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Old 10-30-2008, 04:26 PM   #1
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Nightmare...

I guess it's appropriate to have a good nightmare this close to Halloween but damn!

OK, so today I tuned up the Sarge. Got a cap, rotor, plugs, wires air filter...etc.

I tuned it up then I went to change the oil. The filter I looked up was wrong. I worked parts WAY to long to look myself up the wrong oil filter. I jotted down the number of the filter that was on the Jeep, borrowed tiny's rig and drove back to the parts store.

When I looked the filter back up, the filter I originally purchased was the one it called for. The filter on the Jeep fits a considerably newer XJ. OK, the Jeep is 21 years old and I can see there being an engine change along the line but it has me a little spooked. I know it's just my imagination running wild because the Jeep does run beautifully but still...

Oh well, on to the next part of the nightmare...

The Evap Emissions system had been bypassed. So, I figured I need to hook it back up due to the fact that I have to have this thing smog tested. So, I hook it all back up and when I start the Jeep I get this insane high idle. I thought it was just my stupidity in hooking it back up. I figured I hooked it up wrong. I checked the repair manual and guess what?! The illustration shows all kind of goodies that should be hooked up that aren't. Vacuum Tees and lines that just don't exist on my Jeep.

So, I guess I have to go to the store and buy a bunch of spaghetti to hook this thing up right. I would rather stick a needle in my eye.

Has anyone else had to rebuild their vacuum system from scratch?

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Old 10-30-2008, 04:54 PM   #2
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Has anyone else had to rebuild their vacuum system from scratch?
Sorry, that was not good input.

I have never done vacuum lines on a YJ before. I did it on a 81 Chevy PU once and it wasn't that bad. I had a diagram and all the correct parts.

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Old 10-30-2008, 04:58 PM   #3
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holiday inn express. staying at a mere holiday inn is like the equivelant of getting a preschool diploma. staying at a holiday inn express is like graduating summa cum laude from harvard law school.
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Old 10-30-2008, 06:50 PM   #4
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I helped a friend with a V6 XJ on his emissions stuff... holy crap! Be prepared to spend some time out there with it.
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Old 10-30-2008, 07:10 PM   #5
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I helped a friend with a V6 XJ on his emissions stuff... holy crap! Be prepared to spend some time out there with it.
HEHEHE... Yeah, thats kinda what I expect. Jeez, this is gonna suck.

Using the diagram in the book I made this pic on Paint:



I figured I'd post it in case anyone with an early YJ / 2.5 needs a reference.

Anyway... You see all the black and gray? Yeah, I have to build that!
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Old 10-30-2008, 07:23 PM   #6
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Are all the line missing? or just rotted/retired in place. When I did this I kept running short (I didn't buy enough) on the amount of lines I purchased. Don't get stingy and some pictures for routing would be handy.
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Old 10-30-2008, 08:34 PM   #7
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I am not sure about your State regulations Cain but here in Maryland I got around the smog because the Jeep is older than 20 years, here I registered my Jeep with HISTORIC tags and therefore no emissions / inspection are required.
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Old 10-30-2008, 08:57 PM   #8
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Are all the line missing? or just rotted/retired in place. When I did this I kept running short (I didn't buy enough) on the amount of lines I purchased. Don't get stingy and some pictures for routing would be handy.
Yeah... Everything is capped off with vacuum caps. I went back to the parts store tonight... I bought a freakin' box of of 65 tees and connectors, a bunch of vacuum hose. Hopefully I can get it all ironed out before the weekend.

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I am not sure about your State regulations Cain but here in Maryland I got around the smog because the Jeep is older than 20 years, here I registered my Jeep with HISTORIC tags and therefore no emissions / inspection are required.
Yeah? I'm not sure about the historic plates here. I do know that the reg says if your car needs a smog check if it's more than six years old and made after 1976.
And, when I lived in WV if you had Antique plates you could only drive it on weekends and to and from events. I'd have to check it out. Thanks for the idea.
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Old 10-30-2008, 09:39 PM   #9
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Maryland has a similar rule - you're not supposed to drive Historic or Street Rod vehicles "daily". No rule about days of the week, or day/night specification.

My answer if it comes up?

"Sorry, officer...my <whatever other vehicle> is in the shop waiting on parts".
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Old 10-31-2008, 12:12 AM   #10
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Or you could register it here at my place Cain, NO EMISSIONS!!!

