'77 fj40 California Help locating vacuum leak and routing of emissions

[Broc2C]

Recently acquired (Sep. 11 2016). California Spec. 1977. Was sitting since 2009. I rebuilt the carb. and have all smog related components installed. Now getting it ready to pass CA smog before I forge on.
I have the factory service manual as well as the emissions repair manual + Haynes manual to refer to. Previous owner passed and a relative provided a receipt for complete engine rebuild 30,000 miles ago dated late 2000. Other than that not much of a background.

Following the troubleshooting guide in the emissions manual, the BVSV (lt. blue) has been determined to be bad.

I am struggling with two issues: the routing of vacuum lines and a vacuum leak.

Vacuum lines first...When I compare the VSV currently on the vehicle, to any other seen on-line for comparison (CA spec 1977); it matches up. The VSV noted in the service manuals depict a different set up entirely. The service manual indicates two "0" ports and is without a no. 5 port. Note on the schematic where the vacuum line coming from the gas filter on the intake manifold splits and goes into the zero "0" ports. This has me a bit confused.

Vacuum leak: I have tried soapy water and propane enrichment and the only leak I could find was at both of the connections to the pipe leading from the EGR to the EGR cooler. Can this be the cause?
I cannot get it to idle down properly and the exhaust indicates a lean burn; it stinks & burns your eyes.

The 2nd to the last photo is what my VSV sticker should look like- I think.

Any advise would be much apreciated - Thank you in advance.

 

[Broc2C]

Schematic view doesn't correspond to actual VSV

 

[spotcruiser]

Just curious, what's the month of manufacture for the truck and what year is that hose routing diagram from? Is there just the one BVSV at the thermo housing?

I ask because a 9/77 truck would be a '78 model year. My Sept. 77 truck has two BVSVs, which agrees with the OEM 78 emissions schematic. Perhaps your truck is a later version?

 

[iptman]

8/77 CA spec here. This is my sticker.

You should start by replacing all the vacuum tubing with OEM which you can get from a dealer in 30cm sections. I think I bought 15 sections for less than $40. I also follwed the page you posted from the FSM. Hopefully you have all the splitter/connectors. Let me know if you need any specific pics and I'll post them up. We Cali spec owners need to stick together.

 

[Broc2C]

Just curious, what's the month of manufacture for the truck and what year is that hose routing diagram from? Is there just the one BVSV at the thermo housing?

I ask because a 9/77 truck would be a '78 model year. My Sept. 77 truck has two BVSVs, which agrees with the OEM 78 emissions schematic. Perhaps your truck is a later version?

It is March 1977. The hose routing diagram is from the 1977 factory repair manual. Yes just one BVSV. I have the '78 and '76 factory emissions manual and neither compare to what is present in my '77 -

 

[iptman]

SOR has a reprint of the 77 emissions manual for $50. Only place I've found it.

 

[Broc2C]

8/77 CA spec here. This is my sticker.

View attachment 1345384

You should start by replacing all the vacuum tubing with OEM which you can get from a dealer in 30cm sections. I think I bought 15 sections for less than $40. I also follwed the page you posted from the FSM. Hopefully you have all the splitter/connectors. Let me know if you need any specific pics and I'll post them up. We Cali spec owners need to stick together.

I agree about the tubing I had the blue stuff lying around and thought I would use it just to get it dialed in. I appreciate that you are willing to post pictures of your VSV it could be that I have the wrong one. If you post a pic depicting the ports, that would be great. Also could you write in text what the numbers on the sticker relate to, it is a bit difficult for me to read on you picture. Thanks!

 

[78fj40mg]

Is your VSV original to your vehicle?
Also the VSV looks modified or repaired are you sure it still works?

I recommend the 77 emissions manual as each year is different, the '76 and '78 emissions manuals will be of no use to you.

 

[Broc2C]

SOR has a reprint of the 77 emissions manual for $50. Only place I've found it.

I have the '77, Meant to say in addition to the "77 I looked at the '76 & '78 as well...

 

[78fj40mg]

Here's a link to the '77 emission manual Page 223 Land Cruiser Toyota Maintenance, Emmissions & Front Axle Manuals

 

[Broc2C]

Is your VSV original to your vehicle?
Also the VSV looks modified or repaired are you sure it still works?

I recommend the 77 emissions manual as each year is different, the '76 and '78 emissions manuals will be of no use to you.

Is your VSV original to your vehicle?
Also the VSV looks modified or repaired are you sure it still works?

I recommend the 77 emissions manual as each year is different, the '76 and '78 emissions manuals will be of no use to you.

I have the '77, Meant to say in addition to the "77 I looked at the '76 & '78 as well...

As far as the electronic aspect it tested fine. Have yet to test for vacuum and drivablity. trying to get the routing in place first. Yes that is a bit of JB weld (there when I got it).

 

[78fj40mg]

I have the '77, Meant to say in addition to the "77 I looked at the '76 & '78 as well...

Is this diagram from the '77 emissions manual?

 

[Broc2C]

This is where the above schematic is from...The 1977 emissions repair manual- just so there is no confusion. I have this to refer to.

 

[Broc2C]

Is this diagram from the '77 emissions manual?

Yes.

 

[78fj40mg]

OK great, first determine if your engine has all the components outlined in the diagram, second make sure all the vac hoses are connected correctly in accordance with '77 manual.

Regarding your vacuum leak use starting fluid while engine is running spray the areas that you suspect of having a leak, if there's a leak the engine will surge, turn engine off and replace all leaky vac hoses.

 

[Broc2C]

OK great, first determine if your engine has all the components outlined in the diagram, second make sure all the vac hoses are connected correctly in accordance with '77 manual.

Regarding your vacuum leak use starting fluid while engine is running spray the areas that you suspect of having a leak, if there's a leak the engine will surge, turn engine off and replace all leaky vac hoses.

Yes all good info. In the beginning of the post I had identified all parts as being present and that I had checked for vacuum leaks. I guess what I am hoping to get from this is post is: Do I have the correct VSV for my application and is the leak in the pipe leading to the EGR cooler going to create a significant vacuum leak, which would effect idle and/or a lean condition, or do I need to look elsewhere.

 

[spotcruiser]

Can you read the part number at the top of your VSV. I can't quite make it out in the photo. According to the fiche, the part number should be 17650-61040 for a Cal. Spec. 8/76-9/77 VSV.

That agrees with the photo posted by iptman.

 

[iptman]

I think that was a stock photo he found not his vsv. His vsv appears to have a faded sticker on it.

 

[spotcruiser]

Yeah, I see that now. I corrected my post #17.

I think that was a stock photo he found not his vsv. His vsv appears to have a faded sticker on it.

 

[iptman]

See if some of these pics help. I don't think that egr pipe is part of the vacuum system. It doesn't

look stock either so you may have an issue on the visual inspection.