Air Injection Nozzle Ports in Cylinder Head

[LXCRSR]

I have an '82 FJ40 that was de-smogged some time ago while the vehicle resided on the east coast.

I am needing to put the smog and emissions systems back on the vehicle in order to get it to pass emissions in Utah. However, the ports where the air injection nozzles go either have plugs or in the case of the two closest to the firewall, have the nozzles left in them. This wouldn't be so bad if they weren't corroded so badly (hence my mention of the east coast above).

I am currently soaking everything in penetrating oil hoping beyond hope that I will be able to get the plugs and injection nozzles out. But being a realist, I am doubting this is going to happen.

If I can't get them out, what are my options? Would a good machine shop be able to back out the plugs and nozzles and clean the threads up without ruining the motor? Or would I be stuck with needing to get a new cylinger head?

Someone please give me some hope.

Tom

 

[FJ40Jim]

You won't need a new head.

Worst case: the head will have to come off, get tore down and hot tanked so the machinist can see what needs to be done, then clean and re-tap the AI ports.

 

[LXCRSR]

Jim,

Can this be done without having to pull the motor? Any idea of the cost of having this done (need to prepare the wife for this type of thing)?

Tom

 

[Pin_Head]

A good machine shop can get them out even if the head of the nut breaks off. Welding up the inside of the nozzle and welding a new nut on them is the most common way with the engine in the truck. When the weld cools, the metal shrinks, making it easier to get out.

 

[FJ40Jim]

Jim,
Can this be done without having to pull the motor? Any idea of the cost of having this done (need to prepare the wife for this type of thing)?

Like Pin says, it usually is not a problem that requires head removal.

Worst case, $50 per threaded hole, if they are really F-ed up. Usually much less.

 

[LXCRSR]

FJ40Jim,

This is good news! So I am looking at $300 (since mine are pretty f-ed up).

I think I may still get to sleep in the bed after telling her this.

Thanks for you help.

Tom

 

[LXCRSR]

Pin_Head,

Thanks for your help too!

Tom

 

[vtcruiser60]

I have a set of air injection nozzles on my shelf it helps you at all. Send me a pM and let me know your address.

I am all about generating cruiser Karma...especially if it helps me get back into my own warm bed.

 

[LXCRSR]

vtcruiser60,

Thanks for the offer on the air injection nozzles. I am already working with someone to get everything I need but if we come up short on nozzles, I will definitely send you a PM.

Tom