J CARBURETOR 2-6 SUBARU. M MECHANISM AND FUNCTION rem 1, Float System blll SWITCH VENT SOLENOID VALVE 1 992 2. Primary Side ‘SLOW SYST! MAIN SYSTEM ACCELERATING PUMP SYSTEM .. POWER SYSTEM SERVICE ‘SLOW FUEL SHUTOFF SYSTEM 3. Secondary Side MAN UAL ‘STEP SYSTEM .. MAIN SYSTEM 4, Fuel Supplement System When Cornering 5. Automatic Choke System... AUTOMATIC CHOKE MECHANISM... VACUUM DIAPHRAGM MECHANISM .. CHOKE BREAK DELAY VALVE MECHANISM. S$ SPECIFICATIONS AND SERVICE DATA .. ‘SPECIFICATIONS .. MAINTENANCE STANDARDS .. ‘© COMPONENT PARTS: 1. Air Intake System and Air Cleaner 2. Intake Manifold and Carburetor 3, Carburetor ASSY . W SERVICE PROCEDUI REMOVAL DISASSEMBLY INSPECTION .. ASSEMBLY » INSTALLATION REPLACEMENT ... CHECK AND ADJUSTMENT .., T TROUBLESHOOTING .1A0] CARBURETOR oe AND FUNCTION carbure fetor is a two-barrel, down-draft type and consists essentially of the following systems. 1. Float system Stow system Main systern ‘Accelerating pump system Power system choke system Stow fuel shutoff eyetem ‘Stop system Main system 4. Fuel supplement system when cornering ‘5. Automatic choke system 2, Primary side 3. Sacondary side-—{ 1. Float System ‘The primary and secondary sides share the same float system. The fuel in the fuel tank is routed through the fuel pump and needle valve into the flost chamber, The fuel level in the float chamber is always maintained con. stant by the functions of the needle valve and float, The height of the fuel level is adjustable by adjusting the float seat. A; SWITCH VENT SOLENOID VALVE The switch vent solenoid valve goes off when the ‘engine stops (with ignition key in the “OFF” position) and the valve seat is pushed by the spring tension and blocks the inner vent. ‘This directs the pressure inside the float chamber and the evaporative gas toward the canister through the outer vent pipe. When the engine is started (with the ignition key in the “ON" position), the solenoid vaive comes on and the magnetic force overcomes the spring tension. By this, the outer vent is blocked and the inner vent functions normally. ‘To conieter t Fun! int pipe unl return pipe Fier ‘Needle valve lost Susltch vent solenoid valve Annee vant pipe Outer vant pipezt CARBURETOR fo2Ao) 2-6 I 2. Primary Side A: SLOW SYSTEM FUEL [Farcanie |_,f ram ramen iow Pinay) z Economizer air bleed (Primary) [>| Slow system passage an [awed ‘Slow air bleed (Primary) So By-pase hole “Throttle bore (Primary) — J tate nozaie To ineke marifold | Re | | J) Primary throttle valve z = Fig. 2CARBURETOR B: MAIN SYSTEM rue Float chamber |_| main jot rior Y Emulsion tube AIR t "A horn ‘Main air blood (Primary) ¥ ¥ ‘Large vertur (Primary) ‘Small venaur (Primary) Main nozzle (Primary) a Throttle bore (Primary) [PT intake manifold 1. Secondary main’ 2. Secondary main nozzle 3 Choke valve 4 Primary sir vent pipe 5 Primary main nozzle Primary main air bleed 7 Primary main jot 12 Primary emulsion sabe Primary throtdle valve 10. Secondary throttle vee 114. Secondary emulsion tube 42. Secondary main jet EECARBURETOR IM2co]_2-6 ’ ACCELERATING PUMP SYSTEM et est ane! |_,[ eave an |, Fo ona Tage vol Pinan le Po noe |e —[onervove a ‘Throttle bore (Primary) }—To intake manifold + Hon chemer 1 rp ar 2 Pin 3 Pore wha 4 Inmet a 2 Our asi walht yf, i waar Fig. 4CARBURETOR FUEL Float chamber L,[ Power vaive Lf emution ive erimary) | yf tain nante (Primary) Entry of fuo to main system ‘Thratte bore (Primary) ‘Large vertu (Primary) ‘Small vertu Primary) t To Intake manifold Primary sideCARBURETOR IM3A0]_2-6 —; SLOW FUEL SHUTOFF SYSTEM When the ignition starter switch is in the position other than “ON” or “START”, current does not flow to the anti-dieseling switch and the anti-dieseling switch nee- dle valve cuts off fuel feed passage, thus preventing the engine from dieseling. 