FJ40 carb rebuild options

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black95

black95

10 Year 15 Year
Joined
Aug 25, 2008
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Colorado
I just bought an FJ40 and was wondering what you 'mudders think I should do with the carb. This cruiser has been sitting or over 5 years, so I want to do something with the carb before I just try and fire it up. I'm very mechanically adept, so I will not pay anyone else to do this.

Called Mark's offroad, and he doesn't sell carb kits anymore.

Thought about the trollhole carb, but my cruiser is perfectly stock, so I kinda want to keep it that way. What are the benefits if any to desmogging? I live in Colorado at 8,500 feet and wheel trails above 10,000 on a regular basis.

Does Napa sell carb kits? I'm not one of those "keep everything Toyota" guys, so that would be an options if they sold them.

Thoughts???
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Nice Cruiser!

Yes, Napa sells carb kits for these. Also, any number of supporting Mud vendors also sells these kits. You can click on the vendors link above to find a vendor such as Cruiser Outfitters - www.cruiseroutfitters.com - that sells a good quality kit.

Congrats on your purchase!

:cheers:
 
I just did this rebuild on my 78, take your time. I used a Ultrasonic Cleaner (heated) and simple green 1:4 plus 1 teaspoon of Dawn Dish Detergent and mine looks much better....don't know how it will run yet. Take some pics up close...once you get it down to pieces and start putting it back together it will help. Go ahead and get a Diaphragm for your secondary assist. NAPA has the best price on these. Be sure to check out your solenoid to make sure it is working (mine was not) . I spent an entire day cleaning my parts and sub assemblies in the Ultrasonic. My particular Ultrasonic got to around 140 deg. F so I could only stand to handle the parts for a sec or two taking them out...keep some old towels or clean shop cloths handy and the parts dry really quickly due to the heat. I finished off by squirting Carb cleaner through every orifice on the carb to be sure they were clean and open....wear safety glasses(don't ask) As soon as I get my fuel lines in I am going to install mine and drive the old gal after sitting up for several years.....a work in progress......what Cruiser isn't ?

Dwight


PS I have never used it but a friend used some full strength Castrol Super Clean a few years ago on a RC Airplane engine and it ate the aluminum away and ruined the engine...so be careful with the carb.
 
black95 said:
I just bought an FJ40 and was wondering what you 'mudders think I should do with the carb. This cruiser has been sitting or over 5 years, so I want to do something with the carb before I just try and fire it up. I'm very mechanically adept, so I will not pay anyone else to do this.

Called Mark's offroad, and he doesn't sell carb kits anymore.

Thought about the trollhole carb, but my cruiser is perfectly stock, so I kinda want to keep it that way. What are the benefits if any to desmogging? I live in Colorado at 8,500 feet and wheel trails above 10,000 on a regular basis.

Does Napa sell carb kits? I'm not one of those "keep everything Toyota" guys, so that would be an options if they sold them.

Thoughts???
Click to expand...

yes, autoparts stores sell them, usually a special order item, and then you still have to make sure it's not for a Weber or Rochester 4-barrel carb :bang: - don't ask me how I know :rolleyes:

that said, why not call Kurt and get what you really need for a better price ?

X2 on cruiseroutfitters.com :cheers:

BTW, the carb cleaner you get in a bucket can at the autoparts store (for like $25) works just fine :D
 
I love my troll hole carb. It is almost identical to the stock carb it replaced. 3/8" shorter but filled with spacer. 1 hour install, runs great and maintains the stock look. Good luck.
 
If you're like me and a "big parts" guy", send it to Mark A in Burbank and have him rebuild it. I can do suspension, racks, and power steering, but I have no patience for a carb rebuild. He made my F.5 run like brand new.
 
I get all my kits from Napa and if Kurt has them there you go if your planning on owning this for awhile then I suggest buying a kit break out your FSM and learn to rebuild it yourself. They really are a simple carb to rebuild I have done all mine and a few buddies. remember Clean , Clean , Clean. I used the Carb Dip they sell at Napa also. Nothing againest the professional carb rebuilders but why pay 3 or 4 hundred bucks without trying to rebuild it yourself the kits cost around 30 bucks.
 
