you measure an[FONT="] open circuit,[/FONT] this needs to be repaired and I recommend using the jumper wire at the link below (insulation can handle high temps)
2) the trace that connects the 220uF capacitor to the display chip is also in this area and can break. Test by connecting your multi-meter between the second set of points below and repair as necessary.
The wire I recommend is available at this link:
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http://www.mouser.com/ProductDetail...P7B8cvTVWw==&gclid=CNyhk7iM-84CFQEOaQodfwcMxw
With these changes, I have been able to fix every board I have seen. Grand total cost from the sour[FONT="]ce abo[FONT="]ve comes[FONT="] to $14.4[FONT="]9 and all repairs can be accomplished with a basic soldering [FONT="]iron.[/FONT][/FONT][/FONT][/FONT][/FONT]
HTH
Todd
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First, thank you VERY much for updating this thread. It's perfect time because I was at the point where I wanted to try and fix my own console.
Before I go tearing into mine, I thought I'd ask a few questions.
Referring to both your previous posts:
Power Circuit
Is it best to go ahead and replace the 3 electrolytic capacitors while I've got it apart, even if the test between pin 3 of the regulator and the negative pole of each capacitor results in 0 ohms?
I've already purchased both the high temperature capacitors from Mouser. I'm assuming it would be best to use the 150c models over the 105c, if I feel like attempting them?
CPU Reset Circuit
When I test between pin 2 of the regulator and pin 5 of the CPU I get 68.2k ohms.
When I test connect between this solder blob and pin 5 of the CPU I get the same reading.
Should this reading be 0 if the trace is broken, or 0 if the trace is intact?
Are the blue isolating capacitors meant to replace the orange #'s 1,2, and 3 in the first picture? If so, do I need to remove the originals or does it not matter since they're being bypassed?
Does it matter which way the [FONT="]4MHz crystal is installed?[FONT="] I don't see any markings on it, so I'm as[FONT="]suming not. [/FONT][/FONT]
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