Builds OL'BETSY ZX: 1991 HZJ77

[JDM Journeys]

You might find this thread to be helpful...

remove fuel tank

I wanted to get the fuel tank off to see if there was rust on the top side which is invisible. The skid plate has a dent in it and I wanted to make sure it was not rubbing the tank. Top of the tank needs some help. After straps and hose connections, you have to get the filler tube disconnected...

forum.ih8mud.com

It has the procedures on installing the filler neck, hose diameter etc.
Good Luck Ralf

I've read through that thread about 5 times and consider it biblical in its importance!! Thanks again for taking the time! I will have it open on my garage TV when the time comes...

 

[JDM Journeys]

My entire rear floor (under back seats) is now covered in killmat, (under the carpet/oem insulation), along with most of the cargo compartment and the wheel wells. Not sure if I'll notice much difference or not, but I'm imagining things will be quieter on gravel at speed?

Still need to do the front floor and doors, but I'm not in the mood to pull the front seats right now. I can do that once the rear buildout is put back in place.

Had to take a break from the fuel tank - I can still smell diesel, and I haven't even touched it today.

 

[Felde]

Great you at least have something satisfying accomplished and the path ahead for an annoying issue at least clarified.

 

[Rigster]

I realize this will be a little while, as you are waiting on parts to come, but once you have the sound deadener in place, and you get it back on the road, could you let us know how much of a difference was made? If it is worth doing in your opinion, then I may add it to the list of things to do for mine.

Thanks bud!!

 

[JDM Journeys]

Shall do Darren. Funny enough, the suction tube that was supposed to take 10 days to get in stock (and I wasn't even sure it would come back in stock) got shipped today! My fill tube assembly is supposed to ship by 21st or so, so it may not even be too long?

In other news, got the tank down today. It was about as unpleasant as I imagined. Dirt in my eyes, more fuel dripping down my neck, etc. Lol.

On the plus side, tank isn't bad at all. Needs a good cleanup and of course more por15 but overall in good shape. I'm glad I ordered the fuel fill-assembly. It might have been salvageable but I'm glad I won't have to worry about it. Skid plate looks good too. And all bolts came out!

Even the floor underneath looks good! This rig was media blasted and coated before I got it but you always have nightmares about what could be lurking, unseen. There's still factory paint there. I'll coat it anyways because it's accessible. But aside from yours truly photobombing, it looks pretty good!

The suction tube however looks as bad as I suspected. Well... Hoped I guess is a better word? I'm thinking this is the last piece...

 

[JDM Journeys]

Bottom of tank is now looking better. Hit a few places with my flap disc, and then coated with POR15.

Cleaned up the floor where the tank normally butts up to, and then took the opportunity to do a little sprucing up.

And finally we painted the inside of the skidplate.

Now we wait for paint to dry. Also took the chance to fix my non-op tail light. Broken wire! Now fixed: soldered and sealed up with shrink tube.

 

[JDM Journeys]

Well... Suction tube and filter is on hand. Unfortunately I've hit a snag. Amayama, after processing for a week, is now saying the rubber tank hose and vent assembly are both out of production. Partsouq doesn't show any availability whatsoever.

And I had to cut the rubber line to get tank out. So... I'm open to suggestions.

 

[JDM Journeys]

77213-60170 is showing as superseding 77213-60100. Wonder if it's any more widely available...?

 

[Felde]

I got the filler hose from euro4x4 in France.
Good Luck Ralf

 

[JDM Journeys]

Can't find either of them anywhere. So... Ordered a length of 2" hose with two slight bends, and am hoping to cut it in just the right place so that I capture the spirit of the original. Meanwhile, the vent tube assembly is cleaned up, wire wheeled, and POR15'ed. How is it that I can wear nitrile gloves. And STILL get that $hit on my hands?

Retrofit hose shows up today and then we begin the reverse process. I sure hope it has the intended results.

 

[ATL Cruiser]

That POR15 is an amazingly nasty product. I got my face covered in it while under undercoating an old Volkswagen. It was a long two months.

Is that hose fuel rated? I might replace mine. Although, I guess it really doesn't matter, because fuel only touches it for a few minutes at a time.

 

[JDM Journeys]

That POR15 is an amazingly nasty product. I got my face covered in it while under undercoating an old Volkswagen. It was a long two months.

