Build 1982 FJ60 - Project Clifford

[sadovnik]

Next project is swapping the carb. It currently has (as best I can tell) an EMPI EPC 38E that's running but in bad shape - choke is disconnected, tuning is out of whack, the truck is known to diesel and vapor lock, etc.

My plan was to clean it up, tune it, and sort out the desmog from there. As I got started on that today I noticed it's leaking fuel from this pressed (or maybe cast?) plug next to the fuel inlet. It starts immediately and is steady so...change of plans. I'm going to swap it rather than try to get it running better.
View attachment 4202365View attachment 4202366

Luckily I have its replacement on hand. The PO had purchased and intended to install a new-in-box OEM 21100-61012, which this forum taught me is the non-US market carb. He also had a used US-market carb. He included both in the sale, so now I'm just making sure I have all the bits and pieces on hand to swap in the 61012 before I get started.
View attachment 4202368

I'm studying the 'How to desmog...' pdf and hope to clean up the desmog job as I install the new carb. It was done by a PPO and there are a few mismatches to the pdf. I also read a couple of threads on the one-wire vs two-wire fuel-cut solenoid and I think I'm comfortable with the differences and how to handle it (one-wire connection to ignition-switched 12V, please holler if that's incorrect). I'm planning to replace all vacuum lines and the fuel filter when I do the swap.

One question I'm pondering is whether to re-jet the carb before I install. I'm in Colorado around 6,000 feet and intend to take it much higher, and I've read a number of threads about how to handle that. The original HAC is gone and I don't think I could rig it to the non-US carb anyway, and I've come across a couple of sources (City Racer, e.g.) that recommend smaller jets above 4,000 feet. Thoughts?

Other advice as I dive in? What else should I look out for...?

I don't see a carb insulator in the pictures you posted. The heat insulator acts as an insulator and a spacer. You will need to source that before you swap out the OEM carb. And yes, you will need smaller jets if it's coming from sea level, but I think they're included in the carb you already have. Check this photo for reference. You might also need to replace the 4 studs as some of those aftermarket carbs use bolts instead of studs. The part number for those studs is 90116-08042.

I am semi local to you. Let me know if I can be of any help.

 

[Sperl]

I don't see a carb insulator in the pictures you posted. The heat insulator acts as an insulator and a spacer. You will need to source that before you swap out the OEM carb. And yes, you will need smaller jets if it's coming from sea level, but I think they're included in the carb you already have. Check this photo for reference. You might also need to replace the 4 studs as some of those aftermarket carbs use bolts instead of studs. The part number for those studs is 90116-08042.

I am semi local to you. Let me know if I can be of any help.

Great feedback, thanks. A brand new heat insulator is in the treasure chest of parts PO included in the sale, along with an air cleaner assembly in good shape and lots of other bits. I’ll have to check on studs - good recommendation there.

That spare jets storage is a clever move, I’ll check those when I get home.

I would absolutely take some semi-local help! I’ll send you a note…

 

[Sperl]

Still gathering parts and studying the desmog pdf to reset mine during the carb swap, made some progress identifying and matching parts and need-to-change plumbing. Painter's tape tags in the engine bay to keep things straight.

I had a laugh when I eventually found the HIC valve. Maybe whoever removed the air cleaner assembly flipped it to protect it in storage?

 

[Sperl]

Windshield washer system was present and about half full but not working. The fluid in there was way funky. I tried some straight 12V to test the pump but...no luck. Removed it and pulled it apart in hopes that a cleaning would get it going but...no luck again. It did clean up nicely and went into the parts box until I'm far enough down my project list to worry about sourcing a new pump and get it back in.

I took advantage of the reservoir being out to evict some stowaways from the front fender. They're been buzzing in and out since I took delivery of the truck, this was one of four nests I've found in various nooks.

 

[sadovnik]

You’re going to need a new hard line between the fuel pump and the carb. I just went through this recently. You can make it yourself if you’re handy (unlike me), buy a new one from Redline for insane money, or get a used one. Here’s a picture of mine when it arrived vs. after some elbow grease.

 

[Sperl]

Fun win for the day was bringing the carb cooling fan back to life. I tried direct 12V and ground to the connector plug and it fired right up. Three dead wasps and a handful of leaves shot out, so I suppose it hasn't run in a long while.

