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FJ40 I call Shipwreck

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  • SuperBuickGuy
    replied
    Promised pictures of tank

    yeah, it looks like it literally combusted....

    so I got that issue resolved with the pump and new tank, but I still had a stutter at 2000+ rpm.... the mystery deepened when the computer showed everything working happily.... spark, and it's not the first time I've had a coil say FU when it got warm.... didn't really care about getting a performance one but I did care about getting one today - so I did.... and it works great now

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  • SuperBuickGuy
    replied
    and then it started leaking

    take apart

    reassemble with tape rather then paste


    leak free again - and it runs fine now. I'll take it for a spin tomorrow, but I think I'm going to build a heat shield for the tank.... that plus the air gap it has now ... I dunno, maybe the sheets of fail were plugging the sock....

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  • SuperBuickGuy
    replied
    onward

    cut the fill off the old tank and weld onto the new

    welding

    and the side

    hmmm, and another


    more welding

    so a puzzler.... I had this reflective stuff on the old tank, and it looked like it got warm.... but I've gone back to pictures when I pulled the tank out once before and there wasn't an issue

    I may have dodged a bullet....
    plumbing - part of the issue with the old was it had a fuel smell - that I attributed to the non-vapor-proof braided return line


    runs again, fuel sender is correct (which will be nice), and no fuel smell - that said, expect pictures of the old fuel tank and the time when I had pulled it out....

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  • SuperBuickGuy
    replied
    I don't know why it failed, but it was supposed to be happy with the new fuel.... coming off in sheets does not suggest that it was happy

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  • STINEY
    replied
    I am suspicious that all of the traditional tank coatings are like the old fiberglass boat tanks - perfect products in their day, but now with gasoline being something different than what it used to be.........

    Ethanol is just one of the modern components that don't play well with older style materials. Who knows what else is in todays "gasoline" that causes things like that coating failure in the FJ.

    Gas sure don't smell ANYTHING like it used to when I was a kid in the 80's. Now its just butt nasty......it was almost sweet back then.

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  • DanStokes
    replied
    Yes, I was thinking RedKote. I'm welding two tanks together so there will be a weld all the way around it. I'm doing belt and suspenders to make sure to avoid leaks and the coating is the final step. The tank halves are new and I'll clean them well following the weld so I think the coating should have maximum chance of adhering. I hope.....

    Dan

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  • SuperBuickGuy
    replied
    no coating, just use drain cleaner and a chain to break down the scale and convert the rust.... what kills me about all of this - when I repaired the fuel sender, the coating was fine.... now? not so much
    Last edited by SuperBuickGuy; December 20, 2019, 11:51 AM.

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  • STINEY
    replied
    RedKote

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  • DanStokes
    replied
    That coating was nasty. I plan to line the expanded tank in the Volvo and now know not to use that stuff - I'm leaning toward the red product that's been around for years (can't remember the name of it).

    Dan

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  • silver_bullet
    replied

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  • 65RHDEER
    replied
    I think you've got it licked now SBG, well done.

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  • SuperBuickGuy
    replied
    parts.... wheee

    correct hole saw

    marking


    bit of acetone and it looks decent

    painting the hole

    old tank, didn't blow the hydramat off, but lordy did that coating fail



    and the assembled Holley intank with new hydramat

    and roughly in place, I'm going to weld the old filler onto the new tank

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  • SuperBuickGuy
    replied
    onward, fitting

    pump goes between the straps

    and dead end, thought it needed 3 1/2" hole saw, no, 3 1/4.... ugh
    other bad news is I don't have enough fuel line - so even worse news I had to buy from Summit to have any hope of it arriving before the weekend.....

    and the codes.


    first is P0305 = misfire... yeah, no kidding
    second is interesting P0505 = IAC malfunction
    the FiTech ones are (and a pain to find)
    38 is timing interference
    53 is IAC again....

    now the puzzler - none of these codes appeared at first break-down (it warmed to 140* then wouldn't run - like no fuel no run)....

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  • SuperBuickGuy
    replied
    theory is the pump comes tomorrow.... so forward
    remove the seat

    see the silver stuff that's lifting? that's the POR tank coating.... the inside of the tank looks about the same

    drain the gas


    and shoot.... okay, I should have checked this long ago (when I tried to burn it down) but it appears I need to do some recoating under the tank


    What's interesting (at least to me) is the ceramic coating/sound deadener survived just fine, it's the liner on top that got baked.... I was a fan of the coating before, even more so now

    the tank fits the hole, but it's not without needed mods


    probably I will weld a new neck in place....



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  • SuperBuickGuy
    replied
    and Summit is as incompetent as the rest.... that package, arrived today.... pretty sure it's free.

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