1. Economizer ar bioed 2 Primary slow alr bleed 3 Antisaling witch 44 Primary slow jet 22475 Fig. 6 3. Secondary Side ‘A; STEP SYSTEM FUEL ain Float chamber Tir horn Main jot Secondan Siow sir blood (Secondary) + Slow jet (Secondary) 5 — top system pasvege == Step hole “Tote bore (Secondary) ¥ To intake manifold2-6_IM3B0] CARBURETOR ‘Secondary slow jet Secondery slow sir bleed Secondery throttle valve Step hole Secondary main jot Secondery diaphragm Delay valve oo) 82788 Fig. 7 B: MAIN SYSTEM rue ain Float chamber ‘ic horn L - ¥ t : Main ot Secondary) ina biaod (Secondry) : v4 Emulsion tube (Secondary) t ‘Main nozzle (Secondary) ‘Smell venturi (Secondary) Large vertur (Secondary) Throttle bore (Secondary) v To intake manifold For the construction, refer to “Main System” in the Primary Side section.CARBURETOR : 4, Fuel Supplement System When Cornering When the car makes @ right turn, the fuel level within the float chamber is tilted. This causes the fuel to flow through the fuel supplement passage to the nozzle, From the nozzle, the fuel is directed to the downstream side of the large venturi to improve driving perfor- mance eround corners, hes Float Fost level Oritice Fuel aupptement passage Outlet port ‘Primary large venturt easune e477 Fig. @2 IMSAq) 5, Automatic Choke System ‘A; AUTOMATIC CHOKE MECHANISM 4. LINK MECHANISM CARBURETOR This automatic choke is the system that automatically adjusts choke valve and throttle valve openings in accordance with change In coolant temperature. Automatic choke system consists of wax element, fast idle cam, fast idle lever, and main vacuum diaphragm. <-> Cooling water, Temperature docroaret Fant ile cam roller (Carn adjusting werew ving Wax element Wax holder (Cam follower lever Beare Fig. 9 (Engine start with low coolant temperature } ‘When coolant temperature is low, wax element is in the compressed position. As first idle cam compresses wax element rod by the force of return spring, connecting lever is raised and choke valve closes fully, ‘The best throttle valve opening can be obtained by the fast idle lever roller set on the crest of the fast idle cam. ( Choke release ) ‘As wax element expands and rod extends when engine warms up, fast idle cam rotates and choke valve opens fully. As fast idle cam rotates, fast idle lever comes off fast idle cam and throttle valve opening returns to the nor- mal idling position. Engine warming up is thus com- pleted. 10CARBURETOR 2. Unloader mechanism ‘When engine Is accelerated on cold start-up, unloader system opens choke valve in accordance with rotation of throttle valve to prevent fuel mixture from becoming too rich. ‘Choke valve position (en theotie vale futly opend 0,2 Throttle vale positon (when choke valve starts to opend Choke valve Connecting lever Peimary throttle valve ‘Unloader lover Choke lever A 82.473] Fig. 10 Choke valve opens in response to throttle vaive vie links which move in directions shown by arrows. IMs82} 2-6 B: VACUUM DIAPHRAGM MECHANISM This mechanism automatically controls choke valve opening just after engine is started, To obtain the fuel mixture best suitable for wide range temperature (from ‘extremely low to normal temperature), choke valve ‘opening is controlled in 2 stages by manifold vacuum ‘and choke strangler spring pressure. 1. At low temperatures ( 1st stage ) 1 Piston spring 2 Adjusting krob 3. Choke stranger spring 2.480] When engine st diaphragm operates, raising diaphragm rod to open the choke valve. Choke valve, however, opens slightly because of restraining force of choke strangler spring (spring that closes choke valve). 