14-0- 1

GROUP 14 - FUEL SYSTEM

SECTION 0 - INDEX
Section Page
Subject Number Number

I NDEX................................................ 0

CARBURETTOR SERVICE INFORMATION AND

ADJUSTMENTS ................................. .... 1
General Information ................................... 1
Carburettor Servicing .................................. I
Idle Speed and Co Concentration .............. ........ 1
Accelerator Cable Adjustment .......................... 3
Accelerator Pedal Switch Adjustment .................... 3
Accelerator Cable and Pedal............................ 3
SERVICE DIAGNOSIS ............................. . . . .. 2
RESIN BODY CARBURETTOR .......................... 2K
Specifications......................................... 1
General information................................... 2
Carburettor Operation ................................. 2
Automatic Choke ..................................... 4
Carburettor Dashpot .................................. 5
Carburettor Removal .................................. 6
Carburettor Disassembly ............................... 6
Carburettor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 9
Carburettor Installation ................................ 9
Carburettor Adjustments ............................... 10
Electrical Component Testing ........................... 14
MECHANICAL FUEL PUMP ........................... 4
Specifications......................................... 1
Service Diagnosis ..................................... 1
General Information................................... 2
Testing Fuel Pump .................................... 2
Fuel Pump Replacement ............................... 2
ELECTRIC FUEL PUMP ............................... 4A
Specifications......................................... 1
Service Diagnosis ..................................... 1
General Information ................................... 2
Fuel Pump Testing .................................... 2
Fuel Pump Replacement ..................... . ......... 3
FUEL TANK ........................................... 5
General Information ................................... 1
Fuel Tank ............................................ 1
Fuel Gauge Sender Unit ............................... 2
Electric Fuel Pump (1986 Models) ....................... 2

