Offically an FJ60 guy.

[fishontro]

**** nice find. Let us see some pics of your suspension swap. And as for the cat pee, believe me some people are just nuts. That stuff is toxic. How did you black out your grill? I'm thinking of de-chroming my rig but not sure how to go about it.

It's not that hard to do, but to do it right would require way more prep work than I did. I simply de-greased with Super Clean and shot it with Rustolem semi-gloss Black. I will redo it right when I have to remove it again or get bored.

I should have removed all the chrome sticker first. Next time I want to try the Krylon Fusion and see how long that lasts.

 

[fishontro]

Okay, so I did some digging around and found SOR's heat insulator plate made of stainless steel. Rather then buy it, I made it.

I've read a thread or two on removing the shaft and valve, then welding up the hole, but can't I just cut the "wings" off and keep the shaft in there? I have everything off and would rather do it once.

 

[fishontro]

Going to ditch the 10 gauge plate I made (good thing it was free) I would have to have the exhaust manifold machined down to make everything fit.

Should have it up and running sometime next week with another pre-test.

 

[fishontro]

Everything is back on and after few set-backs is running again.

I get to take the carb back off though, looks like the manifold is leaking. I torqued them in the proper order to 36 ft lbs, guess I have to go a tad tighter. Think I need to replace the seal for the exhaust down pipe as well, bolts are tight, but exhaust is getting out. Bummer.

I went ahead and swapped on the EGR cooler from the donor too, cleaner is better.

Stoked I got to hear it run again though!!

EDIT: It seems I did not get the bottom 2 bolts on the intake/exhaust manifolds tight enough (still had 2 full turns to feel pressure) SO, NO MORE EXHAUST LEAK!!

Now I need to fix a vac hose fitting I broke while wrestling the exhaust manifold out, put the hood on, then go for a drive!

 

[fishontro]

I thought I had found the leak, but I was wrong. After tightening the bottom bolts on the intake/exhaust I could no longer SEE exhaust, but still heard something.

So, I took it all off again and re-did everything. I found that 2 of the top three seemed to loose.

After getting it all back together, it runs way quieter now.

Tempted to go get a smog test tomorrow, but really have a gut feeling I should go through the AI system from top to bottom first.

Who knows, it may pass as is. Freshly rebuilt JimC carb has me really want to drive the thing!

 

[fishontro]

3rd time was not a charm in my case. FAILED AGAIN!!!

The numbers actually got worse...

HC at idle is 320 (Max is 150)

CO at idle is 5.25 and 3.91 at 2500 RPM (Max is 1.20)

Ugh...bout ready to kick this thing to the curb.

 

[sl33py]

Bummer! Do you have any exemption options? Here in WA if we fail we can do $150 towards smog repair (at smog licenses shops) and request an exemption if it still fails.

It seems like something is definitely not right with those numbers. Smog pump and assorted all working? Hoses connected correctly? Have you gone through the CSV,VSV,XXV... crap and make sure it's all hooked up correctly and working? Have smog manual?

keep at it - it will pass with some TLC and you want to keep this truck!

GL!!

 

[shotgun12321]

I smell a trail rig!

 

[fishontro]

Bummer! Do you have any exemption options? Here in WA if we fail we can do $150 towards smog repair (at smog licenses shops) and request an exemption if it still fails.

It seems like something is definitely not right with those numbers. Smog pump and assorted all working? Hoses connected correctly? Have you gone through the CSV,VSV,XXV... **** and make sure it's all hooked up correctly and working? Have smog manual?

keep at it - it will pass with some TLC and you want to keep this truck!

GL!!

None that I know of. I do have the 2f Emissions Manual, just not familiar with all the VCV, BCV, r2d2's, C3po's...

I will have to spend some serious time on AI System tonight and tomorrow. I took a week off to get this thing registered. I really want to drive it for more than a day.

I wish a 2f guru lived near by to help out, before I'm done, I'll be a guru.

I smell a trail rig!

Had a trail rig, needed more room for the wife, daughters, dog, ice chest, tent, rifles, glock, tools, parts...

 

[sl33py]

None that I know of. I do have the 2f Emissions Manual, just not familiar with all the VCV, BCV, r2d2's, C3po's...

I will have to spend some serious time on AI System tonight and tomorrow. I took a week off to get this thing registered. I really want to drive it for more than a day.

I wish a 2f guru lived near by to help out, before I'm done, I'll be a guru.



Had a trail rig, needed more room for the wife, daughters, dog, ice chest, tent, rifles, glock, tools, parts...

having a local cruiserhead would help for sure - any local clubs? have you checked the forum for a local group?

As for hoses - it's a bit of a spaghetti mess... BUT my idiot self has done it and it's easily a - job. Go through the diagrams - make sure it's all connected correctly. check the VSV's/c3po's are testing ok (procedures in emissions manual). I replaced a bunch of hoses w/ new McMaster Carr and reconnected some that were wrong from PO.

I don't know enough to give you more specifics. Someone like JimC can rattle off specific culprits for those specific #'s... but i'm not him.

Last ditch - any good smog shops nearby? A lot of the time you can find (again - in my area) a shop that will get you to pass by tweaking everything while they sniff your exhaust. But if stuff is not connected correctly you'll likely still be fighting with this and out some more $. So even just double checking your hoses (not misrouted, cracked, or disconnected all together) first would be a good idea.

Just know that a lot of the time afterward you will want to adjust stuff to run better - sniff worthy or not...

not much help but GL!

 

[cruiserfj45]

Wow even with a fresh rebuild on the carb it is still failing. I would send Jim C. a message and see if he has any tips. I wish I had a gas analyzer to adjust the carb while it is running. Have you checked compression? I would love to have time to help you out in person. It would also be great if I lived closer. Keep us updated.

 

[fishontro]

I'll bother Jim after I know the AI System is working as Toyota intended it to. I'm sure his carb is not the problem.


Pulled PCV Valve, passed the tests.

Pulled Smog Pump since I have a spare I took off the donor. Not really that hard of a job after doing the intake/exhaust, this was a breeze.

When I spin both by hand, the donor has way less air movement, so I tore it apart (both are remans). The donor had the funky hoses, so this gets to be my parts pump. Wish I had the fancy air pump tester. I do feel better knowing that the smog pump is moving air though.

Not sure if I want to tear into the "good" one yet.

Should I order OEM belts, or does NAPA suffice?

 

[orangefj45]

the oem belts are only a couple of bucks more and you can't beat the quality imho.

georg

have you done a compression test?!

 

[fishontro]

orangefj45 and cruiserfj45: With the luck I've been having, I'm almost scared to find out the result of a compression test. I'm gunna go kick a tree with my shins for awhile now.

 

[orangefj45]

compression test is always one of the first things you do.......

have you adjusted the valves?

georg

 

[fishontro]

I did these numbers on a cold engine and about 37 degrees outside...
Dry
1) 150
2) 145
3) 130
4) 145
5) 125
6) 130

cruiserfj45 and I did a Valve Adj. october-ish. 8-13, cold.

 

[cruiserfj45]

Did you just go out tonight and do a compression test? You really want this thing running. Not too bad on the #'s. Did you have the throttle wide open and a battery charger hooked up? I'm guessing not with those #'s.

 

[orangefj45]

yup, a little more variance than i like to see but overall those nubmers are'nt bad for the milage on the engine.

i like adjusting my valves with the engine warmed up......

i think it's time to check all the vsvs and so on.

georg

 

[fishontro]

I wonder if my cat was not hot enough.

 

[cruiserfj45]

I alwase run it nice and hot before a smog. I would check all your AI components before I go in for another test.