New Vacuum hose, found some weirdness...

[RunTrout]

So I'm replacing the vacuum hose all over my 60 (got nice 3 and 5mm silicone hose from BoostController.com). I got to the Air Bypass Valve (ABV). The line going into the top had a small BB or bearing shoved into the hose.

I'm guessing the ABV diaphragm is bad, and someone 'fixed' it by just cutting off flow with the BB.

Any thoughts? I'm thinking of testing the valve, or seeing how the engine runs without the BB in the hose. The vehicle passed emissions a few months ago with no issues.

If the ABV is bad, what should I expect for engine performance?
Not finding much useful in Haynes or Chilton.

The nuts and bolts I got down... the vacuum hose nest for the 84 FJ60 is another beast altogether.

I'll add pics of the new hoses tomorrow. I ordered 20' red 3mm ID, 15' blue 3mm ID, and 10' yellow 5mm ID. I noticed that people are using 3.5mm ID hose, but that the stock is 3.3mm. The 3mm is tight, but the silicone is pretty flexy and goes on easy. I didn't want any small leaks due to the 0.2mm size difference.

I'm doing complete component systems somewhat color matched (i.e. HAC gets all blue hose, ABV gets red, etc.) Looks pretty cool so far and helps delineate the different systems visually. Don't worry I just used the three primary colors, not the whole rainbow

 

[Gurr]

Can't wait to see those pics.

Search FSM in the forum search tool, there is a link that will give you the fat manuals for emissions and whatnot. WAY better then the haynes and chiltons combined.

 

[RunTrout]

Got the FSM. Way cool, thank you.

It looks like someone used a BB to plug the circuit to VSV2. I guess if the ABV diaphragm was not working the BB would prevent constant fuel vapors from running a circuit back through the air filter during the both phases.
It runs good after warming up, but has a rough cold start. I guess I will use my newfound FSM knowledge to test out the ABV tomorrow.
(funny, the thing runs fine, but I still just need to meddle...)

 

[2mbb]

The ABV diaphragm has a bleed hole in it anyway such that it will open under high manifold vacuum, but close when the manifold vacuum is low. Putting a BB in the vacuum line between the VSV2 port F and the ABV vacuum port will essentially keep the ABV closed all the time. This condition still allows for air to be injected into the exhaust ports, but air will not be injected into the exhaust pipe during decelleration or at speeds above 50mph.

The AI system has no effect on engine performanced (assuming no gross vacuum leaks, no siezed air pump, etc.). Its purpose is to increase the oxygen in the exhaust gases to allow the catalytic convertor to work. You probably pass smog because the test does not induce the conditions that are being prevented by the presence of the BB.

I would use the emissions manual to check the operation of the AI system. If it seems to be working properly , then leave the BB out. If something is not working you can evaluate whether to get a replacment part or put the BB in.

When I purchased my FJ60 (in California), I think I found BB's as well as holes carefully cut into the vacuum tubing, just on the underside--a visual inspection could not see the holes. All the parts worked when I put new tubing on. I don't know what the PO or his mechanic was thinking...

 

[RunTrout]

Pics as promised.
Not entirely done (when is done?)
My engine is not so clean... But I'm working on it.
Really cool easy job for $50. 3mm ID in blue and red fits nice and snug on fittings. 5mm ID (yellow) seems a bit small, but is hooking up well on the fittings. Truck still runs nice; I'm not going to mess with the bb yet.