Is that hose fuel rated? I might replace mine. Although, I guess it really doesn't matter, because fuel only touches it for a few minutes at a time.

Lol. On your face? Oh boy. My students know when I've been working on OLBETSY just from my hands on Monday morning.

It's fuel line hose, yep. Still waiting on my length of 1/2" hose. Almost put the tank up this afternoon but access to add the 1/2" hose on after the fact seemed doubtful for my paws. So maybe tomorrow?

 

[JDM Journeys]

Here we go!

 

[JDM Journeys]

All right. That was the most frustrating thing I've done in a while. I wear xl gloves and my hands aren't made to get where they needed to get. The tank wasn't really happy to go back in place. A jack, ratchet straps, pulling back wheel, jacking up the truck more... All the things I could do made virtually no difference. Eventually I got it in place. My carefully cut fuel filler hose worked fine. And my 19/32 hose (couldn't find ½ inch on short notice) fit perfectly on the overflow tubes.

Pumped it up via primer. Cranked it over with a break in between and suddenly it started and idled like nothing happened. Lots of bubbles came through the "viewport" and some smoke to accompany, but eventually I blew through what I could see. Checked for leaks then TEST DRIVE time.

A few imperceptible stumbles up the street and then smooth. Did about 5kms. Once I got a puff of smoke (air pocket) and then when I got home I blew through a few more bubbles. But after that it wouldn't smoke at all, even when I gave it a hard rev at idle...

So... Next test is the morning cold start. This is where I always say it's fixed and then back to the drawing board. So I'll simply say I'm optimistic and we'll see how it plays out?

 

[JDM Journeys]

First follow up:

Yesterday morning I started it up and got about 10 secs of smoke. But no bleeding had been done, and also I forgot to extend the glow time past the light going out. Drove it 160kms yesterday.

This morning? Proper long glow and then... NO SMOKE. NONE. ZERO NADA. It was probably 7°c in my garage but still... Smooth start, zero smoke. Started on about ¾ of a turn. This isn't proof of solved yet, but it's looking very good.

So good that I stopped on the way in this morning and grabbed a few pics to get the new stripe "in the wild".

 

[JDM Journeys]

Little side project... I want an armrest. My drive is long, and my want turns into need after about 20 mins.

I've been experimenting with different DIY possibilities but have probably settled on a tall 30 cal plastic ammo can. More to come when my (third) ammo can arrives. Gotta get the exact right size.

 

[Rigster]

First follow up:

Yesterday morning I started it up and got about 10 secs of smoke. But no bleeding had been done, and also I forgot to extend the glow time past the light going out. Drove it 160kms yesterday.

This morning? Proper long glow and then... NO SMOKE. NONE. ZERO NADA. It was probably 7°c in my garage but still... Smooth start, zero smoke. Started on about ¾ of a turn. This isn't proof of solved yet, but it's looking very good.

So good that I stopped on the way in this morning and grabbed a few pics to get the new stripe "in the wild".
View attachment 3307617

View attachment 3307618

This is how it is supposed to start and run. Congratulations on your persistence my friend! I always found it suspect when people have to constantly bleed injectors, etc. They should self bleed after priming, and if it isn't, then you are still getting air in the system from somewhere.

I am impressed with your ability to keep at it until you got to the root cause of the issue.

Now drive it and enjoy it!

I was out driving mine today and was just admiring how nice it was to be cruising in a vehicle that makes me so happy.

 

[Gun Runner 5]

Little side project... I want an armrest. My drive is long, and my want turns into need after about 20 mins.

I've been experimenting with different DIY possibilities but have probably settled on a tall 30 cal plastic ammo can. More to come when my (third) ammo can arrives. Gotta get the exact right size.

P.M. sent

 

[Blomdala]

Little side project... I want an armrest. My drive is long, and my want turns into need after about 20 mins.

I've been experimenting with different DIY possibilities but have probably settled on a tall 30 cal plastic ammo can. More to come when my (third) ammo can arrives. Gotta get the exact right size.

I used to keep this blue yoga foam brick from my wife in the truck, it was just the right height sitting on the center console for my elbow to rest (plus it was soft!). Not fancy, but effective and cheap.

 

[ATL Cruiser]

I used to keep this blue yoga foam brick from my wife in the truck,

Those yoga bricks are so awesome. I use them all the time.