Builds Gen. Waverly

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Some smog tech for today, thanks to @Spike Strip! He was kind enough to send me a new check valve, to see if that hopefully helps my 0% O2 readings on the smog check. The smog pump was rebuilt by B-Z about a year ago, but I never checked the check valve on the air rail, and it was definitely blocked up with carbon and trash. I tried blowing through it while on the rig, and didn't get much going out the other side. Certainly way less than what I got from the new one once received.

Here's what it looked like pulled off the rig, plenty of sooty goodness in that pipe but nothing terrible. Used a 22mm wrench to support the air rail, and a 30mm wrench to take it off after soaking with PB overnight. Came right off but there was a bit of effort involved, I could see how it would be easy to collapse the rail without supporting it.

IMG_0788.jpeg


And the old one off the rig. I dumped a ton of brake cleaner in it to see if I can get it to clear up some, will hang on to this as a spare just in case. U-joints and flanges were off yesterday's driveshaft project on the 40.

IMG_0789.jpeg


New one for comparison. Good quality and fit right on the end of the air rail. The bib is a tiny smidge smaller than the OEM one, but it works fine.

IMG_0790.jpeg


Anyhoo, that's done. Hoping it helps long term, interested to drive it this week and see if it makes any noticeable difference.

EDIT - first drive and there's a tiny bit more pep from the ol' 3FE. Could be in my head though - pep and 3FE don't really go together..
 
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So... the General gave me a little heartburn yesterday, going out to do some yard sale stuff. Hard start at one stop, lots of cranking but eventually fired up, then no start with lots of cranking at the last stop. Fortunately wasn't too far from home, called AAA to make sure it wasn't the battery. AAA tech said the battery checked out, but then tried it himself and it fired right up after giving it a little gas when starting. Which doesn't really make sense to me, since it's "fool injection."

The only thing I can think of why that worked is the TPS has moved, so I should probably give it another once-over. Didn't throw any codes either. I also followed the FSM on the ISC, which tested fine, and then followed the rest of the test procedures listed. Changed plugs back to the W14s rather than the 16s. 16s ran just a smidge hot, with a small black sooty spot on the insulators from 3 and 4, but no trash on them at all which was nice. We'll see how it goes with the colder plugs.

However, I did pull the new fuel pressure regulator off and threw the one that came with the rig back on, and that seemed to help, fired right up after cranking twice. Will drive it a few times this week and see how it goes.
 
All my starting (intermittent) issues were resolved with a thorough Cold Start Injector cleaning.

Weird stuff like, I just topped of the tank and won’t start for 10 minutes. Or no start in higher humidity.

Fires off every time now, or legend has it… 🤫
 
Right on. I will have to toss my spare in the back just in case. The one on there came from Death Valley Paul (RIP), while I was going through the CA smog nonsense the first time around. I did loosen the banjo bolt on the cold start injector and got a healthy spray of gas, so I know it's getting fuel, but it could be t*ts up too.

I also ordered a new air filter, the one on there is nasty. Did not help to try and start without one yesterday, though.
 
Well, here's the answer to what I've searched on Mud and elsewhere for - the Exped MegaMat Duo Medium fits in the back of the 60/62 when fully inflated. It is technically 41 x 72" and the space in the back of the rig is more like 40 x 70", but since it's inflatable, I figured it would squish up just a smidge where it needs to. I will probably deflate this a bit to make up for the smaller area. But, it fits FTW! Certainly isn't cheap (got it on sale from Backcountry, REI's anniversary sale is coming up soon), but it IS really nice.

Assuming I don't have to report for jury duty on Friday, I'm taking my youngest out camping for the weekend. Just putting this out into the universe - please don't pick me!

IMG_0801.jpeg


IMG_0802.jpeg


IMG_0803.jpeg
 
majdomo said:
Well, here's the answer to what I've searched on Mud and elsewhere for - the Exped MegaMat Duo Medium fits in the back of the 60/62 when fully inflated. It is technically 41 x 72" and the space in the back of the rig is more like 40 x 70", but since it's inflatable, I figured it would squish up just a smidge where it needs to. I will probably deflate this a bit to make up for the smaller area. But, it fits FTW! Certainly isn't cheap (got it on sale from Backcountry, REI's anniversary sale is coming up soon), but it IS really nice.

Assuming I don't have to report for jury duty on Friday, I'm taking my youngest out camping for the weekend. Just putting this out into the universe - please don't pick me!

View attachment 3901372

View attachment 3901373

View attachment 3901374
Click to expand...
Dang, can only find this on Amazon US and with shipping and VAT would cost $430.
Wifey says "NO". :ban: lol
 
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Take a look at the rest of the Exped line, they are a Swiss company so my guess is that they make one for the EU that has the same dimensions. Maybe it goes by a different name over there? The metric dimensions on this as listed on the bag is 183cm x 104cm.

