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Old 05-04-2010, 12:10 AM   #1
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03 TJ Error Codes

Ok, so I'm coming to the close of a two year project on my '03 TJ. I'm ready to finally crank it, but it won't start. The starter turns and the engine tries to turn over, but it won't actually start.

However, if I prime the engine (pour gas directly into the throttle body) the engine will start up and run until the gas is used up.

I'm currently getting the following error codes:
P0122 - Throttle position sensor voltage low
P0463 - Fuel level sender voltage wrong
P1495 - Leak Detection Pump (LDP) pressure switch problem - the solenoid circuit

The related stuff that may affect it (i.e. the things I've changed) include:
- trading out the stock gas tank for a Genright Comp Tank (Click Here) but kept the existing sending unit and related parts
- moving the evap canister to up under the new comp cut wheel well. verified that all connections, etc are as they were when I removed from stock location. they are also tightened down so there are no leaks.

Stuff that I've checked:
- have replaced the batteries with a pair of new Optima Yellow Top batteries (and have run a charger on them)
- verified connectors are properly seated
- verified fuses are good
- replaced the fuel relay (just in case)

Currently thinking that:
- the 1495 error is remnant of an attempt to start before the evap relocation was complete. it likely just needs to be cleared...
- the 0122 and 0463 are probably due to a possible bad ground, but I'm not sure

Anybody have any suggestions on where to start?

And yes, I'll post lotsa pictures once the project is complete (and running )

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Old 05-04-2010, 06:53 AM   #2
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Is it getting fuel to the rail? Do you hear the fuel pump kick on? Do you still have the stock onnector from the fuel pump/gas tank to the Jeep. If so I would double check that as that connection is know to look fine, but the wires on the gas tank side will pull out just enough to cause issues.. That's all I have..which ain't much.

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Old 05-04-2010, 04:49 PM   #3
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Nope, doesn't look like fuel is getting to the rail (should have mentioned that). I've tried putting it in the 'on' position -- which should kick on the pump to at least pressurize the lines -- and press the schrader valve on the fuel rail. If the pump were working, in theory, gas should get squirted out due to the pressure.

Nothing happens so I'm pretty certain the pump is not pumping.

Also should have mentioned -- the fuel level gauge doesn't appear to be working. The tank is full (enough that it spills out the neck), but the gauge shows E.
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Old 05-04-2010, 08:36 PM   #4
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Update:

Picked up a Superchips programmer today.

Went thru and cleared the codes and tried to start again. Nada. And no codes.

Came back a couple hours later and tried again...nada. And no codes.

I would expect that if there were a problem, the codes should show up again.


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Old 05-04-2010, 08:41 PM   #5
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is the everything grounded out right , there needs to be a ground to the body and frema from the engine block otherwise it could cause the computer to not work properly, just a suggestion
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Old 05-04-2010, 09:02 PM   #6
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Grounds look good. I've got a #2 cable going between the batteries (neg of course) and running to the tub and to the engine block.

Gonna pull the plug by the tank tomorrow and check ground continuity from the plug to the frame and the tub.

I'm actually hoping that there won't be continuity -- meaning there is a break in the line...find the break and solve the problem.
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Old 05-04-2010, 09:05 PM   #7
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that would prob. be your best way to start, good luck with it
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Old 05-07-2010, 02:41 PM   #8
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Another update:

Got under there today and:
- started with no error codes again
- verified that both grounds in the plug just outside the fuel tank have continuity with the rest of the tub (tells me there are no breaks in the grounding lines)
- the "fuel level sensor signal" (pins 2 and 3) are reading 11.26 volts
- the "fuel pump relay output" (pins 1 and 4) are reading 0 volts with ignition in on position and 10.76 volts while ignition is trying to start
- got the P0463 (Fuel Level Sender Voltage Wrong) error code (duh, the cable is unplugged)
- cleared codes, tried starting again and nothing. Tries to start like usual but doesn't. No pressure on the fuel rail and no fuel gauge reading (says completely empty)

Any suggestions or ideas?
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Old 05-11-2010, 10:37 AM   #9
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'nother interesting observation. Typically the fuel gauge only shows that the TJ is completely on 'E'. Was thinking that the sending unit may be bad, etc. However, I put the computer back to stock mode (have a Superchips programmer) and suddenly the fuel gauge shows the tank is full (which it is).

Noticed this once before, but the gauge dropped back to nothing within a few seconds so really thought nothing of it.

???
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Old 05-11-2010, 08:58 PM   #10
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Dropped it off at the dealer yesterday and sure enuf, as expected, the fuel pump is the culprit. They are going to drop a new one in tomorrow or the next day (depending on when they get it in stock).




...and yes, coulda done it myself, but just at a point where I want it done. 2 years in the making and I might actually be driving it again this week

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