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My 04 fix/build thread!

9K views 54 replies 10 participants last post by  Trav1s 
#1 · (Edited)
Here we go hopefully have it fixed in the next couple weeks. Then I'll start making mods :D
Red one is mine. The white one is just for parts. I'll be selling what I don't use so be on the lookout for that!
 

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#3 ·
I see lots of stone white parts in the parts machine. The red one looks really sharp in that color.
 
#6 · (Edited)
pm me with left over parts my cousin has a i6 and I have a v8. both wj. always looking.to replace broken items

Turbo charged G2X using tapatalk 2
It will be a bit before I am done with mine but I'll post a thread in classifieds and a link to it on this thread when I know what all I have to sell. Keep watching.

Update: I got a little work done on it today. The passenger side "frame rail" (technically it's a unibody) was crunched a little so I cut about 6" off and replaced with the 6" I cut off the parts rig. Welded up and after grinding welds and painting it will be hard to tell it ever happened. Didn't get pics but I will soon.
 
#7 ·
Well good news and bad news. Good news first. I got my jeep done and am now driving it a LOT! Runs great. Maybe it's because I have been driving a gutless jetta for 2 years but I love this thing!

Now bad news. I have a problem with getting so wrapped up in what I'm doing and not getting distracted even to the point of not eating that I totally forgot to take pics of the process! Sorry I know, I know :slapfight:.

Here is a recap of what I did. First off cut out the old bumper support. Then cut off the front 6 inches of the "frame rail" from both my jeep and the parts jeep. Welded in the parts jeep frame section on my jeep to fix the damage. Welded on the bumper support from the parts jeep.

Next onto the cooling systems. New radiator and ac condenser. Mounted together with the factory fan. Now I hit a road block. I had no freaking clue where all the hoses hooked up so this took a bit of figuring, come to find out the radiator was for a jeep with the towing package which mine did not have so I had tranny cooler line hooks and no tranny cooler lines. Stolen off parts jeep and bonus now I have a tranny cooler and tow package!

Next onto the cosmetics. Mounted the headlight support (this is broken and will be replaced in the near future but I was on a schedule) come to find out the headlight support didnt match the grill or bumper I had so I had to get creative (as I said this all will be fixed when I replace the headlight support. Next shiny new headlights. One taillight (no idea why this was missing or why they cut the factory harness to get it out rather than just unplug it) some wiring and done.

Next I aligned the hood, grill, headlights. Swapped the wheels and tires from the parts jeep to mine (much better condition although smaller).

Now the test drive. Out of the driveway its running great for about 2 miles then dies! Limped it back home at about 15mph no codes, indicator lights, nothing. Smelled dang hot and after some screwing around found out that it was vapor locked in the coolant system. Lots of spilled coolant and time later fixed and running great.

A few minor issues yet to be fixed. Voltage and temp gauge not working for some reason. Probably a temp sensor and ???? Defiantly charging according to my test meter so I don't know wtf. Still have to charge the ac. Check, check and check fluids for the first few hundred miles. Tranny flush and service and finish the sea foam treatment (only added to oil and fuel no vacuum yet). Then on to mods!!

Here are some pics of the second test drive after cooling issues were sorted out. Sorry for the long post.

Dont mind the sun in the one pic. These were taken before I swapped wheels and tires and before I washed it. This is a berm that my dad has around his property (dont ask why he has an 8ft berm).
 

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#10 ·
Nice job :thumbsup: You'll learn to take pictures of everything soon! We love pics!! Plus you don't what
:pics:

^ posted in every thread.

Great job though!
 
#12 ·
Well drove it to work (45 miles one way) yesterday and ran great for about 30 miles then started cutting out/bogging. Pulled off the freeway and ran into the store for a sec came out and it was fine for another 13 miles. Limped to work. Had to fight it the whole way home.
So today I get to replace the coolant temp sensor, PCV valve and hunt for a vacuum leak then do the sea foam treatment to the vacuum line, hopefully get some things worked out before we head to the beach on monday.
 
#13 ·
Well I got a little work done today. Found a vacuum leak behind the right headlight. Idles much better now. Replaced the temp sensor with one from my parts jeep and still not reading right. I'll have to do some tests to see if the sensor is the problem or if it's wiring.

Next problem. This thing runs rediculously hot. Even with the temp sensor unhooked so the fan in on full it still gets crazy hot. Seems like its circulating ok as the hose from engine to radiator is hot and radiator cap is cool so that tells me that at least hot coolant from the motor is going into the radiator. It gets hot to the point that it doesn't run worth a crap. Any ideas?
 
#14 ·
Dustin are you using the bleed screw on yhe thermostat housing when filling with coolant? Did you check the thermostat to see if it was stuck after sitting for 4 years. Did you make sure the fan is plumbed right. You CAN NOT keep overheating a 4.7 and STILL keep driving it to the point it won't even run right. They're aluminum heads! It will be a miracle if you didn't warp one already or take out a head gasket at the very least. A properly cooled 4.7 wont wander up or down much from the 210 mark so if it starts climbing above 230 or so and doesn't come down you probably have issues and at least should stop and let it cool down. I hope you didn't trash the poor thing after all the work you put into it.
 
