Mid ’76 FJ40 Federal Resmog

[Red Panda Roll]

Awesome! Thanks @akingf5371. I will definitely reach out to you with questions. So far I'm just kind of taking stock of what's present/absent emissions-wise. I will most definitely have questions, though.

I may stop by the Rising Sun Rally tomorrow. My FJ40 isn't actually running, yet, but if it was I would make sure my bezel is right way up.

 

[CaliFJ]

Excellent write up and the pics really helped. I recently imported a '76 FJ40 into Kali from Kolorado. I have temp registered the vehicle here but have to pass smog to complete reg. My Colorado plates don't expire until April '17, so I'm probably okay unless I'm caught speeding (ha ha). I have a few parts that came with the rig, and have a line on an air rail from a local to me Mud'r. @afmcgraw - Any chance you created a list of all the parts needed? Would be great to have something to use as a checklist.

 

[CaliFJ]

@afmcgraw - does this list look correct?

Description Code Price
Smog Pump, 75-1/79, Rebuilt 141-C301R $200.00
Smog Pump Pulley, 75-79, Used 141-C203U $25.00
Air Pump Bracket, 1/75-8/80, Used 141-CD04U $35.50
Air Pump Bolt 141-05 $2.25
Air Pump Adjuster Bracket, 1/75-8/76, Used 141-C06U $20.00
Air Pump Belt, 1/75-1/79, FJ40/FJ55 141-45C207 $15.00
Air Pump Inlet Hose, 2F, Used 141-08U $45.00
Air Pump to ABV Hose, 2F Type, Used 141-09U $40.00
ABV (Anti Backfire Valve), 2F Type 141-10C $185.00
ABV Mounting Bracket, 2F Type, Used 141-11U $16.00
Hose, ABV to Air Injection Manifold, 2F Type, Used 141-12U $42.00
Hose, Air Pump to Rail, 81-87, FJ60 141-6D12 $40.00
Air Injection Manifold, 1/75-1/79, FJ40/FJ55, Used 141-45C213U $120.00
Air Injection Plug 141-15 $3.10
EGR Hard Pipe Gasket, 1/76-1/79, Cal 141-C16C $5.05
EGR Hard Pipe Gasket, 1/76-1/79, Fed 141-C16F $8.35
EGR Hard Pipe, 1/75-8/76, FJ40/FJ55, Used 141-45C217U $50.00
EGR Hard Pipe, 8/76-1/79, FJ40/FJ55, Used 141-45C317U $50.00
EGR Cooler Inlet Nut, 1/75-8/87, Used 141-CD18U $3.25
EGR Cooler, Fed, 1/75-8/76, Used 141-C19FU $80.00
EGR Cooler, Cal, 9/73-8/76, Used 141-C19CU $60.00
EGR Flex Pipe, 1/75-8/76, FJ40/FJ55, Used 141-45C220U $70.00
EGR Flex Pipe, Cal, 1/76-8/76, FJ40/FJ55, Used 141-45C20CU $50.00
EGR Flex Pipe, 8/76-8/87, FJ40/FJ55/FJ60, Used 141-456CD20U $40.00
EGR Flex Pipe Nut, All-87 141-21 $5.25
EGR Cooler Gasket, 74-75 141-C22 $6.50
EGR Valve, 9/73-1/79, Used 141-C23U $80.00
EGR Union Nut 141-24 $3.75
EGR Union Sleeve 141-25 $4.50
Vacuum Switching Valve (VSV), 9/71-79, Used 141-C26U $80.00
Vacuum Filter, Single Port 141-27S $21.50
Vacuum Filter, Dual Port 141-27D $22.75
Vacuum Filter, Triple Port 141-27T $39.99
VTV (On Thermostat), 77, Used 141-C28U $15.00
Heat Riser Shield, 2F, 75-79, Used 141-C29U $60.00

 

[AdamKFarmer]

Whoa, you just copied a list that includes every year model. I would search for the smog FSM and go from there.

 

[CaliFJ]

Whoa, you just copied a list that includes every year model.

Sorry. I just edited the list to only include parts in the '76 range since I'm guessing this is mostly an issue with rigs around that range.

 

[AdamKFarmer]

Sorry. I just edited the list to only include parts in the '76 range since I'm guessing this is mostly an issue with rigs around that range.

