Brian/99uzj100
SILVER Star
I took my rig for it's smog test (every 2 years) and was shocked it failed as a gross polluter, with high CO (too much fuel) I was shocked because it was running so well. My bad for not getting a free sniffer test before the actual test.
Some basics on my 40:
76 CA spec FJ40
10k and 3.5 years on a professionally rebuilt 2F and carb rebuild (R.I.P. Marlin Czajkowski)
OEM 1977 FJ40 vacuum advance distributor routed to carb vacuum (Stock was vacuum retard)
Timing @7 B.T.D.C.
Dwell 41.7
Intake manifold vacuum @ 19.5
I rebuilt the carb myself this time using a Keyster rebuild kit, F.S.M.'s, and Pinheads excellent videos.
I didn't find any obstructions in the carb, just some varnish from our crappy gas. I put it back together and it failed the sniffer test again.
Here's some of the things I tested next:
Power valve operation - Pass
Thinking maybe not enough air:
Smog pump output - Pass
Air Bypass Valve - Pass
Air injection rail check valve - Fail (It was allowing air to pass both ways) Replaced with a spare that functioned properly (one way airflow)
I read on another Cruiser forum about a 60 series failing smog because of high CO and a bad air rail check valve, so I thought cool, problem solved.
Failed sniffer test again, no difference in CO!
Charcoal canister - Bench tested per FSM and disconnected during sniffer test, failed again.
I then thought maybe my Emission Control Computer might have an intermittent problem. I've read here on mud about the soldering becoming loose.
Before I looked at the ECC, I started working backwards from the carb at wired connections.
I turned the key to the "on" position for the fuel cut solenoid test "Click" sound. What I heard was a series of rapid clicks (5-10) then nothing. I removed the solenoid and bench tested it with the same result of rapid clicks.
I bench tested a solenoid from a spare carb and got a nice single click, Installed it on the carb and went for a sniffer test.
It read normal CO levels, so the tech ran the full test on the machine and it passed with lower emissions than it did two years ago!
It's worth noting that most of the threads I've read about bad fuel cut solenoids have to do with idle problems. My rig idled and ran fine.
Also the malfunctioning solenoid was aftermarket. The used one I replaced it with is clearly marked AISAN.
Some pics:
Unfortunately I skipped this page in the FSM during the carb rebuild...
So shiny and new looking, how could this be malfunctioning?
No name aftermarket
OEM for the win
Before and after smog tests
CA smog tests REALLY blow!
Some basics on my 40:
76 CA spec FJ40
10k and 3.5 years on a professionally rebuilt 2F and carb rebuild (R.I.P. Marlin Czajkowski)
OEM 1977 FJ40 vacuum advance distributor routed to carb vacuum (Stock was vacuum retard)
Timing @7 B.T.D.C.
Dwell 41.7
Intake manifold vacuum @ 19.5
I rebuilt the carb myself this time using a Keyster rebuild kit, F.S.M.'s, and Pinheads excellent videos.
I didn't find any obstructions in the carb, just some varnish from our crappy gas. I put it back together and it failed the sniffer test again.
Here's some of the things I tested next:
Power valve operation - Pass
Thinking maybe not enough air:
Smog pump output - Pass
Air Bypass Valve - Pass
Air injection rail check valve - Fail (It was allowing air to pass both ways) Replaced with a spare that functioned properly (one way airflow)
I read on another Cruiser forum about a 60 series failing smog because of high CO and a bad air rail check valve, so I thought cool, problem solved.
Failed sniffer test again, no difference in CO!
Charcoal canister - Bench tested per FSM and disconnected during sniffer test, failed again.
I then thought maybe my Emission Control Computer might have an intermittent problem. I've read here on mud about the soldering becoming loose.
Before I looked at the ECC, I started working backwards from the carb at wired connections.
I turned the key to the "on" position for the fuel cut solenoid test "Click" sound. What I heard was a series of rapid clicks (5-10) then nothing. I removed the solenoid and bench tested it with the same result of rapid clicks.
I bench tested a solenoid from a spare carb and got a nice single click, Installed it on the carb and went for a sniffer test.
It read normal CO levels, so the tech ran the full test on the machine and it passed with lower emissions than it did two years ago!
It's worth noting that most of the threads I've read about bad fuel cut solenoids have to do with idle problems. My rig idled and ran fine.
Also the malfunctioning solenoid was aftermarket. The used one I replaced it with is clearly marked AISAN.
Some pics:
Unfortunately I skipped this page in the FSM during the carb rebuild...
So shiny and new looking, how could this be malfunctioning?
No name aftermarket
OEM for the win
Before and after smog tests
CA smog tests REALLY blow!