#15 ·
Dustin are you using the bleed screw on yhe thermostat housing when filling with coolant? Did you check the thermostat to see if it was stuck after sitting for 4 years. Did you make sure the fan is plumbed right.
I was using the top bleed screw, by the top rad hose. I haven't pulled the thermostat out yet but will be doing that monday. The fan is plumbed right for sure. Fan seems to fun fine. I make sure and shut it off and let it cool when it get real hot. I have been as careful as I can but not having a working temp sensor it's hard to know when it's getting hot.
 
#16 ·
Ok so new temp sensor in and it's still not reading on the gauge. Tested the wiring and it is with in spec so between that and my voltage gauge not reading right I'm thinking maybe a gauge problem or possibly a PCM problem.

However with the new sensor in the fan was turning on and off regularly. I do have a good leak in the rad though so I'll be replacing that I guess, and I'll do a 180 stat while I'm at it. It is flowing for sure but I figure I might as well go for it while it's apart. Piece of mind mostly.

Still not running worth a crap. It sat in my driveway for 20 min going between idle and me reving it to 5k on occasion and it ran fine. Got it on the road and within a mile it started stalling out? Of course no codes. When in my driveway it was sitting on ramps under the front wheels.

I'm lost here please help guys.
 
#17 ·
More info on the stalling issue.

After driving about 1/4 mile after having run great in my driveway it would start loosing power but still revving then stop revving. After pulling to the side of the road for about 3 min with trans in idle and motor still running it would be normal for about 100 yards then start doing it again. After getting it home and stopping in my driveway it would rev just fine.
 
#19 ·
I did a radiator shortly after purchasing my WJ. Got it from Rockauto for 60% of the cost at my local Napa. While I was at it I had the cooling system flushed and filled with Global antifreeze. Definitely runs cooler and engine temp stays more stable no matter outside temperatures.
 
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#20 ·
Got it from Rockauto for 60% of the cost at my local Napa. While I was at it I had the cooling system flushed and filled with Global antifreeze. Definitely runs cooler and engine temp stays more stable no matter outside temperatures.
Damn! I totally spaced Rockauto! Would have saved me $60. :mad: Oh well shipping is free and fast through summit racing so I'll just suck it up.

Good call on the global antifreeze I'll do that as well after I flush the system.
 
#21 · (Edited)
Ok so new radiator and thermostat in without too much trouble. Now it is still having issues with stalling. I replaced the TPS. Finally it is throwing some codes so that helps though.
Codes are P0171 and P0174. I don't have the book right in front of me but they were both something about lean fuel. Anyone had these codes before that can point me in a direction? Fuel pump? Pressure regulator? I have done a seafoam treatment.
I dont have a gauge but it seems to have plenty of pressure at the fuel rail. With the motor off key in on position I can hit the relief several times and not get any pressure drop.
Thanks in advance.
 
#23 ·
Rock auto usually pretty good for parts, and you can find a 5% discount code with a quick google search.
 
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#25 ·
Hey I would be interested in the seats(whole set)
-leather
- Not too many rips/tears
- Reasonably priced
- Reasonable shipping cost to 92020

Mine is a Laredo 2WD with cloth, non electric seats.
Starting to work on it, will start build thread, started by sanding the trimmings readiness for some bumper coating. Good luck with the build.
 
#26 ·
@Dustinmk4: I'm also interested in some parts if/when you decided to part out.


Hey I would be interested in the seats(whole set)
-leather
- Not too many rips/tears
- Reasonably priced
- Reasonable shipping cost to 92020

Mine is a Laredo 2WD with cloth, non electric seats.
Starting to work on it, will start build thread, started by sanding the trimmings readiness for some bumper coating. Good luck with the build.
If you do this, let me know. I live 10 mins from you and it would probably be cheaper to bring stuff in together then separate. Just a thought.
 
#28 · (Edited)
Well got a diagnostic from the shop and they said it was "probably the fuel pump or the fuel filter" So I rplaced both and man am I glad I did. The screen on the bottom of the pump was laying in the bottom of the tank and just crumbled when I touched it and the filter just poured out brown nasty old fuel. With those installed it started great and ran perfect!

Oh and P.S. My skid plate didn't have ANY rust on it ha ha! Yes I'm rubbing it in.
 

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#33 ·
Did you change the fuel filter/pressure regulator that is located above the axle? I did that yesterday and it runs much smoother. After hours of reading about this it seems that people frequently see noticeably increased fuel economy too. I have not drove mine enough to tell.

http://www.wjjeeps.com/fuel_filter.htm - Good resource. I did not depressurize the system and I did not take a gasoline shower.

 
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#29 ·
How long did you WJ site before you purchased it?
 
#31 ·
No doubt modern gas sitting in the tank unused contributed to the mess. Glad you got it going.
 
#35 ·
Addco rear, bushings and hood struts will be here thurs and I just placed an order for a beyond ported tb from flyin ryan! Can't wait to get all this stuff done. If I can get the money scrapped up I'll order a data logger and SCT tune by next month. It's going to be a very good fall ha ha.
 
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