Sputter's Return to Stock

Got the seats, center console and carpet in. Got the Tumble feature working on the passenger seat.
Going to work on replacing the thermostat, troubleshooting the fan relay and installing seat covers.

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Turns out I have a bad (new) fan relay and that’s why the fan is not coming on. I hooked up the relay to my battery on pins 3 & 4 which should have completed the circuit on pins 1 & 2 but continuity was poor. Got a new one on order.

I’m waiting for a bunch of parts to come in before I can get this thing on the road. Specifically I am waiting on a muffler adapter, coolant sensor pigtail, new fan relay and steering wheel boly
Until then, I have a few minor things to work on today.
  1. Begin building the custom console lid.
  2. Finish installing front seat covers.
  3. Tighten e-brake cable
Interior is starting to look good with the seats and carpet in place. 😀

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Waiting on the ham to finish smoking I thought I would tinker around with the Jeep. I cleaned off the old floor mats, installed the new coolant temp sensor pigtail and attached the muffler. Bit by bit!

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Some good and bad today. I got the exhaust installed but had to rig up a hanger because the hangers were missing. I swear this jeep was parted out before someone got it back running. So many weird things missing.
Also added a new battery and new fan relay but still have the P1491 issue. Jeep intermittently starts but I have replaced the battery, ignition switch and ignition actuator pin. When is does start, it idles ok but when you give it gas it backfires and stutters. On top of that, the oil sensor is leaking. 🤬

In any case I think I’ll take a break from it for a few days so I can lower my blood pressure and do some research.

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Replaced the starter relay. Jeep seemed to start easier - definitely kicked in the starter everytime. I will test again tomorrow and see if that fixed my intermittent starting issue. Still stumped by the fan relay.
 
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Finally an easy win! Starter relay fixed my intermittent starting issue. Now getting a couple of new codes to diagnose.

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Great job Dad, your daughter is one lucky girl! That Jeep is gonna be one sweet ride when you’re done 👍

And thanks for posting your project. I always seem to learn a little bit more about Jeeps following threads like this.

Kudos on using solder sleeves too! Not a lot of people know about them. I worked 30 years for Raychem, they’re one of our products.

I’ll be watching as you get everything finished up. Hopefully you can get a picture of your daughters smile first time she drives it!

Cheers!
 
Great job Dad, your daughter is one lucky girl! That Jeep is gonna be one sweet ride when you’re done 👍

And thanks for posting your project. I always seem to learn a little bit more about Jeeps following threads like this.

Kudos on using solder sleeves too! Not a lot of people know about them. I worked 30 years for Raychem, they’re one of our products.

I’ll be watching as you get everything finished up. Hopefully you can get a picture of your daughters smile first time she drives it!

Cheers!
Thanks I appreciate it! Still a lot more work to be done as I am finding new problems every day but it is part of the adventure. My daughter get's the jeep for 4 years and then I will get her something newer and install a Z3 corvette engine in it! Can't wait for that build project!
 
Sputter, when I had the same codes on my 2000 it was the evap fitting on top of the tank broken clean off ! Only found it when changing the tank.
 
New oil sensor, thermostat and walker O2 sensors installed. Also found the cause of my fan relay not starting up. Getting a voltage drop on the return wire from the coolant sensor to the PCM. Going to get some new wire and run a bypass to confirm.
Got a used air box on order from Daveysjeeps so hopefully that may help with the backfire. If not I’ll move on to the fuel injectors.

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A few odds and ends this evening. Got the bracket for the air cleaner and cleaned it up along with the used air cleaner from Daveys Jeeps. Mocked it up while waiting on the bracket to dry. Also got the steering wheel and air bag back in.

Tomorrow working on the fan relay again, test the exhaust for leaks and inspect the leak detection lines for leaks.

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You got that interior looking nice! Any action on the cooling fan?
 
You got that interior looking nice! Any action on the cooling fan?
Thanks Lew! Going to work on that tomorrow. Got a new connector for the fan relay so I can swap it out if need be. Will report back in the morning.
 
Got some items done. The shock is tightened. Regapped plugs. Added more transmission fluid. E-Brake has been adjusted. Fixed thermostat leak.

My big problems still remain though. After replacing the connector for the fan relay in thought sure I would be good to go but something is telling the PCM that I have high resistance on pin 17. I guess the next step is to inspect the full wire and make sure it’s not fried somewhere.

Another big problem I have is a backfire through exhaust and stutter when I increase fuel after it warms up. I already replaced the upstream and downstream O2 sensor, gapped the plugs and replaced the tps. Still having backfires.

Codes I am getting are related to leak detection, transmission sensor and fan relay. I think the transmission one is just from low fluid though.

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Decided to send the PCM off to a different vendor and make sure it is functioning properly. While waiting I decided to do a smoke test on the evap system. Found a leak at the fuel pump detection filter so I got one on order. Also decided to fix up the rear brake pads. Got them cleaned up but had to pause because I got a lead on a $40 back seat. Heading out to get the seat so will finish the brakes tomorrow.

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Rear brakes kicked my *ss. I must have installed them 3 times before I got them right. Good video by bleepingjeep helped out immensely. Also finished up the steering damper and added a new PCV valve. SIA electronics said they couldn’t fix my PCM so I am waiting on a replacement to come sometime next week.

in the meantime, I’ll work on my Land Rover to help lower my blood pressure!

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