1984 FJ40 Restoration

[sarmadqureshi]

Smooth sailing brother.
Can you do me one favor. Can you measure the length of the oil dip stick and let me know, on the 2F.

Thanks

[nOmS6]

@sarmadqureshi: thanks bro. Will measure the dip stick length for you in the evening when visit the workshop. Will also check the manual for factory specs and will let you know.

@daudbros: 2F will consume more CNG for sure but I am no expert or advocate on CNG conversions for cars designed for petrol. I think usman in Islamabad had a CNG with his 2f recently. He said getting Rs 4/km. I know a consumption of 1km/litre with petrol is way too low. I have not tested mine but am pretty sure I am getting somewhere around 4-5km/litre even now when the engine and carburetor is not finely tuned still. I am expecting to get 7-8 km/l on highway after the running period is over and engine is properly tuned up.
There is something wrong with your engine tune up or the carburetor to give such low mileage. (you know this already ) I would suggest getting the engine tuned first before going for a carburetor change. I have orginal factory specs for valve, point and plug clearances. These helped a lot tuning my engine as the mechanic was setting all clearances wrong initially. If you want, I can send copies to you. That might help. What kind of condition your valves, plugs and carburetor is in at this point? does your exhaust throwing out a lot of unburnt fuel? is the running of engine smooth or with hiccups?

I would love to share all I know and will try to be of help. Can't accept a 2F giving 1km/l on petrol.. no no.. bad repo for such a great engine..

[daudbros]

@sarmadqureshi: thanks bro. Will measure the dip stick length for you in the evening when visit the workshop. Will also check the manual for factory specs and will let you know.

@daudbros: 2F will consume more CNG for sure but I am no expert or advocate on CNG conversions for cars designed for petrol. I think usman in Islamabad had a CNG with his 2f recently. He said getting Rs 4/km. I know a consumption of 1km/litre with petrol is way too low. I have not tested mine but am pretty sure I am getting somewhere around 4-5km/litre even now when the engine and carburetor is not finely tuned still. I am expecting to get 7-8 km/l on highway after the running period is over and engine is properly tuned up.
There is something wrong with your engine tune up or the carburetor to give such low mileage. (you know this already ) I would suggest getting the engine tuned first before going for a carburetor change. I have orginal factory specs for valve, point and plug clearances. These helped a lot tuning my engine as the mechanic was setting all clearances wrong initially. If you want, I can send copies to you. That might help. What kind of condition your valves, plugs and carburetor is in at this point? does your exhaust throwing out a lot of unburnt fuel? is the running of engine smooth or with hiccups?

I would love to share all I know and will try to be of help. Can't accept a 2F giving 1km/l on petrol.. no no.. bad repo for such a great engine..

Dear This 1/km is still higher siide I think it's consume more then this. I will be thankful If u send me setup details. I am very much upset due to this I cannot use my FJ40 due to high consubtion of fuel. I will be waiting for it,

Regards

[sarmadqureshi]

AOA, It's excellent restoration work you have done a lot. I want to know that I have FJ40 1984 Model too. I install CNG Kit in it, But the problem. is it's consume lot of CNG and you have all the time refill it. If I use Petrol it's gives only 1km per litter.

I want to know about your TLC consumption ? If it's good I may change carborater to get good mileage

Please advise me.

Regards

Ahmed Dawood Karachi
0321-202-7788

o:o:o 1km/liter ....... no way.
Your tune-up is all wrong then. I can't be that low.

[daudbros]

o:o:o 1km/liter ....... no way.
Your tune-up is all wrong then. I can't be that low.

Dear Samad, do you know any good micanic in Karachi if yes let know.

Regards

[nOmS6]

THE POWER STEERING IS WORKING : finally

The new mechanic has been able to get the power steering working on my rig. He replaced the pump with a more powerful one from a later Toyota and replaced the pressure pipe with an original one, but the result was still not perfect. So we changed the Power Steering gear box and VOLA! the power steering is behaving now as it should have in the first place. His diagnosis: water must have entered the old box and ruined it. I am happy as long my rigg is steering smooth and without effort.

THE BRAKES ARE RESPONSIVE : not hard anymore

The new mechanic also suggested changing the original brake servo with one that came on later models with disk brakes. The later one has double diaphrams. So we went ahead and replaced the servo as well. And now my brakes are responsive and do not require that you press them with all your life force in order to stop the vehicle. I am happy with the brakes now.

RADIATOR:

I didn't replace the original radiator as the previous mechanic said that with servicing it will be fine. Now he told me that the front lines are clogged.
So I am looking for a 4 or 5 line radiator to replace the one that came with the vehicle. This would be the last big part replacement on my rig for now.

ROLL CAGE:

This is a tricky one. If I go for a cage designed to hold the soft top and look good, I lose on the strength/safety requirement. And if I go for safety I lose the cosmetic appeal of the car when the hood will be removed. So I am thinking..