On the shaped one - the length in the bed is a strict 70" / 178cm between the tailgate and rear seat folded up. 190cm might be a little too much, making it bunch up. I also didn't get the dimensions on width behind the wheel wells, but can if it helps.
 
majdomo said:
Take a look at the rest of the Exped line, they are a Swiss company so my guess is that they make one for the EU that has the same dimensions. Maybe it goes by a different name over there? The metric dimensions on this as listed on the bag is 183cm x 104cm.

On the shaped one - the length in the bed is a strict 70" / 178cm between the tailgate and rear seat folded up. 190cm might be a little too much, making it bunch up. I also didn't get the dimensions on width behind the wheel wells, but can if it helps.
Click to expand...
Yeah, the width of the seat above the wheel wells would be great (I would do it myself but my truck is still 5 hours north of going through final prep for inspection). And I did factor in that it was a bit too long but that model has a break in the top section that can fold up and might make a comfy pre-sleep reading position:
1746717435013.png

It looks to be at least ~20-25cm so folded up like that would leave enough room. I'm 177cm, so, in that config, my feet might slightly overhang.
 
I'll measure it later tonight when I get home. I like that foldy bit at the top!

@zeeklafreek - Measurements - from tailgate closed to the rear of the wheel well, 71cm / 28"

IMG_0806.jpeg


Across the rear tailgate, at the center of the plastic trim at the end, 142cm / 56"

IMG_0807.jpeg


Flush across the back, edge to edge ignoring the trim, 150cm / 59"

IMG_0808.jpeg


Ahead of the wheel well to the back of the seat bottom folded forward, safely 29cm / 12"

IMG_0809.jpeg


Finally, between the rear doors, 152cm / 59.75"

IMG_0810.jpeg


Hope this helps! Got out of jury duty, so we are on for camping tomorrow, excited!
 
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Camping trip over the weekend was a mixed bag. We had a great time, but a 4 hour drive across the LA basin to the San Jacintos on the hottest day of 2025 so far, without solid working AC took its toll. We arrived in the mountains to find all the yellow post sites already taken, some by people who looked like they'd been living there for a while. SoCal is expensive to live in, but damn.

Found a developed campsite as the sun was going down, got camp all set just in time to catch this.

IMG_0811.jpeg


And since it was raining only a day or two before this, the wood was all damp and we couldn't get a fire going for anything. Fortunately it stayed warm overnight, only got into the low 60s by early morning. The Exped pad did great for the two of us though.

IMG_0813.jpeg


Next morning. Great view, but had to cut it short and come home early. More on that later.

IMG_0815.jpeg
 
Saturday morning, drove into town to pick up a few things that we'd forgotten at home. After leaving the rig parked for about 5 minutes, it refused to start again.. shot some ether into the intake, and it sputtered to life for half a second, but that was it. I was literally on the phone with AAA when one last turn of the key got it started again. Drove back to the campsite, threw all our stuff in the back with the engine running, and cannonballed home. Daughter none too pleased, but we avoided a long tow.

I'd run through the FSM tests on the FI system already, but tried and succeeded in replicating the problem in the driveway yesterday morning. Cold start timing sensor checked out, and both the EFI and circuit switch relays were fine. ISC checked out , swapped out the plugs and wires, timing is spot on, changed out the cold start injector with another known good one, along with the FPR. However, jumping Fp to B+ gave me no fuel pressure. Took out the jack and support from the driver's rear quarter panel, got down to the plug behind the driver's rear wheel well, and here's what I found:

IMG_0822.jpeg



IMG_0823.jpeg


Yep. Clipped the plugs, soldered the wires together and it fired right up. I am thinking this has been the source of a few problems during my ownership - fluttery idle (hopefully), that one time it tried to die on me after getting off the freeway, the other couple of times when it DID die on me after getting off the freeway.

I would recommend any 62 owner to check it out and make sure this plug is solid, or even better, just solder the damn thing together as PM. What a pain. And I almost threw more parts at it by buying a new fuel pump, fortunately that money can go toward other stuff.

One last thing, my Chinesium low pressure filler hose for the AC arrived. 5 minutes later, had ice cold AC with a few ounces of R134A. PO did the conversion, but it was low and though I'm sure if there's a slow leak, this won't last, am enjoying it for now.

IMG_0824.jpeg
 
majdomo said:
Saturday morning, drove into town to pick up a few things that we'd forgotten at home. After leaving the rig parked for about 5 minutes, it refused to start again.. shot some ether into the intake, and it sputtered to life for half a second, but that was it. I was literally on the phone with AAA when one last turn of the key got it started again. Drove back to the campsite, threw all our stuff in the back with the engine running, and cannonballed home. Daughter none too pleased, but we avoided a long tow.