But yeah, look into other forms of registration. Some don't require emissions testing depending on how the vehicle is used... I donno how Cali is about that stuff though.
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Old 10-31-2008, 12:27 AM   #11
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Hey Chris, you should've just left it all as it was when you got it and had it tested. If it failed then I think there is a program in Ca. that will help you get it fixed correctly with state funds. Might as well make Cali work for you for a change.
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Old 10-31-2008, 01:10 AM   #12
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Hey Chris, you should've just left it all as it was when you got it and had it tested. If it failed then I think there is a program in Ca. that will help you get it fixed correctly with state funds. Might as well make Cali work for you for a change.
Thank you Jack! I had just read about that program. Since I've already got the parts and love to tinker, I'm gonna get underway. But if what I do still doesn't let it pass then I am going to go that route. Nice catch Jack! Thanks again!
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Old 10-31-2008, 07:28 AM   #13
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I pretty much got the Historic tags so that I could run my rig with the true-duel exhaust and not have any CATs, and it would be damn hard to prove that my rig is my DD unless the same cop pulled me over repeatedly.

Good luck whichever way you go.
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Old 10-31-2008, 07:54 AM   #14
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i'm thinking about getting historic plates on mine. i want to bypass my catalytic converter what kind of trouble can i get in doing that? once you are registered as a classic car in nj you no longer need to get inspected, so will anyone even find out?
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Old 10-31-2008, 02:43 PM   #15
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Update:

So, this morning, I started tackling this project. Once I wrapped my head around it, I was amazed at just how simple a task it was.

The diagram was dead on. Once everything was hooked up I held my breath as I turned the key. Bear in mind, yesterday, I had to turn the throttle adjustment WAY back. When she fired up the idle was real low. I adjusted it back up to 1000 rpm and listened to the orchestra that is a Jeep idling perfectly. tiny and I cruised around the complex and the biggest difference (other than how phenomenal the thing runs) is the lack of choking exhaust fumes wafting in the rolled up back window. I'm not kidding, this thing used to run so rich that it choked you and made your eyes water in the garage. Now it's clean burning. And ZERO acceleration was lost to the upgrade. I'm chuffed. I guess I need to make an appointment to get it smogged now and see how it does.
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Old 10-31-2008, 02:56 PM   #16
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Well that is much easier than a GM V6 in an XJ to hook up. Plus, we didn't have a complete diagram like that. Good job on getting it running.
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Old 10-31-2008, 02:59 PM   #17
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Well that is much easier than a GM V6 in an XJ to hook up. Plus, we didn't have a complete diagram like that. Good job on getting it running.
Thanks Az!

I was doing a little digging around today and I confirmed the "Late Model XJ" engine thing which I discussed yesterday.

On the manifold where the firing order is there is a great big "XJ" casting right below it.

So as it stands today... I have an 87 YJ with a 96 XJ engine. Maybe Frankenstein isn't dead after all.
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Old 11-02-2008, 04:27 AM   #18
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Thanks Az!

I was doing a little digging around today and I confirmed the "Late Model XJ" engine thing which I discussed yesterday.

On the manifold where the firing order is there is a great big "XJ" casting right below it.

So as it stands today... I have an 87 YJ with a 96 XJ engine. Maybe Frankenstein isn't dead after all.
Chris, if that's the case then I don't think you will have any problem what so ever passing CARB. They should only test it based on the emissions equipment for a 1987 motor. If you have everything hooked up from the 96 it should be heads and tails above what's needed.
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Old 11-02-2008, 09:55 AM   #19
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Chris, if that's the case then I don't think you will have any problem what so ever passing CARB. They should only test it based on the emissions equipment for a 1987 motor. If you have everything hooked up from the 96 it should be heads and tails above what's needed.
Thanks Jack! I do have it hooked up (according to the book) the way a 96 4cyl "Wrangler" is supposed to be hooked up. I don't have a book for the XJ. Everything seems to be operating normally. I'm assuming the the XJ and YJ emissions systems in 96 were either the same or similar. I was shocked that all the components were there. Granted, there were some questionable wire connections at the plugs for some of these components. Kinda looked like whom ever did the engine change either did it in a hurry or wasn't savvy with a pair of wire strippers. I HATE to see wire nuts on ANYTHING automotive! But, I digress.

Keep your fingers crossed!
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Old 11-02-2008, 01:01 PM   #20
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i got kinda this evap problem...im glad yours worked out.

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