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03-20-04, 03:43 PM
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#1 (permalink)
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Site Addict
Join Date: Aug 2002
Location: One of Four Presidential Flying Saucers
Posts: 1,456
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Big request for 60 owners
I finally got a chance today to peer into the engine bay with the emissions control manual from Toyota. At first glance and a little vac hose tracing, it looks like I've got really hard core problems. I traced about 3-4 lines that were totally plugged into the wrong places. Systems that aren't supposed to be connected are connected - kind of looks like the PO's mechanic put it all back togehter by memory, not by the book.
So here's my request for any 60 owner who's feeling extra charitable and has a digital camera: I need some good, high-res photos of your vac lines and what they're hooked too - just the stuff on the driver's side in front of the carb - just the small line stuff (like the air injection and EGR stuff). The layout in the manual doesn't exactly match what I've got (the manual, according to Toyota, covers 80-85, but there's a few things that just don't match up from my truck to the manual. I need a real world example to look at instead of a tech manual.
Unless there's someone in Fort Worth who's willing to let me look under the hood of their 60 and have a little comparison time...
I know it's a lot to ask...but I want to make sure before I start pulling vac lines off...you know?
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03-20-04, 04:59 PM
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#2 (permalink)
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250+ Club
Join Date: Nov 2002
Location: denver
Posts: 587
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Big request for 60 owners
I've lived the nightmare. I can't sent you pictures but I can suggest you order the factory 2F emissions manual. It tells all and shows the proper way to diagnose all the vacume switches that go bad and mess up the vacume lines. Sorry I sold my manual with the 2F I removed.
devo
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03-20-04, 06:20 PM
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#3 (permalink)
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I m m o d e r a t o r
Join Date: Feb 2003
Location: If ya don't know, I ain't tellin'
Posts: 1,146
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Big request for 60 owners
I love the SOR site:
This picture is from this page: http://www.sor.com/sor/cat048c.tam?xax=26677
Also, buy the emissions manual (the 1981 manual is good for all FJ60s).
Good luck!
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03-20-04, 06:57 PM
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#4 (permalink)
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Site Addict
Join Date: Aug 2002
Location: One of Four Presidential Flying Saucers
Posts: 1,456
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Re:Big request for 60 owners
I've got the 2F emissions manual - that's how I've found what's wrong thus far - but the manual isn't exactly clear. That's why I'm wanting photos to look at.
But the SOR site might be just the ticket - it's a lot more clear than the emissions manual...
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03-20-04, 08:29 PM
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#5 (permalink)
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IH8MUD Lifer - No Appeal
Join Date: Aug 2003
Posts: 2,516
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Big request for 60 owners
I have a very stock 2F - I'll try to get some useable pics in the AM.
Mike S
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03-20-04, 08:54 PM
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#6 (permalink)
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250+ Club
Join Date: Mar 2004
Posts: 681
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Big request for 60 owners
Here's another... when you're talking about fj60 emissions, you can't have too much information. BTW, your engine bay diagram should be the most accurate, provided it's still legible. I've gone through the same ordeal where i've found misrouted vacuum lines and other foul-ups left by the dealership. I've since checked each system for routing and functionality and replaced all the vaccum lines in the process. Truly a relief when corrected. Make sure that all the VTV and vacuum check valves are in their proper orientation, too.
The upper right shows the vacuum lines to the carb on the valve cover side.
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03-20-04, 11:15 PM
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#7 (permalink)
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Forum Regular
Join Date: Feb 2002
Location: Henderson, NV
Posts: 165
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Big request for 60 owners
Check your email. I am not sure if the pic attached will help, you will probably need a lot more angles.
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03-20-04, 11:52 PM
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#8 (permalink)
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the Dude abides...
Join Date: Oct 2002
Location: Pismo Beach
Posts: 910
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Big request for 60 owners
You might want to check out this thread:
http://forum.ih8mud.com/index.php?bo...5526#msg115526
Not for the faint of heart.
