Tearing down my HJ47 troopy (2 Viewers)

[gswest]

Thanks HJ, I'll give that a try.


I did manage to get a new battery installed today and also got some fuel back in the truck. It was nice to turn the ignition on and see things light up; unfortunately the brake lights came on, which was because I didn't screw the brake sensor module in all the way, so it thought the brakes were applied. I had to take the speedometer back out to get access. Getting that speedo cable off and back on sucks. I bled the brakes yesterday and only found one leak, I bled the clutch and it appears to work. So now I just have to get the antifreeze in and prime the fuel injector pump and we'll see if she'll fire up. I'm on duty tomorrow, so Saturday will be the first try at ignition.

 

[gswest]

First try at ignition, negative. Actually, I was only trying to see if the ignition switch would work; it didn't. So I used a jumper cable to see if the starter would turn over, and it did. I'd already tested the starter, so I expected it to work. At this point, I was just wanting to see if the motor would turn over on its own power; the battery. After a few tries with it turning over using the jumper cable, the ignition switch strangely began to work on it's own. After re-reading the 2H manual, I went thru the fuel pump bleeding process again and after a few steps, it fired up! There's diesel smoke wafting thru my neighborhood and I'm proud at this point to be the polluter. Yes, My 2H is making smoke again, finally!

 

[Weber Sarge]

Just a thought on that cable end -
You could perhaps drill a small 1/16" hole in that valve arm just at the center where the cable is suppose to hook up , put a Z-bend in the cable like used on lawn equipment , insert into that hole (won't be easy next to the firewall , might have to remove the valve ) and that should work and be a bit cleaner install .
I have had some luck taking cables apart and installing new sheathing/wire , but it's a real pain as some are hydraulically crimped .
Sarge

 

[gswest]

I'll try that Sarge. I'm not too happy with the connectors as they are. On another front; the 2H seems to run well but the fuel warning light is blinking, suggesting I have water in the sedimenter?? I'm planning on taking it apart to inspect it after one more try at draining it and bleeding the system again. My fuel should be fine since it was always kept indoors in clean containers. The fuel tank was empty when I re-fueled it, and I let a little run out to make sure there was no stuff in the bottom of the tank.

 

[lostmarbles]

............the fuel warning light is blinking, suggesting I have water in the sedimenter?? I'm planning on taking it apart to inspect it after one more try at draining it and bleeding the system again. My fuel should be fine since it was always kept indoors in clean containers. The fuel tank was empty when I re-fueled it, and I let a little run out to make sure there was no stuff in the bottom of the tank.

I have an idea the sedimenter light can be triggered by an alternator malfunction too (as well as being triggered by water in the sedimenter).

 

[gswest]

Tom,
I took the sedimenter off and it was full off debris from the fuel tank. I knew I should have had the tank flushed and inspected! After I took the sedimenter off and cleaned it and re-installed it, the flashing light returned on re-ignition. I may have two problems; a fuel tank with tons of corrosion and stuff floating around in it and a sedimenter assembly that is (electrically) bad. I used my multi meter on it and couldn't get any reading, but I don't really know how that meter works , so I ended up with no real answer. Tomorrow I'll take the sedimenter off again. If it's full of fuel tank crud, then I'll remove the fuel tank and have it cleaned and sealed (if possible) or find another tank. In the mean time I'll find out if my fuel sensor actually works. A new one is a couple hundred bucks American. The motor does run and once it gets the fuel, she idles fine. I'm hesitant to drive it since it's been so long sitting dormant.

 

[gswest]

After some thought,,, the fuel tank is probably very dirty. I thought ignorantly, that the diesel residue would be rust inhibitive. Guys are telling me now that once I emptied the tank, corrosion probably immediately began as it sat in my storage unit..... #*?@ me!
Oh well, just more $$$. Can I borrow $3 grand from anybody?? Just kidding.... We need more than that.

 

[gswest]

Kudos to the IH8Mud Website managers.

