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Old 01-25-2015, 09:07 PM
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subzali subzali is offline
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Default The Projects

So rather than create a bunch of different threads about all the miscellaneous stuff I have to do to the Brahma, I decided to create one thread and I'll update it as I get projects done.

And since my FJ40 is feeling a little ghetto lately I'm going to call this thread "The Projects"

This first post will be about my 2015 Re-Smog Project.

In 2010 I started this thread about Desmogging a 2F:
http://www.risingsun4x4club.org/foru...ad.php?t=14682

I have been leaning toward re-smogging my FJ40 but the State of Colorado is forcing the issue because when my Collector's Plate registration renewal comes due this March, if they follow the law that was passed last year they should require me to pass an emissions test.

So this morning I began by searching through my garage to find all my long-lost smog parts that I took off in 2005 (and then added to in 2009 when I took off the EGR stuff):



I had a box of vacuum hoses:


I had 6 air rail extension pieces (one is in the baggie):


I had 2 EGR assemblies to choose from:


I had my air rail safe in a box:


I had 2 ABVs to choose from - one had a broken mounting bracket so I used the other one. I also had 2 adapter pipes from the EGR valve to the carburetor:


I had my old air pump and some other stuff:


So this is where I started this morning:


Check my driver side motor mount while I was there and it looks correct even though it is missing the cotter pin - never noticed that little skid plate before though:


No EGR:


Took the air cleaner off:


After some futzing about I had the EGR mounted:




Don't forget the EGR gasket:


Next up was the air rail. First I soaked the air rail plugs that have been in there since 2005 in PB Blaster:


I decided to take the valve cover off to give myself easier access, especially to the #6 plug:




With my makeshift cheater bar I was able to get all the plugs out:


I had to grind a little bit out of the JT Outfitters power steering bracket to get the #1 air rail extension back in place - all the rest went pretty easy:


It now makes sense why this water fitting is so wonky on the head - it has to dodge the air rail:


Got everything lined up and torqued down:




One side of the extension is a tapered thread the other is a straight thread:


I then decided to give myself a little bling in the form of a 2F embossed valve cover and screw-in oil cap. I need new valve cover seals:


Next was the smog pump. It barely made it in between the steering intermediate shaft, EGR tubing and the power steering pump hoses. It turns out my pivot bolt is not the original bolt, so that needs to be remedied. It also appears that the support bracket needs a bushing or something, which I was hoping someone could confirm for me. In other words, the rear mounting hole for the smog pump is larger than the forward hole, so for a bolt to be held firmly around its circumference there needs a bushing in the rear hole to take up the extra space:


Next it was time to mount the ABV. Found its original home on the driver fender:




Decided it was time to put the air cleaner back on with new OEM wing nuts and seals:


Hooked up the new air intake hose I got from BTUMAN on MUD - I've been running nakman's dryer hose for a long time now but decided to go with this:


It's not perfect, but neither was my previous solution:




I have this in the garage, in pretty good shape, some small cracks, just in case. Need to figure out how to take care of it.


As of Feb 2, 2015, these are now available - would have gone with this if I had known it was coming:
http://forum.ih8mud.com/threads/air-...d-fj55.836312/





Next I had to find my vacuum valves. They were in the obvious place with my grease guns, yard flags, and files . Mounted the VCVs - the bracket only goes one way on the thermostat housing:


Mounted my VSVs and vacuum surge tank on the driver side fender. This stuff is specific to 1977 models, so I made sure to take care of it. My EVAP VSV (the top one) had a broken nipple and was inop when I took receipt of this vehicle, so I got a new one from cruiserparts.net. It took a couple tries to get one that was functioning, but we finally got there:


Starting doing up my vacuum hoses:




My Red VTV also had a broken nipple so got a new one from cruiserparts.net. Again took a couple tries to get the right one, but we're good now:


So here's where we ended the day. Not as nice as simps or anyone else in the club, but should be functional and pass visual as long as they don't care about my '78 carb that has extra connections I can't use and my '79 distributor that also has an extra connection I can't use:




I'm still missing some parts - notably the smog pump tensioner bracket and smog pump pivot bolt, which I'll post up in the classifieds for. But at least all of my major components are accounted for after all these years.

