Jim S. FJ40 Tuneup (1 Viewer)

[DSRTRDR]

Oh NO!! Asbestos! We're all gunna die...........

just don't inhale

 

[Tools R Us]

One of the parts that proved elusive was the intake tube. There is lots of silicone "turbo tube", but IMHO, is way too stiff, would be hard on the air cleaner. Got this stuff from Fleet Pride, much more flexible. It is 3" inter-cooler output tube, from Power Products, CSB30. Still needs to be cut to size, shorter and installed.

 

[Tools R Us]

The shroud had big holes at the top and bottom. Hacked some sheet, tacked it on. Didn't take a pic of it done.

 

[DSRTRDR]

what animal left those prints

 

[Tools R Us]

When working on harnesses, it's best to have a tool to remove the connectors. There are several commercially made, I have a collection of them that I never use, somewhere? Prefer to make them to fit the job, the strips that hold windshield wiper refills in are perfect, just the right size, amount of spring, a couple of minutes on the sander, done.

Reading some (lots) of Toyota EWD and wire repair manuals, found this:

 

[Tools R Us]

On the '62, where the harnesses connect together, the check connector, some relays, etc, are under the hood. We had a couple of problems with that. First there isn't much room on the firewall, second, the interior part of the harness is short, reducing options on harness routing, ECU mounting, etc.

So unwrapped some of the harness, pushed the pins out of the connectors, put them through the grommet, moved the grommet down the harness and put them back together. Now it's all on the inside and have more wire to work with.

 

[Tools R Us]

The exhaust mounts were weak, junk, broken, so upgraded them to HD figure 8 type, much more solid.

 

[Tools R Us]

The belt routing/tensioning setup was a kludge deal at best. The main problem was on the power steering side, we went round and round about what to do with it. Ended up using parts from a Isuzu Rodeo, Honda Prelude, from MikeOB1 and some . It works well and both sides use the same belt, adding options if a trail issue ever happens.

Also, the new home for the ARB compressor, moved back under the brake master.

 

[Tools R Us]

A new thing that we are working, air cooled wiring, guna be the next big thing!

 

[Tools R Us]

Where/how to bring the harness inside has been a long term challenge. The PO had chopped a couple of holes in the right spot, but they were 1 1/4" and intersecting, we need a 2 1/8" hole. Got a handy hydraulic punch from Harbor Freight, worked great, first punched out the hole to ~2 3/8".

 

[Tools R Us]

Then punched a proper sized hole in a hunk of sheet, cut away anything that wasn't needed, beat it into shape, stuck it on with sealer. Now we have a proper sized grommet hole.

 

[Tools R Us]

Been doing a bunch of wire splicing, so shot some pix of my favored method. Own, have used tons of crimpers, for small wires, this type is my favorite. For this type of work I never use insulated terminals or, like in this case, remove the plastic.

Hold the crimp with the split at the spike on the crimper. Put it over the wire and crimp solid. Then using the rounded part, close the gap, use good solid force.

 

[Tools R Us]

This makes the closest to factory crimp that I have found, is very solid, never had one fail. With shrink wrap, it isn't much bigger than the wire, so doesn't make much of a bulge in the harness.

Also, if possible, when splicing whole harnesses, never cut the whole harness at the same place. Cut each wire about the length of the splice away from the last. If all of the splices are in the same place it will make for a big, stiff bulge in the new harness and the splices are much more likely to fail, short out on each other.

 

[Tools R Us]

Making headway on it. Most of this will be hid behind the heater duct and the check connector will be on the bottom of the heater duct.

The stock setup was two harnesses, motor and chassis, both had big grommets that we didn't have room for. Once stripped of the stuff that we didn't need, the chassis harness is relatively small, so decided to combine them into one harness and put them through the same grommet. So that big yellow connector that we so carefully pined out and reassembled was cut off, the two harnesses were spliced into one. This simplified the routing and were able to cut out a bunch of redundant wire.

 

[Tools R Us]

Starting to look like a truck again?!

 

[Jim S.]

Nice work with the wiring! The exhaust install looks real clean too. Looks like a Z-line in front of the rad. Is that the heat dissipating tubing we talked about?

 

[Tools R Us]

Yep, the power steering cooler.

 

[Tools R Us]

just don't inhale

That is what they all say when the fun stuff is around!

 

[heywoodjablame]

Man, this makes me wish I had a 40

 

[Jim S.]

Funny. I thought the chicken napper owns a 40. But what do I know???