 

[gswest]

In the process of checking the sedimenter, I've discovered a ton of crap in the fuel tank; I first noticed it in the sedimenter. I should have had it cleaned out before I re-installed it. I had planned to, but got caught up in the progress and blew it off. Big mistake! I had to remove the tank and am taking it to a shop that specializes in restoring/repairing fuel tanks. I imagine, it might be expensive, but I've got no choice, because I don't want to do it myself and screw it up. It may be leaking as well, because no matter how hard I tightened the drain plug, fuel still leaked out in that area and I couldn't be sure where it was coming from. I'll have these guys seal it with something after it's cleaned.

 

[gswest]

Side window seal issue. S.O.R. tells me the side window weather-stripping kits they sell for the 40 series are not as big as the windows on a HJ47. I found a source (Euro4X4parts.com) has these weather stripping kits that they say fit the FJ40 and HJ47 (same size apparently). SOR says I have to cut and glue sections from a extra FJ40 kit to make the length correct. The attachment shows the seal that they say fits both model trucks. Has anyone here replaced their Troopy side window seals?

 

[gswest]

Hood and front grill surround installed. Front Toyota badging with hand restored (by me) Diesel badge. Apparently a new Diesel badge is unobtainable. I've got an adjustment needed to the fenders and hood, as you can see by the hood to cowl gap.

 

[gswest]

I can almost see the light at the end of the tunnel.

 

[lostmarbles]

And that's one glorious beast that's about to emerge from the tunnel too

 

[sheepdawg]

Wow. That is beautiful. I am in awe of your patience and dedication. You must be single with no kids.

 

[gswest]

Thanks, guys. And yes, no kids! 2 dogs and a GF though.

 

[gswest]

I've begun the process of trying to get the front doors lined up and flush. Currently the doors with the weather stripping installed, sit too far away from the door opening. Any hints as to what the remedy for this is, would be appreciated. I ordered weather stripping for a FJ40 and assumed it was identical to my HJ. It may be, but they are so thick, the doors sit 1/2 inch or so away from the opening. unless someone has a tip, I'm going to trim the weather stripping down until the doors fit correctly. I loosened the hinges already, attempting to adjust them that way. But nothing seems to help. The pic shows the door as I'm pushing against it to close it as far as it will go. Not very close!

 

[gswest]

I removed the weather stripping after attempting to trim one down a bit. The doors sit flush without the gaskets in. I'll try trimming one down and re-installing it. We'll see. Maybe some thinner aftermarket stuff will work better.

 

[lostmarbles]

My aftermarket weather stripping was much more substantial than my original (Toyota) weather stripping. I installed it in 2010 and I still need to give the doors a good slam (or apply my knee to right spot) to close them completely.

But I actually prefer it that way...

My doors were always noisy (squeaky) while driving with the original weatherstripping but now they're always dead quiet.

(They poke out a little further than I'd like when closed, but not so much as to be ugly or easily noticeable.)

 

[gswest]

I thought I got OEM window seals, but now as I look at the kit, it was aftermarket. Which is fine, I just need the doors to close, and look correct. I'm not sure if I'll try the OEM ones or not, but for now, it will be a fix to be dealt with later. The doors are on and the latches re-installed. I'm working on the back ambulance doors now and those gaskets seem to fit better, but may need to be trimmed a bit. My glass guy called and I'll have all the weather stripping to do the rest of the glass later this week and he'll come by to do the installation in a few weeks. The windshield needs to be replaced as it was in bad shape. One of the rear door windows I broke removing it, so that has to be replaced as well. After that, the glass will be done. I reinstalled the fuel tank and added 5 gallons of fuel (thru a paint screen). All the crud that was in my tank is gone and the fuel I drained will be screened thru these paint screens to keep the chunks of crap out of the tank. I'll prime the fuel injectors tomorrow for the second time.

 

[gswest]

The doors will open and close and lock now.