2. At normal temperatures (2nd stage ) Fig. 12 When coolant temperature is close to normal tempera- ture [15°C (59°F) to 30°C (86°F), wax element of auto- matic choke system expands, rod extends, and fast idle ‘cam rotates, reducing the choke strangler spring force {ie. spring force that closes choke valve), As piston spring force overcomes the force of choke strangler spring at this time, choke valve opens wider. "CARBURETOR Si “The choke break delay valve mechanism momentarily fc:AGHOKE BREAK DELAY VALVE MECHA- | Getaye an abrupt change in the air-fuel ratio immedi- NISM ately after vacuum pressure is created during starts, - and provides smooth engine operation. Fig. 13CARBURETOR, [soao] 2-6 S SPECIFICATIONS AND SERVICE DATA ‘A: SPECIFICATIONS na 1600 00 6 1000 ce aut BAT “ar Cararetor evasoco Dovesosto Dovswon Airhor a (rmer x oe 58x 68 mm (232x240 Thvotle bore 5) So 34 mm (518 — 1.38 Tar di of reac vee 17 mm (0067 in) aig vertu da PS) Fo 20 mm (079 — 138) ‘Small vortut le 10/13 — 11/16 eon (039/0.51 — 0.43/0.59 in) Main et (3) #101 — #155, ‘Main sir bleed (PS) 775 — #100 Main nozle dia P 2.1 x 9.0 rom (0088 x 0.118 i) {inner x outer) 8 2x 40 mm (0.110% 0.167 in) Main nozale end surtaco|_P & angie s = Emulsion tube P 2 x 4.0% 24.6 mm (0.084 x 0.167 x 0.968 in) [inner x outer xteneth) [S 24x 8.8 x 40 mim (0.084 x 0.142 x 1.87 in) Emulsion hole P 0.6 rom (0.024 in) x7 Ola. x number of notes) Ts 1.05 mmm (0.0473 in) x 4, 1.0 ram (0.080 in) x 16 Slow jet -S) #3 — #110 Slow system Siow air blood (°-5) #160 — #0 Economizer bleed (P-S) O— #0 Power et #50 [Accelerating pump nozzle dia, (0:4 mm (0.018 in) Accelerating pump sys- |= ‘am Welt of elie ane tala ae [Choke system Fill automate choke (Wax type) Starting system [Choke valve angle when fuily ey closed Primary tote vaive angle when fly closed 105" 132-6 [SOBO| CARBURETOR B: MAINTENANCE STANDARDS 1800 ce, 1600 oe Vehicle eur BAT Carburetor Deva40300 Devasos10 fea te perng canance ot primary trona vane] = 95-088 | Gi = 05 — 008 Fast ilo opens | At 25°C (77, (00197 — 0.0268 i | o0197 — 0.0288 in| 0.0268 — 0.0384 in) ing eclunmort Tar idle aponing clearance of choke valve [At 25°6 Ry = 0.70 —0.85 mm (rei) (00276 — 003740) Choke valve clearence when choke opener i operat: Re= 178 —2.0m ing. [At 2°C (FF) or below] {6.0701 — 0.0787 in} ‘Choke valve clearence when throle valve Is opened B= 2.34— 3.08 mm fay (0021 — 0.12130) Primary trots vaive clearence when secondary tht flo valve starts to open valves Primary throttle vaive clearance when adjusting screw Gy = 0:70 289 mm tip contacts deshpot rod (0.0270 $3883 n) Primary throtle valve clearance when le ewch Gi. = 070 = 0.11 mm changes 10 ONOFF {0.0811 + 0.0049 in), (Clearance betweon flat and upper meting surace of oat chamber when float seat comes in cortact with Hm 123— 133 mm (0484 — 0826 in) valve stem Flost sclust-Ciearance betwaon valve stem and float seat when oat is fully lowered Distance betwoen top surface of float and matching | ¢ rm (1.81 — surface of float chambor whan float ie fly lowered PEER eee ee eer L= 1.51.9 mm (0.059 — 0076 in)CARBURETOR [C100] 2-6 C COMPONENT PARTS 1. Air Intake System and Air Cleaner Fig. 14 & Shea TS \ \ge 2 Horaravet “Fiantening torquet Nam (kg, Feb) 3 Duct holder T: 6-7 0.6-0.7,4.3-—5.1) 4 Airintake eluct Air cleaner cover 6 Al cleaner element 7. Air cleaner cate 8 stus 9 Gatket 10. Automatic eemperoture convolier Be-1034CARBURETOR 1 Cerburetor ASSY 2 Gasket 2 Innulator 4 PCV valve 5 Intake manifold CP3. CARBURETOR {C300)_2-6 Carburetor ASSY Choke chamber ASSY [De not sisnssamble the choke