FJ80 Emissions & Possible Vapor Lock

[Spadone]

Does anyone know if the FJ80s have a tendency to not start because of a vacuum issue? I'm trying to search and destroy a gremlin that seems to be plaguing my rig. The truck runs fine but has had a check engine light since I got it last August. Code has always been a P0401 - Exhaust Gas Recirculation Flow Insufficient. What normally happens - or has been happening more frequently lately is that, when warm, after I shut down, I cant get it to re-start. Nothing happens! No clicking - nothing! If I let it sit for 30 minutes or so, however, it will re-start with no issues.

Chilton says the possible trouble areas are: 1. EGR Valve Stuck Closed; 2. Short in VSV Circuit for EGR; 3. Open EGR Temp Sensor Circuit; 4. EGR Hose Disconnected; 5. ECM, but would this cause my rig to not re-start? Confused and looking for help from anyone who knows anything about vacuum systems.

 

[Springs505]

Nothing happens! No clicking - nothing!

If the starter does nothing when hot, I would start there. Often, giving a failing starter a sharp tap with a tool will help it work again. IF this is the case, replace or rebuild.

Check all wires to the starter - the thick one that goes to the + terminal on the battery (this can corrode inside and still look OK outside, check for voltage at the starter), check the solenoid wire for voltage when a friend turns the key, and check ground wires to the engine for tightness/corrosion.

I am confident that an EGR issue won't keep you from cranking, and I don't think that an ECM would, either.

Do you have a FJ80 (91-92) or an FJZ80 (93+)?

 

[Spadone]

I have a 1997 (40th Anniversary) FJZ80. Could not get the starter out yesterday. Will need an impact tool to release it from the bell housing. I did get all of the electrical Ohm tested yesterday and couldn't find anything out of tolerance (distributor, igniter, etc.)when. I did finally start it up I got a bit of a backfire on the first crank. After that, on the second crank, my rig idled high for a moment then returned to normal. Since then it has started every time. Maybe it was something as simple as a loose cable. What was really curious was following all of this my check engine light went out. The P0401 code shouldn't have anything to do with the electrical system but rather the vacuum system. I guess I will never know.

 

[Hoosier Daddy]

Did you disconnect the battery to pull the starter? That would clear the code (and also explain the revs when you started it the first time). The check engine light will probably come back after a few more driving cycles.

There are numerous good threads in the 80's section for trouble-shooting the EGR system. When my 80 threw a p0401 code two or three years ago, it turned out to be the easiest fix of all - the EGR vacuum modulator. Hopefully yours will be a cheap and easy fix too.

By the way, holler if you need a hand diagnosing the EGR.

 

[LCPilot]

I've had two FZJ80s that had a P0401 code. The first one was a bad VSV valve that feeds the vacuum modulator. THe second was a bad VSV valve, vacuum modulator and a carboned up EGR valve.

Glad it is running again.

 

[Spadone]

So it turned out that it was not the starter after all. It turns out that the neutral safety switch had burned out and, that due to a previous oil leak, the connector had started to erode. Had the switch replaced and the cable repaired now everything is running smoothly. Thank you all for the advice/guidance. I still have to tackle the VSV/EGR and some mystery leaks.