The manifold temp sensor (which from wiring diagram I understand was intended to trigger this fan) was cut, so I didn't bother troubleshooting the relays and went with the straight-to-ground option detailed in a few threads (thanks, mud community ). Tested it with ground from battery, then wired in a ring terminal scrounged from some of the remnant electrical I've cut out. The fan now powers up when ignition is switched off and runs for about 20-25 minutes. Turning ignition back on interrupts the cycle and cuts power to the fan. I think I'll wire a simple switch into the ground so I can turn off the fan's auto-run; seems unnecessary in winter, for example, but we'll see.

 

[Sperl]

You’re going to need a new hard line between the fuel pump and the carb. I just went through this recently. You can make it yourself if you’re handy (unlike me), buy a new one from Redline for insane money, or get a used one. Here’s a picture of mine when it arrived vs. after some elbow grease.

View attachment 4203006View attachment 4203007

I have one from PO's parts box that matches contours from fuel pump up and around valve cover, but the last 6" or so to the carb aren't quite right. I suspect it was intended for a non-OEM carb with fuel inlet in a different spot. I resisted the urge to just bend it to fit because it feels like it would fold and crimp easily. What's the technique to adjust/shape it...?

 

[sadovnik]

Something like this, maybe?

 

[sadovnik]

Or this? https://www.summitracing.com/parts/lil-44150

 

[Sperl]

Something like this, maybe? View attachment 4203023

Oops, I definitely could have googled that. Sorry/thanks.

 

[RevISK]

Jumping right in, good for you.
Didn’t see it mentioned but do you have an FSM yet?

Anyone take you up on those lights?

 

[Sperl]

Jumping right in, good for you.
Didn’t see it mentioned but do you have an FSM yet?

Anyone take you up on those lights?

Thanks! I'm having a blast and am already learning all kinds of stuff.
I found a couple of the FSM repositories, they are great resources.

My wife convinced me to keep the lights, sorry. They're in the parts box and will make their way back on once I get the bumper sorted (future discussion, waiting on parts!). I'll edit that post offering them up.

**EDIT - turns out I can't edit my early post, sorry everyone. Maybe due to my newbie status?**

 

[RevISK]

Thanks! I'm having a blast and am already learning all kinds of stuff.
I found a couple of the FSM repositories, they are great resources.

My wife convinced me to keep the lights, sorry. They're in the parts box and will make their way back on once I get the bumper sorted (future discussion, waiting on parts!). I'll edit that post offering them up.

**EDIT - turns out I can't edit my early post, sorry everyone. Maybe due to my newbie status?**

Well, funny thing is I was actually going to suggest you hang on to them.

 

[CardinalFJ60]

Great work!! Love watching this!
I think “rustfarmer” sells the washer kit
If you haven’t already, jump on the Rising Sun forum for local advice and such. Actually, a couple very nice threads on recent 60 refurbishing and restoration.

 

[Sperl]

Great work!! Love watching this!
I think “rustfarmer” sells the washer kit
If you haven’t already, jump on the Rising Sun forum for local advice and such. Actually, a couple very nice threads on recent 60 refurbishing and restoration.

Thanks! A couple of folks have recommended Rising Sun. I don’t spend much time in the Denver area so I’m not sure I’ll make a meetup, but I’ll definitely hop on the forum to tap the local experience and expertise!

 

[JoeW]

Thise sumo gears are a game changer for highway cruising, and it looks like you have orange gasket maker on the case currently?

I rebuilt mine with orange jipe before my gear swap, leaked like it wasn't even there. I used anaerobic sealer when I did the gears and it's dry as a bone now.

 

[Sperl]

Thise sumo gears are a game changer for highway cruising, and it looks like you have orange gasket maker on the case currently?

I rebuilt mine with orange jipe before my gear swap, leaked like it wasn't even there. I used anaerobic sealer when I did the gears and it's dry as a bone now.

So I'll be honest - I had to google a couple of words and phrases from this post. But now I know what sumo gears are and have another rabbit hole to explore!

Was this meant to be on another thread...?

 

[JoeW]

So I'll be honest - I had to google a couple of words and phrases from this post. But now I know what sumo gears are and have another rabbit hole to explore!

Was this meant to be on another thread...?

Absolutely was meant for a different thread, idk how it ended up over here. Sorry about that!

 

[klip]

Good advice though. Anaerobic sealant works great. I used it to put my case together and bone dry as well.

I’ve used the plier type benders to reshape existing brake lines and they work great. They didn’t try to kink the tube at all.

 

[Sperl]

Dropped a simple on/off switch into the carb cooling fan circuit for seasonal use, mounted it to the smog equipment bracket which I decluttered a bit more while I was there. I also spent a few minutes wiping down the driver side fender area and man, that paint looks pretty good! It got me motivated to clean up the engine bay in earnest, but not yet. Future project...