Builds 1993 80, BUILD, another "it has begun" for fjbj40!

[fjbj40]

Pulled the down pipes as I want to move the O2 sensors to the manifolds in the PAIR position.
Luckily the bolts on the cat were new and came of without effort.
Having luck again one O2 sensor looks pretty much new, the other looks original and so did the nuts!
I broke out the carbide burr and sliced through easily

 

[fjbj40]

New bearing installed in idler pulley, nice and smooth, only $5.

 

[fjbj40]

Just checked valve clearances, intake all between .008-.010”. Exhaust all between .012-.014”.
All within spec and I am happy exhaust are closer to max clearance vs min clearance

 

[fjbj40]

Painted valve cover and the center plastic garnish.
Also bent up a nipple protector, it’s drying

 

[Cruzerman]

You may want to also wrap the wiring harness in some heat reflective / heat shield tape as well. Just a thought.

 

[fjbj40]

You may want to also wrap the wiring harness in some heat reflective / heat shield tape as well. Just a thought.

Do you think it is necessary with the EGR pipe removed?

 

[Cruzerman]

Do you think it is necessary with the EGR pipe removed?

Probably not. If there is nothing hot in the vicinity, no reason to insulate it.

 

[fjbj40]

Stuff arrived
Both front 1/2 shafts, birfs, basically everything to put it back together
Except I forgot to order intake manifold gasket on cyl head side. I originally never planned on removing lower intake.

 

[fjbj40]

My buddy made me a axle seal installation tool, work of art and it works absolutely perfectly. Seal goes in straight and ends up being perfectly flush all the way around.
I installed new axles so when they wear I can have the tool machines down to overdrive the seal.

 

[fjbj40]

Knuckles all finished. New Caliper sand pads not in the budget, they still function so I will run till they need replacement.

Next up is all suspension bushings

 

[fjbj40]

Just pulled the power steering reservoir apart to clean the filter inside. 20 minute job from start to finish. It was pretty dirty inside with sludge and super fine particles in the filter. All clean now. I rebuilt the PS pump yesterday so i figured just as well clean the reservoir.

 

[fjbj40]

One more!

 

[fjbj40]

Painted down pipes with VHT flameproof along with the stone shields and installed. Blocked off the O2 sensor ports on pipes and moved them to the PAIR ports. Also installed a Sunsong PS hose, fit perfectly, only drawback is the hose that goes into the box is 18mm instead of factory17mm.

Finished reassembling the TB and reinstalled repainted air filter box.

Flushed a litre of brake fluid through the brake system.

 

[fjbj40]

Few more

 

[fjbj40]

Back together and purring! Cold start use to be 15-1800 rpm, now it’s about 1100 and idles smoothly at 625-650. Idler bearing replacements make it incredibly quiet.
Only problem is CEL, aft sensor is dead! Guess the removal and reinstall killed it. The other sensor looks brand new, no faults on that one.
Zero ohm reading on dead unit.

 

[baldilocks]

What do you credit with producing the slower cold start idle speed?

 

[LandLocked93]

One more!

View attachment 2211977

Did the lid clamp back to the body of the reservoir satisfactorily? What is the condition of the steering box? Curious if cleaning the filter results in functional improvement when (if) the steering box is an unknown.

 

[fz1boxer]

Fantastic pictorial thanks for all the pictures this will help out a lot of future owners.

 

[fjbj40]

What do you credit with producing the slower cold start idle speed?

I think the carbon removal from the throttle body and IAC seat. There was quite a build-up of carbon between the throttle plate and the bore. I literally had to scrape it off with a dental scalpel.
I have also read others had a smoother idle after EGR delete also.

 

[fjbj40]

Did the lid clamp back to the body of the reservoir satisfactorily? What is the condition of the steering box? Curious if cleaning the filter results in functional improvement when (if) the steering box is an unknown.

Yes, I put the reservoir and lid assembly in my vice and clamped them together before I bent the tabs back over. No leakage experienced after.

Here is where I got the idea