I recommend patience and system by system trace using the emission book.
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03-21-04, 08:38 AM
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#9 (permalink)
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Site Addict
Join Date: Aug 2002
Location: One of Four Presidential Flying Saucers
Posts: 1,456
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Re:Big request for 60 owners
It is a pain, but it comes more and more clear as I look at it.
What started it all was failing the smog test - and I've gone through just about everything...it all keeps coming back to the air injection system...and while I was looking all of the lines over, I noticed one free line...no idea where it goes, can't figure it out from the book...then I start tracing lines that I can find (process of elimination) and it's so out of whack, I was wondering how the truck ran at all...
One thing that I found - a big one - was that my ABV, which is part of the AI system, was hooked to the vac switch, which is part of the Decel Fuel Cut system...and the VSV that it was supposed to be hooked to was broken...
That was just taking 5 minutes to look under the hood before a run to the store...
One question though: it doesn't look like it in the manual, but does anyone know if any of the systems are connected at all? (like the AI being connected - by vac - to a component of the EGR system) or do they run independently (other than a connection to the computer)? - if that makes sense...
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03-21-04, 08:49 AM
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#10 (permalink)
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Forum Lifer
Join Date: Sep 2003
Location: WC, CA
Posts: 2,781
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Big request for 60 owners
I agree with pismojim about needing patience for this job. There's a quote from "Zen and the Art of Motorcycle Maintenance" referencing instructions that came with a bicycle: 'Assembly of a Japanese bicycle takes peace of mind'. Find that peaceful place and take your time. I also recommend taking the time to label the hoses, so when you take things apart, it goes back together much easier. I used some cloth/adhesive wire labels that I got at the hardware store. There is usually a single letter or digit port number associated with each of the vacuum devices.
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03-21-04, 09:55 AM
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#11 (permalink)
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250+ Club
Join Date: Mar 2004
Posts: 681
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Big request for 60 owners
[quote author=2mbb link=board=1;threadid=13445;start=msg124667#msg124 667 date=1079884177]
There's a quote from "Zen and the Art of Motorcycle Maintenance" referencing ...[/quote]
Interesting, I've always thought that Phaedrus could have just as easily taken that trip with his son in a Land Cruiser.
[quote author=swank60 link=board=1;threadid=13445;start=msg124665#msg124 665 date=1079883501]...does anyone know if any of the systems are connected at all? (like the AI being connected - by vac - to a component of the EGR system) or do they run independently (other than a connection to the computer)? - if that makes sense...[/quote]
EGR and Spark Control for example are connected since they both deal with timing. They share the upper BVSV on the thermostat housing as well as the main diaphragm of the vacuum advance.
But AI and EGR are separate systems. You may be confusing the VSV's? AI uses 2 VSV's while EGR uses 1 and they're located in the same area.
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03-21-04, 04:30 PM
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#12 (permalink)
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IH8MUD Lifer - No Appeal
Join Date: Aug 2003
Posts: 2,516
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Big request for 60 owners
[quote author=Mike S link=board=1;threadid=13445;start=msg124496#msg124 496 date=1079839753]
I have a very stock 2F - I'll try to get some useable pics in the AM.
Mike S
[/quote]
Great pictures, but I am having software problems and can't download. Sorry.
Mike S
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03-22-04, 08:16 AM
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#13 (permalink)
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Site Addict
Join Date: Aug 2002
Location: One of Four Presidential Flying Saucers
Posts: 1,456
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Re:Big request for 60 owners
That's cool Mike, I appreciate it. I've been emailed a few photos already, and I'm starting to iron out some of the details...
I'll let you all know how it goes...