chamber ABs] Connector Fier Ne Float shate Flost late switeh (for 407) ath pot {for 3AT and 4AT) [Blaphragm chamber omer valve Secondary stow air bleed ‘Secondary slow jet Float chamber drain plug Floetchombar gasket Primary mai jet ‘Throttle return spring ee ‘Throttle chamber lee acjutting serew Throttle adjusting sorew ‘Throttle lover Insulator & gaskets ‘Anti dlasaling awitch ASSY Injector weight Peimary emulsion tubs Peimacy main ar bleed Primary slow jet Sk ball Piston return spring ‘Accelerating pump piston Pump cover Primary slow air blew ‘Accelerating pump connecting cod Rod stopper Accelerating pump lever ‘Tightening torque: Nim (kgm, fib) TH: 20 25 (2.0~25, 14-18) 162 {woAo} CARBURETOR W_ SERVICE PROCEDURE REMOVAL 1) Remove 2) Disconnect fuel delivery, return and air vent hoses. 3) Disconnect all hoses and tubes from carburetor. 4) Disconnect harness connector. 5) Disconnect accelerator cable from throttle lever. 6) Drain coolant so as to prevent it from flowing out. 7) Remove carburetor attaching nuts and carburetor. After removal, cover the area on the intake manifold ‘where the carburetor wes installed, in order to prevent dust from entering into the engine. B; DISASSEMBLY 1, PRECAUTIONS 1) Use wrenches and screwdrivers of proper size to remove nuts and screws, Be careful not to cause burr or up when reassembling. 3) Use clean gasoline and compressed air to clean the Jets and fuel passages. Never use a wire or cloth. 2, REMOVING LINKAGE 1) Remove throttle return spring. 2) Remove pump lever shaft screw, pump lever, ‘washer and spring washer, and then remove rod stop- per. 3, REMOVING CHOKE CHAMBER 1) Unclamp harness. 2) Detach choke chamber and gasket from float cham- ber. Fig. 17 3) Remove piston return spring, ball and_ injector weight from choke chamber. 4) Remove anti-dieseling switch with plunger, spring and gasket, => Fig. 18 4, SEPARATING FLOAT CHAMBER AND THROT- TLE CHAMBER 1) Remove secondary diaphragm hose. 2) Remove snap ring and washer of secondary dia- phragm rod. 3) Remove secondary diaphragm. 184) Separate float chamber and throttle chamber. Float chamber 5} Remove insulator and gasket, Be careful not to damage the longest screw, since it has @ hole which is vacuum passage for the power velve, §. DISASSEMBLING CHOKE CHAMBER 1) Remove accelerating pump piston and pump cover. CARBURETOR [woct 2-6 6. DISASSEMBLING FLOAT CHAMBER 1) Remove primary main air bleed and ernulsion tube. Fig. 21 4) 5) Remove lock plate, float primary and secondary mai 6) Remove power valve, 7, DISASSEMBLING THROTTLE CHAMBER 1) Remove throttle adjusting screw and spring. 2) Remove idle adjusting screw and spring. ‘Special too! Idle adjust driver (498297100) plugs, and 3) Remove nut and parts on throttle valve shaft. a. Keep the disassembled parts in order. b. Be careful not to damage the throttle shaft and throttle valve, Fig. 20 2) Remove float shaft and float with needle valve. 3) Remove needle valve case. 4) Remove primary slow air bleed. C: INSPECTION Disassembled components should be washed in clean gasoline before inspection, Particularly small holes and hollows such as fuel passage must be blown with com- pressed air to remove dust and dirt. Do not use drills or wires to clean the small passages, otherwise the carburetor performance may be adversely affected due to cut or deformation. 1, CHOKE CHAMBER 1) Air horn Check for cracks, damage on mating surfaces, damage on threads, and excessive wear of choke valve shaft contact areas, 2) Choke valve Check for deformation and rust. 3) Choke valve shaft Check for wear and twist. 19{woe} 4) Power piston Check for correct operation. 