So, you're asking for a list? You can go to SOR, look at the schematic and make a list. Or use the FSM. I've in Denver and have good knowledge of the later smog equipment.

 

[Trollhole]

I really feel for you guys. ANd commend the original poster for going through all that. Learned a few things as well.

 

[Pin_Head]

The bar is really low for the tail pipe emissions part of the CA smog test for late 70s FJ40s. The hard part is passing the visual test for everything correct being in its place and then functioning well enough to meet the low tail pipe standards. That means that you need to learn how everything works so you know how to fix it when something goes wrong. There are very few people left that turn wrenches that you can take it to that know how to actually fix them except for replacing stuff at random.

 

[Fast Eddy]

From experience, the EGR has to work and the air injection has to work. The other thing that is very important is to reduce the size of the primary jet. Federal is big, 1.36. CA-spec is 1.24. I'm running a 1.29 that I drilled out from a 1.24 myself and it passes. With the 1.36 it did not pass the HC threshold.

My 'CA-spec '78, I'm sure, has the stock 1.24 jet and it runs like crap until you get into the secondaries. It does pass smog easily.

 

[Pin_Head]

If the jet was too big, it would fail CO and not HC. CO comes from rich mixture burning. HC comes primarily from misfiring.

 

[CaliFJ]

There are very few people left that turn wrenches that you can take it to that know how to actually fix them except for replacing stuff at random.

Mudrak is in Norcal specializes in LC's and is about an hour from my house. Definitely not going to attempt this on my own. Expertise and time working against me. But I have most everything already installed. Just need to add the air rail (which I've found from another local Mud'r) and need to buy a pump and I'm sure some other small parts. Once I have it all, it's off to Mudrak for wrenching it all up. Just hoping all the other stuff currently installed works.

 

[AdamKFarmer]

Mudrak is in Norcal specializes in LC's and is about an hour from my house. Definitely not going to attempt this on my own. Expertise and time working against me. But I have most everything already installed. Just need to add the air rail (which I've found from another local Mud'r) and need to buy a pump and I'm sure some other small parts. Once I have it all, it's off to Mudrak for wrenching it all up. Just hoping all the other stuff currently installed works.

You can bench test just about every electrical component

 

[laxman]

So, you're asking for a list? You can go to SOR, look at the schematic and make a list. Or use the FSM. I've in Denver and have good knowledge of the later smog equipment.

This is a great thread. I’m currently in the final stages of purchasing a 7/76 fj from a shop in Denver. I live in Cali and I’m terrified it’s not going to pass smog. The engine looks great but i don’t think it has an erg. Do you know if there was an erg on the earlier ‘76.

 

[Pin_Head]

Yes. They came in around the 72-73 time frame. Unlike later EGRs from 79 and up, they don’t create a manifold vacuum leak when they leak, so you can’t test them by looking for the engine to stall at idle when you pull a vacuum on it.

 

[laxman]

Here are some photos of the FJ i'm looking at. Any thoughts as to whether or not the right equipment is there to pass? I don't see the egr.

 

[Pin_Head]

It looks petty legit. I can see the EGR inlet pipe to the carb, but I don’t see the valve. Maybe get more pictures looking forward or with the air cleaner moved.

 

[laxman]

It looks petty legit. I can see the EGR inlet pipe to the carb, but I don’t see the valve. Maybe get more pictures looking forward or with the air cleaner moved.

Thanks! Can you circle the inlet pipe on the picture and repost? I’m not really sure what to look for. Very thankful for your help. I have a deposit on the car, non refundable, and have to pull the trigger tomorrow

 

[Pin_Head]

Here you go. Its not surprising that the carb connection is present because it is part of the correct carb.
You will need a functioning EGR valve and I don't see it.

 

[Fast Eddy]

It does look like a good candidate to pass.

If the egr doesn't flow it won't pass at the tailpipe. Also it needs to have the smaller CA jets in the carb, and the vapor recovery system and fuel cap need to hold pressure.

 

[69LC]

I recently bought a 78 2f in an unknown condition to rebuild for our 72.

I have pulled off a few bits I won’t need including the air pump, bracket, block mounted cooler and still am trying to carefully pull the air rail.

I won’t need them.