I'd run through the FSM tests on the FI system already, but tried and succeeded in replicating the problem in the driveway yesterday morning. Cold start timing sensor checked out, and both the EFI and circuit switch relays were fine. ISC checked out , swapped out the plugs and wires, timing is spot on, changed out the cold start injector with another known good one, along with the FPR. However, jumping Fp to B+ gave me no fuel pressure. Took out the jack and support from the driver's rear quarter panel, got down to the plug behind the driver's rear wheel well, and here's what I found:

View attachment 3905773


View attachment 3905774

Yep. Clipped the plugs, soldered the wires together and it fired right up. I am thinking this has been the source of a few problems during my ownership - fluttery idle (hopefully), that one time it tried to die on me after getting off the freeway, the other couple of times when it DID die on me after getting off the freeway.

I would recommend any 62 owner to check it out and make sure this plug is solid, or even better, just solder the damn thing together as PM. What a pain. And I almost threw more parts at it by buying a new fuel pump, fortunately that money can go toward other stuff.

One last thing, my Chinesium low pressure filler hose for the AC arrived. 5 minutes later, had ice cold AC with a few ounces of R134A. PO did the conversion, but it was low and though I'm sure if there's a slow leak, this won't last, am enjoying it for now.

View attachment 3905781
Click to expand...
I ran through all of what you just checked when I discovered that I really didn’t clean my cold start injector as well as I thought. However, that plug is zero fun to get to so permanently mating it and saying bye sounds great.

I also have/had a slow leak in my ac, after filling it a couple times, I tried some of the snake oil 134a that claims to have a sealant in it… well, it’s the longest my AC has held tight so who knows?
 
Holy Smokes Batman, this is an incredible find! Thank you! Will check into this later today as I have the dreaded many crank up attempts after several errand runs. I read your posts as well as RevISK's religiously as I believe our rigs have similar issues. Hopefully not contagious! Is your AC fill hose any better than the cheap auto store fill hose that comes with the can of freon?
Thank you!
 
MWM1 said:
Is your AC fill hose any better than the cheap auto store fill hose that comes with the can of freon?
Click to expand...
Awesome, glad I can help! Just to update, I did a full morning of stop and go errands in the truck just now and it didn't skip a beat.

On the freon - it's not - I just happened to have a can of R134A kicking around the workbench from a prior project, and didn't want to rent the fancy two-sided one from the parts store. About the only benefit I can think of is that my can of R134A is just refrigerant, no stop-leak.
 
majdomo said:
Saturday morning, drove into town to pick up a few things that we'd forgotten at home. After leaving the rig parked for about 5 minutes, it refused to start again.. shot some ether into the intake, and it sputtered to life for half a second, but that was it. I was literally on the phone with AAA when one last turn of the key got it started again. Drove back to the campsite, threw all our stuff in the back with the engine running, and cannonballed home. Daughter none too pleased, but we avoided a long tow.

I'd run through the FSM tests on the FI system already, but tried and succeeded in replicating the problem in the driveway yesterday morning. Cold start timing sensor checked out, and both the EFI and circuit switch relays were fine. ISC checked out , swapped out the plugs and wires, timing is spot on, changed out the cold start injector with another known good one, along with the FPR. However, jumping Fp to B+ gave me no fuel pressure. Took out the jack and support from the driver's rear quarter panel, got down to the plug behind the driver's rear wheel well, and here's what I found:

View attachment 3905773


View attachment 3905774

Yep. Clipped the plugs, soldered the wires together and it fired right up. I am thinking this has been the source of a few problems during my ownership - fluttery idle (hopefully), that one time it tried to die on me after getting off the freeway, the other couple of times when it DID die on me after getting off the freeway.

I would recommend any 62 owner to check it out and make sure this plug is solid, or even better, just solder the damn thing together as PM. What a pain. And I almost threw more parts at it by buying a new fuel pump, fortunately that money can go toward other stuff.

One last thing, my Chinesium low pressure filler hose for the AC arrived. 5 minutes later, had ice cold AC with a few ounces of R134A. PO did the conversion, but it was low and though I'm sure if there's a slow leak, this won't last, am enjoying it for now.

View attachment 3905781
Click to expand...


.

would you like a freshy oem kit-form-kit of those mailed out to you today ......?

these particular oem YAZAKI terminals are a much more nickel-brass-alloy base metal , and then surface treatment plated with marine grade tin
you will have to use Double Open Barrel Dies Rachet Crimpers SST's to correctly make them happen PLANT A-11 solid ...

What actually caused them to get the Funky Green Fuzzy corrosion residue stuff at that bad of a bad level there ?


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;



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.
 
That would be cool @ToyotaMatt ! However I don't have the connector crimps, unless a pair of needle noses would work too?

The reason they get fuzzy is because there's a small vent hole in the inner rear fender right next to the plug location, and the plug itself kinda sits at the bottom of the inner fender... As water gets in there over many many cycles, it's just a matter of time before corrosion takes its toll.

Did a bunch of multi-stop errands yesterday, and it's running great.
 
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