5) Float Check for deformation, damage of seat and stopper, and wear of float shaft hole. 6) Needle valve Check for damage and correct contact against valve seat. 7) Fiter Check for deformation and damage. 8) Air bleed ‘Check for damage on thread and groove 9) Accelerating pump cover Check for crack and damage. 2. FLOAT CHAMBER 1) Float chamber body Check for cracks, damage on mating surfaces, damage ‘on threads, wear of auxiliary valve shaft hole, and wear of accelerating pump cylinder. 2) Injector weight Check for damage and proper contact against seat. 3) Ball Check for damag 4) Piston return spring Check for rust. 5) Jet Check for damage on thread and groove, 6) Emulsion tube Check for deformation. 7) Accelerating pump piston Check for damage and wear, 8) Power valve Cheek for correct operation and damage on thread and groove. : 3. THROTTLE CHAMBER 41) Throttle chamber body Check for cracks, darnage on mating surfaces, wear of throttle vaive shaft hole and damage on thread. 2) Throttle vaive Check for deformation. 3) Throttle valve shaft Check for wear, twist, and damage on thread. 4) Idle mixture adjusting screw Check for damage on tip of the screw. 5) Springs Check for permanent set and rust. 4, OTHERS 1) Washer Check for deformation and damage. 2) Linkage ‘Check for wear of each sliding part. 3) Passages Check for clogging. CARBURETOR D: ASSEMBLY 1. PRECAUTIONS 1) Wash all perts with clean gasoline before reassem. bly. 2) Use new gaskets, lock plate and cotter pins. 3) Use wrenches and screwdrivers of proper size to prevent damaging the parts. 2. ASSEMBLING CHOKE CHAMBER 1) Install needie valve case with washer. 2} Install primary slow air bleed. Needle valve Fig. 22 3) Install float with needle valve and float shaft, and adjust the float level. S Float Fig. 23 4) Install accelerating pump piston and pump cover. 3. ASSEMBLING FLOAT CHAMBER : 1) Install primary and secondary main jets and float f chamber drain plugs with washers and install lock plate.CARBURETOR [woo7|_ 2-6 152.400] ‘Special tool: Idle adjust driver (498297100) 5, BRINGING FLOAT CHAMBER AND THROTTLE CHAMBER TOGETHER 1) Put float chamber and throttle chamber together with insulator and gaskets. 2) Install secondary diaphragm and connect with washer and snap ring, and connect hose, 3) Install injector weight, ball and piston return spring. 2) Install power valve with washer. 3) Install secondary slow jet and slow air bleed. 4) Install primary slow jet and plu 6) Install secondary main air blea 6) Install primary emulsion tube and main air bleed. Secondary tie Primary side Plug end primary tle blood and slow jot Primary main alr blood, demullon tube Fig. 25 4. ASSEMBLING THROTTLE CHAMBER 1) Install adjusting plate, lever, washer, sleeve, etc. onto throttle valve shaft. Be careful not to damage the throttle shaft and throt- tle vaive, 52.408 T 6—8Nm(0.6~08 kom, 43-58 fe) 82401 —= 1 ae o ecco Ff Injector = welane Fig. 27 Install return spring with its hook portion facing down- ward. 6. INSTALLING CHOKE CHAMBER 1) Install anti-dieseling switch with plunger, spring and washer. Connect wiring harness, Bo careful not to twist it. 2) Position choke chamber on float chamber with gas- ket and tighten screws. 7. INSTALLING LINKAGE 1) Connect accelerating pump connecting rod to pump lever with rod stopper by inserting the rod end into the hole in pump lever, and lock rod stopper. Fig. 26 2) Install throttle adjusting screw and spring. 