198809IS Aisan2Barrel

CARBURETOR CLINIC
AISAN
This Aisan carb appears on 1981-86 Toyota Tercels.
Although many technicians consider this unit to be
Remember that due to the way its vacuum supply
is controlled, the AAP only works when the engine's
bulletproof, some problems do occur with it. Probably cold. But a leaking AAP diaphragm can cause the
the most common breakdown on this carb is auxiliary engine to load up fairly quickly and often fouls out
accelerator pump (AAP) failure. Some techs argue that number one spark plug.
as long as the AAP holds vacuum, it's okay. Others You may also encounter hesitation problems, er
say that any sign of fuel residue in its vacuum nipple ratic hesitation problems, an erratic idle, or a slightly
or vacuum line is reason for replacement. Experience rougher-than-normal idle on a Tercel. If you do, check
has shown that a good-working AAP may have some the vacuum modulator valve next to the EGR valve.
fuel residue present. Usually, it pays just to replace This valve helps control EGR operation.
it to prevent a potential comeback.
—By Dan Marinucci
1 AAP DIAPHRAGM
FAILURE
If the auxiliary accelerator pump
(AAP) diaphragm fails, the engine
sucks fuel through it and loads up
when cold. AAP failure usually
causes a fuel-diluted crankcase, so
plan on changing the oil and filter
too. Toyota does sell the AAP
separately.
2 YELLOW MEANS
HANDS OFF!
See the daub of yellow paint on the
screw in the AAP cover? Whenever
you find yellow paint on part of an
Aisan carb, it means it's a factory-
set adjustment. Disturb such an ad
justment at your own risk!
FREE THE WIRES IDLE SOLENOID HERE
I've found it's worth a few extra minutes to remove Remember that the single-wire solenoid on the choke-
these wires from the harness connector. That way, you spring side of the carb is the idle cut-off solenoid.
don't twist them up or break a connection when you're When the engine won't idle, check this solenoid and
removing or reinstalling a solenoid. Who wants to risk its circuit first.
an intermittent connection here?
SECONDARY SOLENOID OPERATION LITTLE STUD, BIG TROUBLE

The secondary solenoid on this carburetor shuts off Note that the air cleaner stud only threads into the air
the fuel to the secondary fuel transfer circuit during horn. The stud's threads never reach the carburetor
deceleration. This reduces decel emissions. If this bowl casting. So if some musclehead overtightens the
solenoid fails to open, you'll feel a lag or hesitation air cleaner wing nut, he could warp the air horn.
when the secondary opens up.
CHOKE BLADE BINDUP POWER CIRCUIT VACUUM LEAK

Whenever you have a hard-start or cold-driveability If the air horn's warped, it can cause a vacuum leak
complaint on a Tercel, be sure the choke blade moves at this power circuit vacuum passage. The lower-than-
freely. If cleaning the choke shaft with carb cleaner normal vacuum signal to the power piston causes a
spray doesn't free up a sticking choke, you know the rich condition because it allowrs the power valve to
air horn's probably warped. open too early and too often.
GOOD AND FLAT HERE DRILL HERE!
When in doubt, straightedge this area of the air horn. Don't be fooled by that big aluminum plug. The anti-
If the air horn's warped more than a few thousandths tampering plug covering the idle mixture screw is
here—and the engine has warped air horn-related directly below the big aluminum D-shaped plug. Hold
symptoms—it's time for a new air horn or a new the carb steady and carefully center-punch this plug
carburetor. before you begin drilling.
CLOSE QUARTERS SOFT SLOT
See the mark I made near the end of this rod? That's The slot in this brass idle mixture screw will distort
all the space you have (about %6 inch) between the plug and open up easier than you think. Be sure your
and the idle mixture screw. Stop drilling as soon as screwdriver fits snugly in the slot. Also, the quicker
you feel the bit go through the plug or you'll drill right you complete your mixture adjustment, the less
into the mixture screw! chance you have of distorting the slot.
A DIRTY JET IS AN IDLE JET SMOOTH SECONDARY MOVEMENT

Yes, the Aisan's idle jet resembles the idle jet in lots Always check for smooth, free secondary throttle shaft
of other Japanese carburetors. Treat it the same way movement. Sometimes, the secondary shaft rusts up
you treat the others. Remove it, flush it out, and flush and sticks. Soak the shaft in penetrating oil until you
out its passage too. free it up.
REMOVE LINKAGE FIRST ONLY CABINET TIPS WILL FIT
You can't cheat here. Before you can get a wrench or A standard screwdriver such as this one won't fit
a socket onto this jet access plug, you have to remove through the jet access holes. You need a screwdriver
the linkage from this side of the primary throttle shaft. with a tip that's the same size as its shank. Tool
companies call these cabinet-type, cabinet-tip, or
carburetor-tip screwdrivers.
REMEMBER THE JET GASKETS PUMP DISCHARGE SEAL

Whether you're removing or installing the main jets If you want the accelerator pump circuit to work prop
in this Aisan carb, it's easy to overlook these little erly, remember to install this seal on top of the weight
gaskets or sealing washers. There's one gasket on the in the discharge passage. Otherwise, you'll have a
primary main jet and one on the secondary main jet. heckuva leak in that circuit when the pump tries to
pump fuel through it.
AAP CHECK BALL SPRING SEAL INSTALLATION TIP

This spring and threaded plug hold the AAP check If you want to be sure that this accelerator pump seal
ball in place. If you mix this spring up with the one doesn't pop out on you, hold it down with a thin feeler
in the main accelerator pump passage, just remember gauge. After you install the air horn, just pull the feeler
that the AAP circuit's spring is the shorter of the two. gauge out and start the air horn screws.

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CARBURETOR CLINIC

SECONDARY SOLENOID OPERATION LITTLE STUD, BIG TROUBLE

CHOKE BLADE BINDUP POWER CIRCUIT VACUUM LEAK

CLOSE QUARTERS SOFT SLOT

A DIRTY JET IS AN IDLE JET SMOOTH SECONDARY MOVEMENT

REMEMBER THE JET GASKETS PUMP DISCHARGE SEAL

AAP CHECK BALL SPRING SEAL INSTALLATION TIP

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