TO REPAIR eal FUEL SYSTEM AISAN CARBURETOR -~ SERVICE INSTRUCTION WORKSHEET 2 BARREL—1.6L, 2TC, 3AC, 3TC, 4AF, 4ALC Engine 1. Saray ea eet ne owing gage coe ilar wh be contents ik won flr err ‘bua ovr = 2, The wx vw spi! he mal carbo twit ck The yaw fer egy om Se carr sei ovals 3. Use he lode view as» de, Te eral sauce ot ara it ay pub lamas Yo aussie Ne Earn enough part exanyadlnspecson 4 Pat et show OOES NOT riot eer the. 5 ay conta etapa aes for ctr ctr ith Is grup Sst eres eae par fr ea ‘om pas kan eau PARTS LIST choke heat ar sha sha ‘choks housing noe housing aseerbh reno ful-of rod lever spacer 17 Shake ft Soemply 38. Solenbid ei ooo 9 TEE cs oeagm 2 Seen decane een ae 8 Siecie Sear i Ed 3: Bin, fst ninge, 32 Float asseme) 35. Nowaio, seat & washer asey Se ite 40. Serer cover ( 3: Gover tle compensator | Pitas DUA > PARTS LIST SHOWN DOES NOT REFLECT THE CONTENTS OF THE KIT.REMOVAL & INSTALLATION NOTES 1. Cover opening on intake manifold after carburetor is removed. 2. Donot remove secondary diaphragm assembly (24) unless replacement is needed. 3. If.choke cover is retained with rivets rather than screws, Carefully drill revit heads off and knock out remainder of rivets, 4, To remove idle mixture needle plug, if applicable, dria hole Inits center and pry out. NOTE: There is only .040” ‘clearance between plug and head of needle. 5. Donnot mix similar parts. Record sizes and location for proper installation. 6. Install parts and components in reverse order of removal 7. Betore instaling pump plunger (38), remove paper sieeve, flare leather cup, then soak in ight oil for a few minutes. 8. When instaling idle mixuture needle (51), turn in until lightly seated, then back out 2¥2--3 turns. 8. Be sure to install throttle body screw (63) n proper location (vacuum passage for power valve piston). 10. Install sight glass (72) with dot toward inside of fuel chamber. CLEANING Cleaning must be dane wih caturtrsasserbed, Use spray cleaner and a st brste brush to remove dit and carbon deposits, Do not use abrasives and wires to clean parts and pssepeways, Wash of in sulable solvent and lew al passageways wih compressed a Geauiion: When cleaning wit solvent co not soak or spray pars contaringrUBber, ste, paste an electical components ADJUSTMENT DATA FGA FG. > FLOAT LEVEL Auto cHoKe /ADGUSTMENT ADJUSTMENT {INVERT AR HORN ASSY. pe ae 1 AISTALL CHOKE COVER SOAS FLOAT TO REST ONNEEDLE BY TOMAINTAN CHOKE VALVE IN MS OWN WEIGHT. SSPRINGLOADED CLOSED 2. MEASURE CLEARANCE “x” AS POSITION. SPECHEED (SEE SEC. CHART) BETWEEN TOP OF FLOAT 8 PARTING SURFACE OF A 7 NS float ae ]2. ALIGN MARK ON CHOKE COVER CENTER TANG AS NEEDED. Los ere Mae noe ee CAUTION: DO NOT ALLOW 7 a eeeeeeeeeeae NEEDLE TO EXERT PRESSURE ‘ON SEAT EXCEPT OF FSOWN L ~ weg | a kick-uP SETTING lad ADJUSTMENT FLOAT DROP aoe [ADJUSTMENT |. FULLY OPEN PRIMARY (SECONOAAN 1. INVERT AIR HORN ASSY. WITHOUT GASKET & LIFT FLOAT BY HAND UNTIL BOTH TABS ‘CONTACT STOPS. 2. MEASURE CLEARANCE “YAS ‘SPEOFEED (SEE SPEC. CHART) BETWEEN NEEDLE VALVE & (CENTER TANG AS SHOWN 3, To ADJUST, BEND BOTH FLOAT ‘TABS EQUALLY AS REQURED, FIG.c PUMP STROKE [ADJUSTMENT 1, MOVE THROTTLE VALVE TO (CLOSED POSITION. MEASURE T FROMTOP OF AIR HORN TO. ‘TOP OF PUMP STEM, RECORD. NEXT, POSITION THROTTLE VALVE WIDE. AGAIN MEASURE | FROM TOP OF AIR HORN TO. TOP OF PUMP STEM. DIFFER. ENCE BETWEEN AECORDED MEASUREMENT ABOVE & LAS MEASUREMENT IS THE LENGTH OF PUMP STROKE ‘TRAVEL AS SPECIFIED (SEE SPEC. CHART). 2. ADJUSTMENT IS REQUIRED, BEND PUMP ROD WHERE SHOWN, THROTTLE VALVE 2. MEASURE CLEARANCE BETWEEN EDGE OF SECONDARY THROTTLE VALVE AND BODY USING A GAUGE OR ORIEL IT SHOULD BE AS. SPECIED. TO ADJUST, BEND TANG ON SECONDARY THROTTLE LEVER, rier FAST IDLE (BENCH) /ADJUSTMENT sporarecorme ayn ere 3 Sean | ae eee ~ 2 rosower mencro.e 7A | - SARS i eneADJUSTMENT DATA (CONT'D) LsUSTHENT 1. MAINTAIN THROTTLE VALVE IN WIDE OPEN POSITION WHILE HOLDING CHOKE VALVE TTOWAROS CLOSED POSITION. 2. MEASURE AS SPECFIED (SEE ‘SPEC. CHART) BETWEEN WALL, (OF AR HORN & UPPER EDGE OF| (CHOKE VALVE. 3. ADJUSTMENT Is REQUIRED, [BEND TANG ON THROTTLE LEVER, NOTE: If ANGLE MEASUREMENT IS GNEN, ADJUST ANGLE OF (CHOKE VALVE AS SPECIFIED ‘WHEN PRIMARY THROTTLE IS \WIDE OPEN. TO ADJUST, BEND FAST IDLE CAM FOLLOWER OR (CHOKE SHAFT LP Fic. # FAST IDLE SETTING ADJUSTMENT ‘SET THROTTLE SHAFT LEVER TO THE FIRST STEP OF FASTIOLE cam, 2, WITH CHOKE VALVE FULLY CLOSED, MEASURE CLEARANCE BETWEEN PRIMARY THROTTLE VALVE AND BODY, OR MEASURE ANGLE OF PRIMARY THROTTLE VALVE. a, To AcuusT, TURN FAST| IDLE ADJUSTING ‘SCREW AS NEEDED, ‘SPECIFICATIONS BY APPLICATION" Pomp] Keka | Fast Fat ‘Aopleation Sire | Seting | le. | Unioader | fae Year roe | fe | roe | Feo | rion TOYOTA — SPECIFICATION I. TwrBTT [ACE Fs 1976.75 so | 02 | ot | me | = CHEVROLET — SPECIFICATION I. ([isss-85_ [rt tng Ls [= a0 TOYOTA — SPECIFICATION 1.D.-B oR at] Coa AAG Eg 7% | 18 | 40 ]on-om) — ] a | a GREG ng mm | te | 20 |orca) = | ae | doe 4863 | Cora -4AC Eng. m | te | a |onco) = | 4 Ft 1882-60 | Gorla STC Ere a 3 | go [NS = | 4 3 ‘era SAC Eng m2 | 13 | 30 oso) = | a | % FOOTNOTES: + Dinersions are gn in iinet. #977 model set 6 ram,