3} Install idle adjusting screw and spring.CARBI [WoEO} URETOR 2) Install pump lever with pump lever shaft screw, spring, plain washer, and spring washer. (1) Remove drain plug (on secondary side). Pay attention to gasoline that leaks. {2) Loosen main jet using MAIN JET SCREWDRIVER {CARBURETOR TOOL SET 498017000). Fig. 29 ‘Throttle return spring 82.405 Fig. 30 4) Make sure that all the linkage operates smoothly. E: INSTALLATION Installation is in the reverse order of removal. Observe the following: 1) After reinstallation, make sure that no leakage oxists around the mating parts and that the vacuum system operates correctly. 2) Perform “Engine idle speed adjustment” and “Engine idle mixture adjustment”. F: REPLACEMENT 1. MAIN JET 1) Removal Bofore servicing, be sure to disconnect battery (~) ter- minal. MAIN JET SCREWDRIVER 52-406] Main jet Fig. 31 (3) Insert MAIN JET HOOK (CARBURETOR TOOL ‘SET 498017000) through hole of MAIN JET SCREW- DRIVER and hook to main jet. MAIN JET SCREWDRIVER, 82.407 Main jot Fig. 32 (4) Loosen MAIN JET SCREWDRIVER further and pull out MAIN JET SCREWDRIVER and MAIN JET HOOK together with main jet. 2) Installation (1) While lifting up float by an L-shaped metal wire a5 illustrated below to prevent its interference with main jet path, insert main jet using MAIN JET SCREW- DRIVER and then tighten, ‘a, When installing secondary side main jet, insert L-shaped metal wire to primary side as illustrated and turn rection of arrow (counterclockwise) to lift up float. b. When instelling primary side main jet, insert L- shaped metal wire to secondary side as illustrated ‘and turn it in opposite direction (clockwise) to lift uP flost.CARBURETOR 1) 2-6 lost chamber 7 MAIN JET SCREWDRIVER mY Laheped mata wice Ta Hi This portion Ineurtoree Fig. 34 (2) After replacement of main jet, install removed parts in reverse order of removal, ® Attach new gasket and lock plate together with drain plug. b, Should main jet have been dropped in float cham- ber be sure to teke it out by removing choke chamber. CHECK AND ADJUSTMENT 1, FAST IDLE OPENING ADJUSTMENT 1) Set carburetor in @ place where ambient tempera- ture is stable and measure throttle valve clearance G, and choke valve clearance R,. Compare the values with those for the temperatures shown in the table below, ‘Tempera: ture corr, ay ee (32) 20 (69) 2010 128 \o.0504) 11.00 00 | 0.76 ko.0a94) \.o269) 068 . 055 .0282) (0.0217) 084 fiocest 0.89 0268) oss lo.ara) 136 fo.os26) 1.90 \o.0304) 0.80 loos) 068 (0.0268) 170 70 | 1.38 fo.ceea)| (o.0s35) 192 fooasn \aar| 232-6 1WoG2] CARBURETOR Standard vaiue of R, at 25°C (77°F): Turning adjusting screw clockwise: (0.7 — 0.95 mm (0.0276 — 0.0374 in) decreases G, ‘Turning adjusting screw counterclockwise: increases G, Fat lle i 30 mm (1.18 In) da, Primary, —J throttle valve ‘Choke lover A Fig. 36 3) When R, is outside specifications, adjust by bending ‘Choke vale claw @). If doing this cannot correct R, value, then bend claw ©. 2. VACUUM BREAK OPENING ADJUSTMENT 1) Be sure that the choke valve is fully closed. choke valve closes fully due to operation of wax ele- ment) Operate choke opener by applying 53.3 kPa (—400 mmHg, — 15.75 inHg) of vacuum and measure the dimension of R. Standard clearance R,: 1.78 — 2.0 mm (0.0701 — 0.0787 in) Fast ile cam 5 2) Adjustment can be made by bending choke lever. Adjusting cow / Smoke fer Stronger sring Choke vate ' 22.800 Fig. 36 } q 2) Turn the adjusting screw right or left to adjust the ~% / CLOSE clearance G, to specification. “open ‘Voeuum presture Fig. 37CARBURETOR [WoG7}_ 2-6 3, ANTI-DIESELING SWITCH ling, disconnect the lead wire from the anti-dieseling switch to ensure the engine eling switch is properly operating if the engine stops. 2) Ifthe engine discontinues to idle after it has started, the problem may be due to a broken lead wire or a faulty electrical system. 