FJ40 Cooling System Complete Overhaul

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Apr 25, 2021
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Just want to share with you about the major work I did to my 1974 FJ40 with the hope that this will ellicit insights or solutions to the challenges am facing now. I overhauled my rig's cooling system by installing first a set of Thermostat as I discovered there was none inside its housing when I opened it for the first time. I also installed a Bypass Hose as there was none as well and replaced all its upper and lower wornout radiator hoses . The stock Radiator was also replaced with a new one with a Nippon Denso Reservoir. Since almost all of the parts of its cooling system were replaced, I decided to replace as well its Water Pump. All of the parts installed are brand new. However, when I started using my rig, I was not happy with its performance. The engine temperature goes up beyond its acceptable level after 10 minutes of idling or driving it. And I believe it will go beyond the Red Line level if I will not switch off its engine to prevent from further heating. Am a bit disappointed because all of the parts i used came from reputable parts providers like VintageTeqParts for the Thermostat, Bypass Hose, Waterpump and Reservoir and Rockauto parts for the Radiator. Prior to overhauling its cooling system, my rig could run more than an hour without overheating. I decided to replace the cooling system parts because they were just too worn out to maitain and would not give me peace of mind when am on the road. Now, I don't know how to fix this mess anymore. Would appreciate to hear any sound insight from anyone. Thank you in advance.
 
Just want to share with you about the major work I did to my 1974 FJ40 with the hope that this will ellicit insights or solutions to the challenges am facing now. I overhauled my rig's cooling system by installing first a set of Thermostat as I discovered there was none inside its housing when I opened it for the first time. I also installed a Bypass Hose as there was none as well and replaced all its upper and lower wornout radiator hoses . The stock Radiator was also replaced with a new one with a Nippon Denso Reservoir. Since almost all of the parts of its cooling system were replaced, I decided to replace as well its Water Pump. All of the parts installed are brand new. However, when I started using my rig, I was not happy with its performance. The engine temperature goes up beyond its acceptable level after 10 minutes of idling or driving it. And I believe it will go beyond the Red Line level if I will not switch off its engine to prevent from further heating. Am a bit disappointed because all of the parts i used came from reputable parts providers like VintageTeqParts for the Thermostat, Bypass Hose, Waterpump and Reservoir and Rockauto parts for the Radiator. Prior to overhauling its cooling system, my rig could run more than an hour without overheating. I decided to replace the cooling system parts because they were just too worn out to maitain and would not give me peace of mind when am on the road. Now, I don't know how to fix this mess anymore. Would appreciate to hear any sound insight from anyone. Thank you in advance.

Btw, everytime after I switch off its engine because of uncontrollable rise of temperature, water from the Reservoir goes out from its exhaust hose and at the end some water from the Radiator goes out and fills in the reservoire tank up to the cap level.
 
You need to Burp the cooling system.
Get a splash less coolant funnel. YOU TUBE how to use it.
I loosen a temperature sensor on my 2Fs head. This helps to let air escape.
You must purge the coolant jackets, hoses and lines of AIR.
It helps to gently squeeze the upper radiator hose as well. This forces air out of the system.
Air trapped in your cooling system will cause it to overheat. I'm sure the new parts are just fine.
 
You need to Burp the cooling system.
Get a splash less coolant funnel. YOU TUBE how to use it.
I loosen a temperature sensor on my 2Fs head. This helps to let air escape.
You must purge the coolant jackets, hoses and lines of AIR.
It helps to gently squeeze the upper radiator hose as well. This forces air out of the system.
Air trapped in your cooling system will cause it to overheat. I'm sure the new parts are just fine.

Thanks @samatulich . Will try your advice.
 
This is good advice @samatulich . With all the other work you have done @FES74 it will likely solve your issue.
 
This is good advice @samatulich . With all the other work you have done @FES74 it will likely solve your issue.
John, is it normal for air bubbles to keep coming out for a long time, even after the thermostat has opened up? I was getting a few small bubbles intermittently for a long time….. just wondering why that might be. I don’t seem to have any leaks. I could have a small leak where I have a Prestone Tee in the heater line. That’s all I can think of.
 
John, is it normal for air bubbles to keep coming out for a long time, even after the thermostat has opened up? I was getting a few small bubbles intermittently for a long time….. just wondering why that might be. I don’t seem to have any leaks. I could have a small leak where I have a Prestone Tee in the heater line. That’s all I can think of.
Not at all unusual for it to take a long time for ALL the air to bubble to the top. Best practice:

A) raise the front end several inches off the ground
B) turn the front and rear heaters on LOW, not high
C) turn the engine on at idle speed…20-30 minutes is what I suggest

and then if no more bubbles for 5 minutes or so:
D) increase the idle speed to 1500-2000 rpm for maybe 5 minutes…if no bubbles, consider it done. And for good measure, keep checking your water level for several weeks.

There‘s other methods for success, but this has ALWAYS worked for me.
 
One other thought. Sometimes you could have a leak & not be able to find it …or even be aware of it. If you want to be sure, go to almost any major auto parts store & borrow their radiator pressure tester. Leave your deposit, take it home, test you system, return it & get your deposit back. Simple job.
 
I wonder why the tstat was pulled? Are you saying it would overheat after an hour? Your a little unclear.
 
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