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 1 4- 1 - 1

SECTION 1 - CARBURETTOR SERVICE INFORMATION AND ADJUSTMENTS

GENERAL INFORMATION I DLE SPEED AND CO CONCENTRATION

The fuel system consists of the fuel tank, fuel pump, To ensure continued compliance with regulations
fuel filter, carburettor, fuel lines and vapour lines. regarding vehicle exhaust emissions it is essential that
The fuel tank assembly consists of the tank, filler i dle CO concentration is maintained within the
neck cap, vents, fuel gauge sender unit and an electric specified limits.
fuel pump (1986 models). Accurate checks can only be performed by following
In operation, the fuel pump draws fuel from the tank the procedures outlined below, using a reliable exhaust
through the filter and forces it into the carburettor. The gas analyzer and an accurate engine tachometer noting
carburettor meters the fuel into the air stream drawn the following.
i nto the engine, in quantities suitable for all engine • The analyzer probe and tubing must be in good
speed and load conditions. condition since any leaks would result in an
The fuel filter is a paper element type fitted in the erroneous reading.
fuel line between the fuel tank and fuel pump. The filter • If a garage exhaust system is used to conduct exhaust
is a sealed disposable type which cannot be serviced gases away during checks it will be necessary to use
and should be replaced at the intervals recommended a plenum chamber (or other means) to reduce the
i n Group 1 - Lubrication and Maintenance. vacuum in the system to 12 mm or less on a vacuum
gauge.
I f the temperature inside the air cleaner reaches 60°C
CARBURETTOR SERVICING during checks the hot idle compensator will be
activated resulting in a false reading. To overcome
Prior to overhauling the carburettor for economy, this a suitable fan may be placed adjacent to the air
performance or sirnilar problems ensure that the fault cleaner intake to reduce temperatures in the air
is not in some other component. cleaner, or the vacuum hose may be disconnected
at the manifold and the manifold outlet plugged.
Service Precautions
1985 Models
When overhauling a carburettor, several items of
i mportance should be observed. Check and Adjustment Procedures
(1) The carburettor should be completely (1) Switch on exhaust gas analyzer and allow it to
disassembled for cleaning. warm up, then calibrate according to manufacturers
(2) All parts (except for diaphragms) should be i nstructions.
cleaned in a suitable solvent and inspected for wear or (2) Connect a tachometer and timing light and start
damage. Since it can be difficult to ascertain whether the engine.
parts are still serviceable, any questionable parts should (3) Ensure that the engine is at normal operating
be replaced. temperature with the choke valve and HIA snorkel flap
(3) Only use air pressure to clean orifices, channels valve fully open.
and jets. NEVER clean jets etc. with wire, drills or (4) Check that the air cleaner is correctly installed.
other mechanical means as orifices may be enlarged. (5) Place the transmission in neutral and switch off
all lights, accessories and the air conditioner (where
Cleaning Carburettor Parts fitted).
(6) Set idle speed to specifications and check
The recommended solvent for gum deposits is i gnition timing.
methylated spirits. However, there are other commercial (7) Insert analyzer probe into the tailpipe as far as
solvents which may be used with satisfactory results. possible.
Diaphragms can be damaged by solvents. Avoid (8) Adjust the mixture screw to obtain the correct
placing any diaphragm assembly in ANY liquid. Clean CO concentration using the following procedure.
the external surfaces with a clean cloth or a soft wire (a) Adjust the mixture screw 1/16 turn richer (anti-
brush. Shake dirt or other foreign material from the clockwise) and wait 30 seconds before reading the
stem (plunger) side of the diaphragm. Depressing the meter.
stem to the retracted position, will provide an
additional hole for the removal of dirt. Compressed I MPORTANT: When setting the idle mixture do
air can be used to remove loose dirt but should not not turn the adjusting screw more than 1/16
be connected to the vacuum diaphragm fitting. ( urn at a time. 'The CO meter is so sensitive that
the ratio must be changed by very small
I MPORTANT: If the commercial solvent or amounts if accurate readings are to be obtained.
cleaner recommends the use of water as a rinse,
it should be "HOT". After rinsing, all trace of ( b) If necessary repeat step (a) until meter indicates
water must be blown from the passages with air a definite increase in richness. This step is very
pressure. It is further advisable to rinse all parts i mportant since some meters (thermal conductivity
i n clean kerosene or pelrol to be certain no trace type) reverse readings and indicate a richer mixture as
of moisture remains. the carburettor is set to lean.
REV. APRIL 86
 14
(c) When it has been established that the meter is
i ndicating a richer reading when the mixture screw is
turned in the rich direction, proceed to adjust the
Drill hole here at a 45° angle
carburettor to achieve the specified CO reading. t owards concealment plug
(d) If the idle speed changes as the mixture screw
is turned, adjust the speed back to the specified r.p.m.
then re-adjust the idle mixture to obtain the specified
ratio.
(e) Race engine at 2000 r.p.m. for 5 seconds, then
recheck idle speed and meter reading. Repeat if
necessary.
(f) Increase idle speed to specified value if this
differs from the mixture setting speed. Drill
hole