'Til next time...
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1977 FJ40 2F "Brahma" + Lockright, tach, Warn 8274, FJ60 Power Steering, no more Sanden OBA (factory emissions)
1996 FZJ80 1FZ-FE factory lockers + Safari Turbo , CDL switch, cup holder, Metric TLC leather, heated seats and JDM switches
2000 Tundra Limited TRD 2UZ-FE SOLD

Last edited by subzali; 02-17-2015 at 09:15 AM.
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Old 01-25-2015, 10:12 PM
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Nice work, Matt! notice any difference in how it runs? man I'd forgotten about that dryer vent...
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Old 01-25-2015, 10:19 PM
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simps80 simps80 is offline
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man that took some good foresight to save all that stuff!!!
that's cool

for whatever reason I get excited about smog equipment that works...maybe its because you know its only going to get worse trying to keep plates on these trucks.

very neat Matt!

as far as that air pump bracket it is bushed down diameter on the the block side of the bracket.....the picture shows the spacer behind and that bushing for diameter
but iirc it was just two separate 'spacers'

edit..
Yea its two spacers front and back..got a better pic..

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Old 01-26-2015, 05:54 AM
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subzali subzali is offline
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Quote:
Originally Posted by simps80 View Post
man that took some good foresight to save all that stuff!!!

that's cool



for whatever reason I get excited about smog equipment that works...maybe its because you know its only going to get worse trying to keep plates on these trucks.



very neat Matt!



as far as that air pump bracket it is bushed down diameter on the the block side of the bracket.....the picture shows the spacer behind and that bushing for diameter

but iirc it was just two separate 'spacers'



edit..

Yea its two spacers front and back..got a better pic..



Attachment 40382

Thanks Mike, that picture helps because I'm missing all that stuff.

But I am also curious about the lower bracket. It seems the rear mounting hole needs a bushing as well.

Tim, I haven't run it yet because I need a new belt for my air pump and power steering pump. But I can't drive it to the store because my steering gear decided to puke all over the place. But that's a different "Project."
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Matt Miller
TLCA# 13684
Rising Sun Bio
1977 FJ40 2F "Brahma" + Lockright, tach, Warn 8274, FJ60 Power Steering, no more Sanden OBA (factory emissions)
1996 FZJ80 1FZ-FE factory lockers + Safari Turbo , CDL switch, cup holder, Metric TLC leather, heated seats and JDM switches
2000 Tundra Limited TRD 2UZ-FE SOLD
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Old 01-26-2015, 07:23 AM
SteveH SteveH is offline
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That was a lot of work - congrats. Looks much like my fully smogged '78. Best wishes in rounding up the last little bits and getting it back on the road!
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Old 01-26-2015, 05:43 PM
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I have an old pump with the lower bracket still attached..looks like you are right it has a bushing in it..
Lemme know if u need it..

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Old 01-26-2015, 07:47 PM
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subzali subzali is offline
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Thanks Mike, Ima gonna see what my man Gene at Groove has for me in a few days and go from there. I will let you know.
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Matt Miller
TLCA# 13684
Rising Sun Bio
1977 FJ40 2F "Brahma" + Lockright, tach, Warn 8274, FJ60 Power Steering, no more Sanden OBA (factory emissions)
1996 FZJ80 1FZ-FE factory lockers + Safari Turbo , CDL switch, cup holder, Metric TLC leather, heated seats and JDM switches
2000 Tundra Limited TRD 2UZ-FE SOLD
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Old 01-26-2015, 10:01 PM
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[sarcasm]Of course you realize that if you hadn't completely resmogged your 40, you would be the individual that would tip the climate change and we'd all die! So good work on that, and thank you for saving humanity![/sarcasm]

Having spent most of last night re-installing the (cleaned, lubricated and now functional again) smog pump on my 60 last night, with the scrapes and bruises on my forearms and wrists to show for it, I totally feel your pain man. Nice work, even if it didn't do jack to make it run better, get better fuel economy, or be more reliable...
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Old 01-27-2015, 12:28 PM
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subzali subzali is offline
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Ha ha thanks for that Jeff.

Does anybody have good pictures of the PCV hose routing, including support brackets?
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TLCA# 13684
Rising Sun Bio
1977 FJ40 2F "Brahma" + Lockright, tach, Warn 8274, FJ60 Power Steering, no more Sanden OBA (factory emissions)
1996 FZJ80 1FZ-FE factory lockers + Safari Turbo , CDL switch, cup holder, Metric TLC leather, heated seats and JDM switches
2000 Tundra Limited TRD 2UZ-FE SOLD
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Old 01-27-2015, 02:22 PM
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Mine goes up from pcv
Two loops on air cleaner carry it around the back.
A bracket mounted to carb insulator plate with loop carries it down then into the fitting on the manifold.

mine has an extra loop now with an oil separator after the last bracket on the carb insulator but before joining the fitting on the manifold....but without that it catches the bracket on carb insulator then into intake

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