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When was the last time you pulled the spark plugs? What do they currently look like? This will be helpful in identifing your problem.

If we are talking about the sending unit having a broken hard line at the bulkhead and it were me, I would just replace the whole thing even if I had to order one. They are under $35 for the part and yes it's a PITA to drop the tank, but even the smallest crack in a fuel line will be trouble.

Now those are some crazy regs........ So, since your block is an 81, can you build to the 81 specs? If it were me, I would go that route. By 81, the in-line 6 would have had more performance options and some emissions control equipment. Do these regs. affect your choice of distributor? If...

what is it connected to inside the passenger area? There are a couple of connections in that general area. It may very well be a wire for the coil, netural safety switch, oil pressure sending unit, oil low pressure stuff off (if equipped) or just a wire that someone else ran that is no longer in...

Correction- the negitive side of the coil, sorry.

If it where me, I would install a Maxi-style blade fuse rather than a OEM link (not sure if going to find it at the local store anyway). As for the Tach wire (hoping it's green colored?) goes to the positive terminal of the ignition coil or if you have HEI, it goes on the blade connector marked...

Maybe one of the Moderators could move this to the correct category and start a new thread?

Yes, if the wiring harness is from the 86 CJ, you can very re-use the delco alt. Depending on what distributor you are planning on using, you will have a little re-wiring to do, but fairly straight forward.

Is the box on the drivers fender well with two seperate wire pigtail coming off the bottom of it? If so, it is the ignition module for a dura-spark unit (emissions equipped vehicle).

I'm kind of at a loss as I'm not familiar with CA emissions regs......... So in reading your posting, if the tag you have states that it's a 77 engine, you would need components that were available for emission from the manufacturer during the specific year? And vice versa for the 81 senero...

If I understand what you're saying, the 86 would have had a delco style altenator with an internal regulator and a simple single post connect (and two slot wire clip on the top). The 304 from a 76 would have likely had an external regulator. Maybe you have mix matched the parts?

One other thing to consider........... CJ's have in-line fusable links at the begining of all primary circuits with the exception of the battery to starter cable. Do you have power at the starter solniod where the cable from the battery connects? If so, you have like burned up a fused link.

X2- It's going to be a PITA, but I would eliminate this possiblity. Other than taking the oil pan off again, you'll only need a plasti-o-gauge and your time to figure it out.

Well said.....Sir!

What do you mean by fasteners? The C clip?

Hey, I didn't notice your newer photos, you have the CTO's in the right places.Look at the new photos, you've done a fantastic job on the motor. I would thing all your going to need is to just re-connect each vacuum line at a time?

Ok.....I need to cut back on the crack! I looked in my Chiltons manual this evening and I (and we for that matter) made some incorrrect assumptions. First off, the one CTO valve in the thermo housing is correct (however I believe from the diagram below, its the wrong one in there currently?) I...

"The second pic is a three pronged connection that is attached directly to the manifold." Sorry, missed this the first time!So, I see how this is confusing. If the bottom (large hose) is connected to the bottom of the valve and runs to the manifold (it would have to be threaded barb just below...

First photo: The CTO that is in your thermo housing needs to move to a thread port on the intake manifold. The temp probe will go in its place. Second photo: The CTO valves can be interchanged, a CTO is a CTO other than the barb/nipple size. They are just thremo switches that control airflow...

I see 69jeepCJ and I are on the same schedule....... In certain circles, I would say" Jinx-you own me a Coke". As he stated, the first photo is were the temp probe goes (I knew something was bothering me about these photos). So where is your temp probe at now? You may need to switch thier...