3) The anti-dieseling switch is malfunctioning if the fterfires when the ignition switch is turned off. 4, UNLOADER VALVE 1) Hand-rotate throttle lever to open throttle valve fully. 2) With throttle valve held in that position, measure choke valve position Ry. ‘choke valve Adjusting caw Standard value of Rs 2.34-3.08 mm (0.0921 -0,1213 in} connecting lever Primary throte valve 2.503) Fig. 38 3) When R; is outside specifications, adjust by bending the unloader lever's adjusting claw. 5, DELAY VALVE 1) Check delay valve. 2) If itis clogged, replace. formance characté ence) Air flow [at - 66.7 kPa (~500 mmHg, ~ 19.69 inHg) vacuum pressur 100 ce (3.4 US fl oz, 3.5 Imp fl oz}/min ic of delay valve (for refer- 6, ADJUSTMENT FOR INTERLOCK OF PRIMARY AND SECONDARY THROTTLE VALVES ‘The primary and secondary throttle valves are inter- locked so that the secondary throttle valve starts to ‘open when the primary throttle valve is opened to a certain degree. This opening angle of the primary throt- tle valve clearance G, should be as follows. St clearance G,: 6.34 0.62 mm (0.2102 + 0.0244 in) 30mm (1.18in) sia 2.504) Fig. 39 7. DASHPOT [EXCEPT MANUAL TRANSMIS- SION VEHICLES] 1) While holding fast idle cam with pliers, align hole in idle cam with hole in bracket. Insert pin into the holes to set throttle valve to the “fully-close” position. 25CARBURETOR 2.807| Fig. 40 contacts dashpot rod, measure dimension “G,”. 2) Hand-rotate throttle lever. When adjusting screw tip Fig. 42 If either or both resistance values are outside specifications, replace with a new microswitch. 3) Check that terminal resistance properly changes, as icated below, when throttle valve clearance is "G,”. Clearance G,: ‘More than 0.79 0.11 mm (0.0311 + 0.0043 in) Terminal/Specified resistance No. 2 —Ground/1 MQ min -» 02 If it does not change, adjust by bending the adjusting claw of adjusting plate. Prleary throttle Agjusting sew veve 2506 Fig. 41 Stondard value G,: 0.70 * $8 mm (0.0276 * 2035 in) 3) If "G,” is outside specifications, adjust by turning adjusting screw. 8. IDLE SWITCH [4AT] 1) Set throttle valve to the “fully-close” position, (Refer to “7. Dashpot”,) 2) Measure resistance values between microswitch ter- minals when throttle valve is fully open (switch lever is away from the contact point) and when itis fully closed (when switch lever is in close contact with the switch contact point), Torminal/Speciied resistence; No. 2—~ Ground/1 MQ (fully closed) 0 Q{fully open)CARBURETOR {wocg| 9. FLOAT LEVEL ‘Unit: mm tnd 41) Measurement ee : 8 Before servicing, be sure to disconnect battery (—) ter- ue iv (1) Remove drain plug (on secondary side). fey Pay attention to gasoline that leaks. a 3 Flat abo g LEVEL GAUGE ie | ~ = B61 ae SETSCREW Fig. 44 (2) Install O-RINGS, LEVEL GAUGE and SETSCREW (CARBURETOR TOOL SET 498017000). (3) Connect battery (—) terminal and start engine. (4) Check the float level. (2) Do not install air cleaner, (b) Operate with vehicle in level position. (c) Install LEVEL GAUGE vertically to carburetor and observe fuel level horizontslly. (d) Measure after fuel level has stabilized during idling. 52.510) Fig. 45 Float level is normal if the level is within two blue lines. Fig. 46 (6) After measurement, install removed parts in Teverse order of removal Attech new gasket end lock plate together with drain plug. {6) If the float level is not within the specified range, adjust the float level. 