Builds Resurrecting a mothballed '86 FJ60

[Seth_O]

So my new gas filter arrived yesterday and I had an hour or so after work today to spend on the '60.

I decided I would just go through the emissions FSM and test every component in there to rule all of that out before throwing $ at a carb rebuild.

I started on the first page, and in an hour only got through a few tests but here is what I found:

1. The 'Outer Vent Control Valve' failed. With 12v applied it still passed air freely. This is into the charcoal cannister, so not sure it impacts my issue, but regardless, it's no bueno. I tested the plug and it is getting power as it should.
2. My VCV tested good. Thank heavens for small favors.
3. The vacuum advance on my dizzy tested good.
4. My violet bvsv passed the cold test. I have not done the hot test yet.
5. The FSM has two different testing procedures for the bvsv. It wasnt clear to me if that means I need to test them in different methods because it doesn't say specifically to test the pink one, it just says the violet can be tested en situ, but then later gives a different test process without saying why or calling out if it's for the pink bvsv. So I tested both on the truck, pink (rear one) failed the cold test. I circled it below. But I don't know if the test was meaningful?

1. I tested all three VTV's (green on the carb and both blues) According to the FSM they all failed. The FSM says air should flow "freely" from side B to side A, and "with resistance" the other direction. Now those are subjective words, but I have 5 kids and am confident in my lungs. From B to A there was significant resistance, and no movement the other direction.

That's as far as I got. I'm open to folks interpretation of what happened.

 

[Seth_O]

Finished the testing I could do with the engine off.

3 bad VSV's and a rotten air bypass valve.

Now I'm shopping for emissions parts. Lots of them.

 

[NeverGiveUpYota]

Holy s*** wow to that bypass hose!!! Where the heck is that from? Few folks I’ve noticed (I think) on the TLCA Facebook page parting out 60’s. Go on and ask.

 

[Seth_O]

I've got some queries out there. The problem is the sheer number of parts I need. It makes me question if I tested everything right.

 

[mwebfj60]

I think I have some VSVs laying around. I’ll check tomorrow and let you know.

 

[Seth_O]

I think I have some VSVs laying around. I’ll check tomorrow and let you know.

Tks, that would be much appreciated!

 

[NeverGiveUpYota]

@Seth_O, Marc reminded me w/ his comment, I have a brand new blue and white one that would go from off the distributor to somewhere in the front. Laughing I bought it ages ago when I was trying to understand the desmog pdf and inadvertently thought I needed it. I’ll find it if you want.

 

[Seth_O]

I decided to do some work on the interior while I wait for emissions parts to arrive.

I cleaned the insides out and stripped it down.

Once it was cleaned and ready, I started laying down some foil. I used sealed bubble foil, as I didnt want anything permanent or semi-permanent on the vehicle.

 

[Seth_O]

Unfortunately/fortunately when I bought the truck it already had the carpet completely removed. This saved me a TON of work, but it also meant that I dont have a template to use to mark my brand new DNP carpet to cut it.

So I removed the shifter cane and layed the carpet out and started my cuts.

I got the front piece layed down and all of the cuts done. I spent like 2 hours getting the holes done for the dash support and getting it installed over the carpet. What a PITA.

I tried to get the t-case cover reinstalled and realized I needed longer bolts. Sigh.

While pulling one of the bolts it flew from my fingers and dropped right down inside the shifter opening for the tranny.

Well dangit.

I fished around inside with my magnetic retrieval tool, but without any luck. After that I called it a day.

 

[Seth_O]

While cleaning things up I found these extra plugs under the seats.

I know which ones are the e-brake, wondering about the others? Anyone know what they are?

 

[4Cruisers]

While cleaning things up I found these extra plugs under the seats.

View attachment 1784367

I know which ones are the e-brake, wondering about the others? Anyone know what they are?

The one on the right with the darker green connector is for your catalytic converter temperature sensor.

 

[NeverGiveUpYota]

The one on the right with the darker green connector is for your catalytic converter temperature sensor.

Ah and connects to the funny looking phallic thing that dangles under the truck... unless you have a cat. I don’t, thus mine dangles.

 

[4Cruisers]

Ah and connects to the funny looking phallic thing that dangles under the truck... unless you have a cat. I don’t, thus mine dangles.

Those sensors are much coveted in California due to their pretty rigorous smog requirements.

 

[NeverGiveUpYota]

Those sensors are much coveted in California due to their pretty rigorous smog requirements.

Well aware. Maybe time to pull and put on eBay eh?

 

[Seth_O]

The one on the right with the darker green connector is for your catalytic converter temperature sensor.

Does it connect to the lighter green one at the top of the pic? They fit together, but are different color greens.

 

[Seth_O]

Spent some more time on the truck. I've been watching the vacuum slowly deteriorate over time and even with all the work it's still not running very well.

I sprayed carb cleaner and think I found some leaks at the base of the carb, and the air rail connection points and at the manifolds, again.

 

[Seth_O]

I pulled the carb, again, and then the insulator plate.

I found this:

I believe this is new damage, I dont recall seeing the cracks in the epoxy when I was in there the first time.

A few mins and some JB weld:

 

[Seth_O]

I found all my air rail connections were just a little loose, so I tightened them down. I also got after my manifold bolts and gave them another little tweak too.

I know I tightened them to spec the last time, so the only thing I can think of is that the heating/cooling cycles combined with the anti-sieze caused them to shake a little loose.

 

[Seth_O]

Tonight I pulled my emissions "computer" and reflowed all the soldered joints. No idea how much of a problem that was but I did find a couple of pretty suspect connections.

The solder was pretty gross after 30 years.

Still waiting on one more VSV from a mud member and then I should be able to try it out.

 

[Nostradamus]

Tonight I pulled my emissions "computer" and reflowed all the soldered joints. No idea how much of a problem that was but I did find a couple of pretty suspect connections.

The solder was pretty gross after 30 years.

Still waiting on one more VSV from a mud member and then I should be able to try it out.

I have a box of emissions equipment stuff from when I went thru a similar saga to get my rig Phoenix AZ compliant. Gave the air rail to another mudder who was in a jam, but if you find you're still missing some stuff, LMK and I can dig thru what I've got. I ended up ultimately registering my rig in Montana, which doesn't have emissions laws, so no problemo any more