cruiser wouldn't start- help

[looking4pugs]

So I pull in to get gas because I am on fumes, and afterward my cruiser won't start.
It cranks
It has gas
I start checking systems while waiting for my friend to return with a tow rope, and I notice that I don't have spark.
So I think an EFI relay or bad coil.
We tow it to the house. Later that night after it has cooled I go out and it starts right up. It drives fine and everything. WTF?!?

Before the gas stop we were coming out of the mountains from biking. My buddies and I tok a more direct route. nothing technical, just steep. I was using my low gears a lot. We were also pushing hard to make it down in time to get to a store before it closed.

I noticed that when I turned the key to the on position while it wouldn't start the "hot a/t oil" light would also come on. Now after it is running fine the "hot a/t oil" and "CE" light come on before you start it but go out after the cruiser starts. I can't remember if they always came on or not.

SOoo , did I overheat the tranny, and is there a thermo safety switch that keeps you from starting a cruiser with an overheated tranny. OR are these two different problems. I don't know since I've never had a problem with it.

It is a '92 with 213K.

Help? Suggestions? comments from the peanut gallery?

THanks

 

[landtank]

Have you modified the wiring to the EFI relay? This is a very common problem with the FJ80s. There is a link in the tech section to instructions on how to fix this.

For now you will want to change out that relay as it's well on it's way to complete failure.

 

[santiagol]

The EFI relay cable fix is a must, when I replaced my 12 ga. wire with 10 ga., the red/yellow insulation was brown/brown from the heat. Landtank is right, the EFI relay is on the way out and should be replaced. Check your transmission oil, it could also be cooked.

These are very tough trucks, I have used(abused) my '91 many times and it comes right back after you give a little rest and a chance to cool off.

 

[looking4pugs]

Have you modified the wiring to the EFI relay? This is a very common problem with the FJ80s. There is a link in the tech section to instructions on how to fix this.

For now you will want to change out that relay as it's well on it's way to complete failure.

No mods to the EFI relay as far a I know of. I was thinking of finding someone that could pull the codes of the cruiser. Would that help verify it is the EFI relay?

 

[looking4pugs]

Check your transmission oil, it could also be cooked.

These are very tough trucks, I have used(abused) my '91 many times and it comes right back after you give a little rest and a chance to cool off.

Yeah, I didn't think I was abusing it that bad. The trannsmission oil is definately not cooked.

 

[Cobra Jet]

Have you modified the wiring to the EFI relay? This is a very common problem with the FJ80s. There is a link in the tech section to instructions on how to fix this.

For now you will want to change out that relay as it's well on it's way to complete failure.

where is this link? I went to the "technical Links" tab and did not see any mention of "EFI relay mod"....

can someone post the link?

 

[santiagol]

The link is: http://www.safari4x4.com.au/80scool/tech/efi_relay.html

Essentially, you replace the existing 12 ga. wire that goes from the EFI relay to the 15 amp fuse with 10 ga. wire. Do this also with the wire running from the EFI relay to the EB1 connector (under the vaccum switches).

This is done because the 12 ga. wire is supposedly unable to handle the current load, but 12 ga. at 12 volts should be more than enough for this 15 amp application. I feel that the real problem is that the EFI relay becomes excessively hot - replacing or adding a 10 ga. cable, in addition to improving the current carrying capacity of the circuit also adds a great heat sink, thus solving the problem. Pulling the cables is a bit of a pain, the FSM has tells you how to make a small tool that will help.

 

[looking4pugs]

The link for the EFI fix is down. Is htere another link for the EFI relay Mod?

 

[santiagol]

EFI Relay Fix

I did a copy/paste from some old thread that I had saved, not mine, that contains the procedure. Also at the bottom is a comment from CDan. This is pretty much the same as you get from the link.
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I did the EFI Fuse to Relay wire within the fuse block.

It was a pain in the arse to get a 10 gauge wire to fit into the little spaces for stock wiring.

I haven't done the EFI relay to EB1 #2 yet because I know where EB1 is, but I don't know which is #2 (there are three wires that go in there).

The swap within the block involved:
1. disconnect battery
2. Take fuse block cover off (inside engine bay, near intake cooling fan).
3. Remove 13mm bolt on the cab side of the block and slide it off of the bracket.
4. Remove the 2 12mm bolts holding the bracket to the inner fender.
5. Rotate the fuse block in the space you created by removing the bracket so you can see the bottom.
6. Remove bottom of fuse block (4 tabs to pop it, 2 on each side).
7. Now you can trace the wire from the EFI Fuse to the Relay.
8. The wires are a pain to get out, there is a little tab that you have to reach into the top of the plug to get to. Put pressure on this tab to the outside wall of the plug and pull from the bottom to get it out. Have patience, it is a pain.
9. Do this to the relay socket and the fuse socket, same proceedure.
10. CAREFULLY pry open and remove the old little wire from the connector.
11. Insert length of 10 gauge wire and crimp the connector.
12. solder a bit to ensure a good connection.

Plug it all back up and reassemble.

That is the basic process.

The EB1 connector (which is the grey connector on the first branch from the alternator going to the vacuum switches behind the fuse block) is roughly the same process if you know which wire to get after. I am assuming the Red and Yellow wire opposite the one replaced for the fuse is the one that goes to the EB1.


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I found my old notes:

There is a 12 gauge wire, red with a yellow tracer that goes from the EFI fuse to the EFI relay. That needs to be changed to 10 gauge. Then there is a 12 gauge wire, yellow with a red tracer that goes from the EFI relay to EB1. That also needs to be changed to 10 gauge. It is a good idea to replace the EFI relay at the same time (90987-02004-83).

 

[looking4pugs]

THanks for the info and the help

 

[trbrown]

I've had the same problem after the mod. I replaced the efi relay and the rig started right up, a day latter the rig would not restart. I still had the old relay in the ashtray so I swapped and the rig restarted. I've swapped them so many times now I don't know which is the newer of the two. My mode was done before I bought it so my problem lies there I'm sure.Good Luck