The Never-ending Problems with my 87 FJ60

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Some carb rebuilders stake that discharge weight in place. Not sure why; maybe to make sure it doesn't fall out when assembling? I've also seen some of them file the head of that discharge weight and then use a small round gasket on top of it, like in earlier LC carbs. Again, maybe to get more positive action out of the accelerator pump?
 
Just for the sake of closure:

I ended up replacing the cat, bad smell is gone. Apparently a cat can test out seemingly alright and still not be doing it's job.

Also, just passed emissions. With flying colors. For a reference point, before going through and fixing the problems in the AI system and replacing the cat, my CO was about 4x the limit and my HC was about 12x the limit. After doing that work, my HC is .2 (limit of around 4) and my CO is 1.5 (limit of 30).

So anyone having high HC/CO problems, it's worth it to go through the whole AI system and get a new cat.
 
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