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10-03-04, 04:11 PM
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#14 (permalink)
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Forum Lifer
Join Date: Sep 2004
Location: Tamarindo, Costa Rica
Posts: 2,847
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In Guatemala (of all places) I noticed a mechanic using fingernail polish to mark vacuum lines before he took apart a motor. I think it was a hyundai van or something, but the principal is the same. Raid your woman's fingernail polish for a dozen bottles (or hit the grocery store) and dab a generous amount of various colors on the lines/connection points while they are still connected.
Of course, this doesn't really help you figure out where they go now, but should help once you've finally figured it out.
Best of luck!
__________________
91 fj80 w/ 93 1HD-T. OME 850/860 w/ 1" front spacer, LEDs, HIRs, Geolander MT's 33x12.50r15, Tuffy center, ARB rear locker (in progress), in garage: lightforce lights, full rack, superwinch X9, maggiolina tent, hella horns.
ask me about Costa Rican Realty
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10-03-04, 04:57 PM
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#15 (permalink)
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Forum Regular
Join Date: Feb 2002
Location: Henderson, NV
Posts: 165
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This may not be much help, but here you go. I can email you direct with a full res. pic. if needed.
__________________
SNLC.org
87 FJ60 'squirted', premium floor mats, synthetic leather wrapped steering wheel, authentic pine air freshner
96 LX450
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10-03-04, 05:45 PM
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#16 (permalink)
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250+ Club
Join Date: May 2004
Location: Seattle, WA
Posts: 451
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Quote:
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Originally Posted by JDay
This may not be much help, but here you go. I can email you direct with a full res. pic. if needed.
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LOL - I have about 1/8th that many hoses under the hood.... oh well!
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10-03-04, 06:31 PM
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#17 (permalink)
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Forum Lifer
Join Date: Apr 2004
Location: Larkspur, CO
Posts: 2,567
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2F Vacuum Lines
I took 24 8x10s of the smog lines in my 84 FJ60 before taking it to the 4x4 shop to have the engine swapped into my 83. You're welcome to borrow them.
Didn't read the other responses, but I also have the factory shop manuals if you want copies of the smog section.
Email me back or call me at work, 6:30AM-5:00PM, M-F 303 688-0675.
Steve Meyer
Larkspur, CO
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10-03-04, 06:55 PM
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#18 (permalink)
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250+ Club
Join Date: May 2004
Location: Awstin
Posts: 684
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GOOD LUCK!
mine is desmoggd and i will probably leave it that way and drive it around illegally until i get back down to texas. then i'll just drive it with illinois plates down there until i get another DD.
i just can't see me having the patience or time otherwise. i'll just take my chances.
__________________
85 FJ60 "Bertha"
TLCA #14740
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10-03-04, 07:40 PM
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#19 (permalink)
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Merchant of Death
Join Date: Mar 2003
Location: Gig Harbor WA
Posts: 12,048
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__________________
Truth is a torch that shines through the fog without dispelling it. Always be true to your work, your word, & your friends, & you will never live a day without peace
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10-03-04, 11:59 PM
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#20 (permalink)
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Forum Lifer
Join Date: May 2002
Location: Greg's place
Posts: 2,978
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Thank God for SBC! 
The motor swap seemed easier to me than trying to figure out what I was missing. Good luck, you are a better man than I just for trying.
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10-04-04, 12:08 AM
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#21 (permalink)
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Tank Buster
Join Date: Sep 2003
Location: Seattle area
Posts: 2,333
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__________________
2001 VW TDI Bora
1987 Toyota HZTJ-60
I'm a democrat member of the House of Representatives, and I've got what it takes to take what you've got! 
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10-04-04, 07:16 AM
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#22 (permalink)
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Are we there yet?
Join Date: Mar 2003
Location: Ingerland
Posts: 701
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HZJ60Guy
I was thinking the same thing. Just in case someone with a diesel has the same question. Here is where the pipes go..
__________________
1997 HDJ80 Manual <70,000 miles
The squeaky wheel gets the grease
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10-04-04, 07:40 AM
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#23 (permalink)
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250+ Club
Join Date: Feb 2004
Location: IOWA
Posts: 493
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Thanks sooooo much for those pictures guys!! I actually know that some of my hoses are plugged in the wrong place but i wasn't for sure on where they actually went in to. once again Thanks!