NOTE: As mixture screw is turned clockwise

(leaner) air/fuel ratio increases and oloCO
decreases. As mixture screw is turned anti- Fig. 1-Removing concealment plug
clockwise (richer) air/fuel ratio decreases and
o/oCO increases.
(e) Insert a blunt punch through the hole and drive
out the plug. DO NOT discard plug.
1986 Models (vehicles with a catalytic converter) (f) Using a new gasket install the carburettor and
On these vehicles the idle mixture screw is set at fit the air cleaner assembly.
(g) Perform steps 1 to 3 as detailed in "Check
manufacture and sealed. It DOES NOT require
adjustment under normal circumstances. If an Procedure".
i ncorrect CO concentration is indicated by poor idle (h) Adjust the mixture screw 1/16th turn richer (anti-
clockwise), wait 30 seconds then take meter reading.
quality, poor performance etc., proceed as follows:
Repeat this step until meter indicates a definite
i ncrease in richness. This procedure is important since
some meters (thermal conductivity type) reverse
Check Procedure readings and indicate a richer mixture as the
(1) Perform steps 1 to 6 as detailed for 1985 models. carburettor is set lean.
(2) Disconnect and plug secondary air supply hose (i) When it has been established that the meter is
at the air cleaner. i ndicating a rich reading as the mixture screw is turned
(3) Insert the exhaust gas analyzer probe into the anti-clockwise run the engine at 2000 to 3000 rpm for
tailpipe as far as possible. 5 seconds or more then allow engine to idle for 2
(4) Check that CO concentration is 0.3 to 4.5 170. minutes.
(5) Unplug and re-connect secondary air supply (J) Adjust mixture screw to give a CO concentration
hose and check that CO concentration drops below of 2.0 +_ 0.507o.
0.05 07o within a reasonable time. (k) Run engine at 2000 rpm for 5 seconds and check
reading, re-adjust CO concentration or idle speed as
required.
(1) Install idle mixture screw concealment plug.
Diagnosis and Adjustment Procedure ( m) Unplug and re-connect secondary air supply
If CO concentration is not as specified during step hose and check that CO concentration drops to 0.05°76
4, proceed as follows: or less within a reasonable time.
(1) Ensure that ignition timing is correctly set.
(2) Clean and test spark plugs, replace as necessary. If CO concentration is not as specified at step 5 of
(3) Check air cleaner element condition and air the "Check Procedure" or step (m) of "Adjustment
cleaner intake system for obstructions. Procedure", proceed as follows:
(4) Ensure that the EGR valve is closing fully.
(5) Check that there are no leaks in the intake (1) Check vacuum hose from intake manifold to the
system. secondary air supply reed valve for leaks or crimping
(6) If the above checks do not indicate a fault, CO and that manifold vacuum is normal.
concentration may be adjusted as follows. (2) Check delay valve, reed valve and thereto valve
(a) Remove the carburettor from the vehicle. operation, refer Group 25-Emissions Control.
(b) Position the throttle body in a vice equipped
with soft jaws, with the idle mixture concealment plug (3) Check secondary air supply filter for blockage
facing upwards. and hose from air cleaner to reed valve for leaks.
(c) Drill a 2 mm hole in the casting, as shown in Fig. (4) If a fault is not evident during steps 1 to 3 a
1, at a 45° angle towards the plug. damaged or poisoned catalytic converter is indicated,
(d) Drill the hole out to 3 mm. replace as necessary, refer Group 11.
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 14-I-3
ACCELERATOR CABLE ADJUSTMENT ACCELERATOR PEDAL SWITCH ADJUSTMENT

(1) Run the engine until it reaches the specified idle (1) Run the engine until it reaches its normal
speed (choke fast idle not in operation). operating temperature.
(2) Ensure the accelerator cable and pedal are not (2) With the pedal fully released the switch should
binding. be in the ON position - check the resistance of the
(3) Remove the air cleaner. switch. Resistance should read 0 Ohms, set the switch
(4) Check that the inner cable to the carburettor is using the adjusting bolt if resistance reads oo (infinity).
not loose and sagging. (3) Press the accelerator by hand and note when the
switch changes from ON to OFF (0 Ohms to infinity)-
pedal movement should be 4 to, 8 mm. Set, using the
adjusting bolt, if required.

Fig. 4-Accelerator pedal switch adjustment

If adjustment is required:-
(5) Loosen the locknut and turn the adjusting nut
so that the inner cable is just about to lift the throttle ACCELERATOR CABLE AND PEDAL
lever.