I've got some pretty good skills, and can fix just about anything (just ask my daughter) :) The cruiser happened to have come with two FSM's, I haven't had a chance to look at either one, I will do that and see how the carb breaks down. Thanks for the info guys, it really helps.
 
Can't believe how much of a project this has turned out to be! I bet everyone feels that way. lol. I have been digging through the interior of my cruiser, fighting rust, mounting seats, cleaning, pulled dry rotted tires off and took wheels to powder coater, chasing bad fuses to get the heater blower to work....i just started to look at the engine.

Pulled the plugs and put a shot of Marvel Mystery oil in the cylinders, letting that sit or a while before I prime the oil pump and turn the engine by hand. looking through the spark plug holes with a flashlight, the cylinder walls look very good.

I checked with Napa on some carb rebuild kits, and they could not find one anywhere in the nationwide system. bummer. I called Mark's Offroad and he won't sell the remaining kits he has because he says they are too hard to get. Bummer. Guess I will keep looking. Friend of mine made me a DVD copy of the rebuild video from 'mud for the use of my engine hoist, so looking forward to getting this carb rebuilt.

As a side note, anyone know if you can get vacuum line that is of the OEM quality that Toyota used? I hate the cheap stuff auto parts stores sell, seems to dry rot rapidly. My cruiser was inhabited by a family of mice that ate most of the vacuum lines...and a million moths that ate the air cleaner paper. :) Talked to Toyota and they said they can order every piece on the engine, but at substancial cost, and they can't get it in bulk. That's really too bad, the factory vacuum line is very high quality.
 
The OEM 3mm vacuum hose is still available from Toyota. Search around on this site, someone posted up the number to buy it in lengths. cruiserdan at American Toyota probably knows the part number too, try giving him a call. Some have switched to 3mm silicone hose from McMaster-Carr et al, and seem to be happy with that as well.

I know several guys in my local club have recently bought rebuild kits for their carbs from NAPA - Keyster is one popular brand. Maybe the '78 parts are harder to find?
 
If you building a 30+ year old carb go ahead and get new float and secondary diaphragm. I don't know if the float is still available from Toyota but don't skimp on this part.
 
Am reviving this thread as I may be in need of aisin carb rebuild. Should I look for someone local to me or send to professional? Or should I just replace it?
 
BlueMarblePA said:
Am reviving this thread as I may be in need of aisin carb rebuild. Should I look for someone local to me or send to professional? Or should I just replace it?
Click to expand...
Would vote for sending it out to a pro who's spent a lot of time on Aisan carbs. You'll save lots of time and frustration, and get back to driving your truck sooner.
 
BlueMarblePA said:
Am reviving this thread as I may be in need of aisin carb rebuild. Should I look for someone local to me or send to professional? Or should I just replace it?
Click to expand...
Rebuild it yourself. It is not difficult, just watch and follow pin heads videos. It takes an hour or so to disassemble and reassemble. However I would let it soak over night it carb dip. Easy job and you'll have a much greater understanding of how the thing works when you're done. Good luck.
 
samatulich said:
Rebuild it yourself. It is not difficult, just watch and follow pin heads videos. It takes an hour or so to disassemble and reassemble. However I would let it soak over night it carb dip. Easy job and you'll have a much greater understanding of how the thing works when you're done. Good luck.
Click to expand...
This sounds like a great idea and this is what I would love to do, but is it really feasible for someone who has never done it?
 
BlueMarblePA said:
This sounds like a great idea and this is what I would love to do, but is it really feasible for someone who has never done it?
Click to expand...


I rebuilt mine the first time, it is not that difficult, just pay attention to detail. Watch the vids from Pinhead, read through the FSM, and take tons of pics, every step of the way, pics, pics, pics.
 
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