LEAF SPRINGS:

This is next in line. The shackles and the pins need greasing and the leafs themselves need to be checked and adjusted to give the rig a proper balance. It leans a bit to the drivers side (very common for TLC FJ40) and is somewhat sloping to the rear. I might add a leaf to give a lil lift and weight carrying ability.

That said... it's fun driving and I am looking forward to when the running of 1000km will be complete so that I can properly flex the rig.

[gamemaster]

masha Allah very well done

[nOmS6]

So it's been some time since my last update on the rig.. In the meantime, the rig is now a member of club 4 X 4 Engaged? and has had its first outing on river ravi.. coverage of which can be found on SUV forums by the title "4X4 Engaged: A winch alone is not enough"

I was quite pleased with the performance on the first 4x4 outing. No hiccups at all..

So I got me Mud Terrains yesterday. These are Cooper Discovery STT in 235/85 R16s. Look great and am hoping will perform even better.

The Roll Cage is ready as well along with padding and cover. The soft top has also been initialized. Inshallah will be ready by next week. Will post more pics with the roll cage after I install it tomorrow.

aiighty..

[sarmadqureshi]

NIce rubbers, how much was a set for ?

[nOmS6]

got them shipped from Karachi, Highway Traders.. for Rs.14000 a piece..

[daudbros]

Excellent Work you done. I think it's best FJ @ pakweels.com. How much it cost you ? Do you have any plan to sell it even I have FJ40 too. But I admit your FJ is very nice and beautiful I ever seen.

Regards
Ahmed Dawood
Karachi

[nOmS6]

@daudbros: Thank you sir. Your words are indeed very kind. The generous appreciation I have received during and about my project FJ40 on PakWheels has been a real motivation factor. Not to forget the tips and "role models" of PW :). The total project cost so far has just crossed 700Ks with the purchase of new tires. Still to get are a soft top, a new radiator, primary beams (current stock ones do not have sufficient light) and winch repair and installation.

I realize being at higher ends with my cost of the project. I had to redo a lot after it came on road. The original mechanic didn't prove to be expert enough and all the money saved by hiring him at the start had to be paid after all to the "real jeep mechanics" in the end. I tried and stay stock replacing most with genuine new or best kabli. Some things I know have been bought expensive. Yea.. i've not done good on budgeting.

How's your FJ40 coming along? I liked the roll cage you made for it. And the flames are just too cool. I hope the mileage has improved from 1km/lt.. mine is roughly doing 4.5km/litre. I'm hoping it will improve after the engine running is complete and the tuning is redone.

Plz let me know your email and I will send you the soft copy of FJ40 Repair Manual. It is quite helpful.

Regards

PS: no plans of selling. the rigs my baby (H)

[isiddique]

@N0ms6 excellent work bro. "primary beams (current stock ones do not have sufficient light" try to get "Relay" install with primary beams.
Relay will give you plenty of light. Mine was installed by an electrician in Lahore.

[Ghilzai]

One of best FJ 40 restorations and got to witness the performance first hand. With new shoes the looks are killin and I am sure the performance too.

Good luck and enjoy .....

[wasifali89]

this is literally awsome

[capsat]

what a marvellous restoration work. Congrats. - allow me to request - post your FJ restoration work in picasa albums and as the work progressed and post the link here. am sure many of us like to see the progress from MT stores to roll-in of rig in PVT plate and new shoes... ! once again what a great job & effort, am sure fruit of patience is always so sweet sexy and adorable

[askhokhar]

I saw the thread in new posts today, and just before I clicked on the link, I tried to visualize how I would do this kind of D.I.Y

... this car is so different from what I visualized ... and, it is far far better than what I thought I would do..!!!

You have done a great job in restoration of the vehicle according to the original specs, and deviated only when it was imperative. Marvelous Sir!!!

Bohat mubarak ho..!!!

Your project deserves excellent 5-star rating

[choctalpur]

Very impressive noms6. I'm not much lover of FJ40, but yours is inspirational.

[tareen]

@N0ms6 excellent work bro. "primary beams (current stock ones do not have sufficient light" try to get "Relay" install with primary beams.
Relay will give you plenty of light. Mine was installed by an electrician in Lahore.

Another solution (though comparatively expensive but simpler & lasting) would be to have flat(er) beams usually referred to as Pajero type or Tube type. They are much brighter & give a nice arc-like light rather than an uncontrolled splash of light ahead.

The usual convex face lights are about Rs.3-400 (new) whereas the flat-face will be around Rs. 1000 a piece (used).

[tareen]

@nOmS6....Brother, awesome choice of rubber. I have yet to see anything more aggressive, grabbing & biting in locally available choices. Another excellent choice you have made is the size.

Thumbs up!