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10-04-04, 08:37 AM
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#24 (permalink)
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250+ Club
Join Date: Aug 2004
Location: Boise, Idaho
Posts: 518
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Swank,
What were the numbers on your failed emmissions?
__________________
Quote:
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Originally Posted by wobbit
here we go again....
Someone will say that eating meat is essential.
Tofu will counter that it's not in a four paragraph diatribe using the reasoning that he is alive.
Someone will say that eating meat is normal.
Tofu will respond that it is normal if you are violent brute in a four paragraph diatribe.
Someone will call tofu a moronic fuckstick retard (or some variant).
Tofu will cry that he is singled out and picked on, not realizing that he is the only veggytarian on the board, and comes across as hyperdefensive and too "in your face, meateater." (in a four paragraph diatribe)
Tofu will sulk off into the corner and not post again until Tuesday.
lather, rinse, repeat
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08-04-05, 10:21 AM
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#25 (permalink)
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Turbo Diesel Lover
Join Date: Apr 2003
Location: Panamá
Posts: 11,429
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Quote:
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Originally Posted by HZJ60 Guy
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for sure .. never see that amount of hoses in my engine room .. ! 
almost one .. or 2 
__________________
HJ-60 2H-T Intercooled Tencha
HDJ-80 1HD-T not stock at all ! Marilu
FZJ-80 1FZ-FE ready to Play ( wife rig ! )
Join us at our local Panamá Off Road Forum
Quote:
Originally Posted by crushers
if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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08-04-05, 10:28 AM
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#26 (permalink)
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what he said
Join Date: Feb 2002
Location: Las Vegas
Posts: 13,124
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And why I am going to the megasquirt TBI system..
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08-04-05, 01:04 PM
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#27 (permalink)
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Site Addict
Join Date: Oct 2004
Location: Clemson, SC
Posts: 1,483
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Damn Landpimp that is a pretty green and a pretty engine. That took sometime..Congrats
__________________
Yee Haw!!! 
1968 fj40 with 33's
1986 fj60 all stock and 31's...340,000 miles
Cruisers....gotta love 'em!
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08-04-05, 11:50 PM
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#28 (permalink)
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Forum Regular
Join Date: Apr 2005
Location: 2300, AUSTRALIA
Posts: 119
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Quote:
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Originally Posted by Tapage
for sure .. never see that amount of hoses in my engine room .. !
almost one .. or 2 |
What he said, diesel!
__________________
1985 HJ60
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08-05-05, 02:39 AM
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#29 (permalink)
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Forum Regular
Join Date: Mar 2005
Location: Kosovo
Posts: 87
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Yowzaa. My hoses are messed up, I can tell from memory. I am going to get on it as soon as I get back.
I have one question:
On the air cleaner there are three 3mm hoses lined up in a row. The middle hose has something spliced in. What is that thing?
As soon as I know I can order one and have it ready when I get back.
Thanks
And double thanks for posting all the pics. I have the smog manual but didnt get too far with it before shipping out, the pics will be a lot of help.
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08-05-05, 05:54 AM
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#30 (permalink)
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250+ Club
Join Date: Jun 2005
Location: San Diego, CA
TLCA# have one but don't know the number
Posts: 391
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you can swing by my place and look.
817-714-0599
Mitch
__________________
94 FZJ-80, 5 285 BFG MT's, freshened up shaved head, valve job, ARB bull bar, fresh OEM tune up, K&N, SCION head unit, fresh cooling system, BA Outfitters full Roof Rack, 2.5 OME MED/MED, Cobra CB w/fiberglass antenna, Hella lights, in process of upgrading the sound system, more to come
I have finally found a rig that fits me.
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Jman
Large
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HZJ60 Guy
Mace