2) Adjustment {1) Adjusting float level Remove the choke chamber and tum it upside down. if the clearance H indicated in the figure is as speci- fied below when the float seat comes in contact with the valve stom, the float level is normal. If not, adjust the level by bending the float seat. Clearance H: 12.3 — 13.3 mm (0.484 — 0.526 in) {2) Adjusting needle valve stroke There are two methods in adjusting stroke. {a) After removing the hook from valve stem, mea- sure the clearance “L” between the float seat and valve stem with the float fully lifted. If the measure- ‘ment is out of spec., adjust by bending the stopper. After completion of adjustment, be sure to fit the hook. {b) Adjust by bending the stopper so that “A” is within the spec. with the float fully lifted. Clearance L: 1.5 — 1.9 mm (0.059 — 0.075 in} Distance A: 46 — 48 mm (1.81 — 1.89 in) 27CARBURETOR ~ 1 Flot seat 2 Flost stopper 2 Float 52513 Fig. 47 Fig. 48 28{009} Trouble end possible cause CARBURETOR 1) Iproper float evel Adjust st love. (8) Damaged gaskets Replace. 8._Dificuly in stating at iow temperatures {1 Maffuncin of choke vaive Trae (2) Mafunetion of choke linkage alt {9} Improper fest idle opening adjust (4 Improper adjustments of auiomatis choke adjust {8} Clogged delay valve Replace. ‘8. Difficuty in ing the engine {1} Improper anti-dieseing solenoid valve operation (Check solenoid valve and harness, Rapair or replace. (2) Obstruction in slow system {Primary slow Jatiprimary slow air Bloed clogged) Ciosn,TROUBLESHOOTING “Trouble and possible cause CARBURETOR fore troubleshooting, make certain that the ignition system and fuel line function correctly. Corrective action (1) Poor contact between needle valve and valve seal, or damaged contact surfaces (Clean or lap contect surfaces, or replace Improper float level adjustment Roadjust float level (a) Worn fost soat or flest stopper Replece fost [ty Worrfoat shot Replace. {6) Darnaged floot chamber gasket or loose earew Roplace gasket of rlighton screw. (6) High fuel pump discherge pressure Inspect and repair or replace fuel pump. 2, Excessive fuel consumption {1} Overtiow_ [@) Improper number of mak jot or slow jet (2) Clogged air bleed (#) Defective power valve or vacuum leaking from power valve ‘system [See tems for 1. Overton”, Replace. [Clean or replace, Inspect and repair or replace. {G] Defective eccelarating pump injector weight seat Inspect and repair or replace. (6) Loose plugs or Jets, or damaged gaskets Retighten of replace. (7) Improper opening of choke vai Inepect and repair linkage, (Improper opening of secondary throttle valve Inspect and repair linkage. 3. Rough ile (1) Improper ile adlustmont Adjust (2) Damaged idle mixture adjusting screw Roplace. [2] Clogged idle hole, by-pass hole, of slow aystem passage (Clean. (a) Clogged siow jet [claan, 18) Woin throttle vaive shaft Replace. (6) Damaged or improperly tightened gasket under carburetor Replace or relghten, (7) Leaking vacuum hoses Inspect and replace. (8) Overtiow [See hems for "1. Overtow”, 4, Low output (1) Clogged main jet clean, (2) Improper throtle valve opening Inspect and adjust (2) Improper chote valve opening Inspect and adjust 5. Hestation (1) Ciogged slow jt main et or emulion ube Gieen: (2 Cogaed by-pas hole or slow eystam pacsage leer {3) Improper idle adjustment Inspect and adjust (@) Matiuneton of sacondary tote valve Aaiust 6. Poor acceleration (1) Defective accelerating pump piston or piston return spring Replace. (2 Matlunction of accslrating pur iret valve or outlet valve [Replace (8) Clogged pump zie clean. (a) Mafunaton of eecelraing pump irkage Repair (6) Deloctive power valve Replace. {8] Matfunction of power valve piston pect end rloce {7\_Improper float level | Adjust tloat level. (@] Maliunation of trot vave Paco. 7. Poor Rgh-apeed porformance {1} Clogged main jot Cloan. (2) Improper throttle valve opaning Adjust. (a) Worn thote valve shat Replace 29