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Finally...a mall crawler



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Old 07-26-2007, 09:06 PM   #1
 
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Finally...a mall crawler

Well it's only been 2+years since I bought my YJ...I finally passed the state emissions test today, and I don't mean just squeakin' by. I was spittin' out 1/4 or less of the max allowed HC and CO on the two speed idle test. It took 4 tries and lots of change this change that to get her through.

Note: if you're running 80 psi in your MPFI system that's suppose to have about 40 psi, the computer, try as it may, cannot overcome the extra shot of gas that keeps dumping into the cylinders every time an injector fires. HC and CO were 3-4 times the limit due to unburned gasoline. After my 3rd failed test, I tested 3 separate (used) pressure regulators and all were coming up 80 psi. Russ Baer at Baertrax said, "I bet you crushed your return line on a rock and it's blocked."

I pulled the return line from the fuel rail, ran a line over to a bucket to catch the fuel and whadaya know...35 psi. I traced every inch of the line and could find no pinches or anything else that looked suspect. I blew air into the line from the engine side and heard nothing in the tank. Hmmm...must be a problem inside the tank. Crap...PITA to pull the gas tank, but I was thinking about doing it anyway to make room for a little rear stretch action.

When I removed the last screw holding the sender/pump assembly down, the whole thing kinda sprung up. That's odd. When I examined the pump/return assembly, it hit me: my long-ago bent gas tank skid was pushing up against the plastic tank, which in turn pushed up against the return hard line. Even with the skid removed, the tank had been deformed for so long it was still going to possibly shut off the return. I cut about 3/4" off the end of the return and strapped the gas tank into the "bed" of the jeep, running new rubber line from the frame up to the tank.

Fixed it.

Now I can legally cruise the Sonics and malls in my YJ. She's inspected, tagged, and a new "street legal" title on the way.

2004 TJ Sport will be for sale very soon. I don't need two streetable jeeps.
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Old 07-27-2007, 04:38 AM   #2
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