1. Accelerator
cable
2. Adjusting nut
3. Accelerator
pedal switch --
4. Stopper
5. Return spring
6. Accelerator
arm bracket 1. 6)
7. Accelerator -
arm
8. Pedal
9. Adjusting bolt
Fig. 5-Accelerator cable and pedal assembly

Fig. 3-Cable adjusting nuts Removal

(1) Loosen the adjusting nut, remove the cable from

t he support and disconnect the cable at the throttle
(6) Tighten the locknut after loosening the adjusting l ever.
nut one turn (manual models) and three turns (auto (2) Disconnect the cable from the accelerator arm,
models). refer Fig. 6.
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 14-1-4

Fig. 6-Cable to pedal arm attachment Fig. 9-Pedal return spring

(3) Detach the end of the cable casing from the dash
panel and remove the cable, refer Fig. 7. I nspection
(1) Check the cable and outer casing for damage and
smooth operation.
(2) Check the accelerator arm for bending.
(3) Check the return spring for deterioration.
(4) Check the cable end fitting.

I nstallation
I nstall by reversing removal procedure noting the
following:-
(1) Apply multipurpose grease (NLGI No. 3) to all
moving parts of the pedal.
(2) Apply dry sealant to the bracket mounting screw
holes, install the bracket and tighten the screws to 8-12
Nm.

Fig. 7-Removing accelerator cable

(4) Remove the mounting bolts and withdraw the

pedal, refer Fig. 8.

Fig. 10-Installing accelerator arm bracket

Fig. 8-Accelerator pedal mounting bolts (3) Ensure the cable is installed without kinks or
sharp bends.
(5) Remove the return spring from the accelerator (4) Adjust the cable as previously described.
arm, the split pin from the pedal shaft and remove the (5) On automatic models adjust the pedal switch as
pedal from the bracket. previously described.
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 14-2-1

SECTION 2 - SERVICE DIAGNOSIS

Condition Possible Cause Correction
POOR COLD STARTING (a) Incorrect starting procedure. (a) Follow starting procedure outlined
i n Owners Manual.
(b) Choke valve incorrectly adjusted. (b) Check choke valve setting.
(c) Choke wax element sticking or (c) Replace wax element.
faulty.
(d) Choke valve, linkages or fast idle (d) Check linkages and choke valve
cam sticking or seized. for freedom of operation. Clean
or replace components as
necessary.
(e) Air cleaner or air cleaner gasket (e) Fit air cleaner correctly.
fouling choke valve.

ENGINE STALLS AFTER (a) Choke valve not set correctly (a) Follow starting procedure
COLD START during starting. outlined in Owners Manual.
(b) Choke valve incorrectly adjusted. (b) Check choke valve setting.
(c) Choke breaker incorrectly adjusted. (c) Check adjustment, correct if
necessary.
(d) Fault in EGR system. (d) Check system as outlined in
Group 25.
(e) Fast idle speed incorrect. (e) Remove carburettor and check
throttle valve to bore gap.
(f) Vacuum leakage at hose, manifold (f) Locate and rectify leak.
or carburettor.
(g) Fuel starvation. (g) Refer to possible causes listed
under "FUEL STARVATION".
(h) Carburettor flooding. (h) Refer to possible causes (a) to (d)
listed under "CARBURETTOR
FLOODS OR LEAKS".

ENGINE RUNNING (a) Choke breaker incorrectly adjusted. (a) Adjust choke breaker.
RICH AFTER COLD (b) Choke valve incorrectly adjusted. (b) Check choke valve setting.
START (c) Poor coolant circulation around (c) Top up cooling system and
wax element due to low coolant check for leaks. Flush cooling
l evel or blocked water passage. system, if necessary to remove
blockaee.
(d) Float setting too high. ( d) Adjust as necessary.

POOR DRIVABILITY (a) Choke valve incorrectly adjusted. (a) Check choke valve setting.
DURING AND/OR (b) Fast idle speed incorrect. ( b) Remove carburettor and check
AFTER WARM UP. throttle valve to bore gap.
(c) Heated inlet air system (c) Check system as outlined in
malfunction. Group 25.
(d) Fault in EGR system. (d) Check system as outlined in
Group 25.
(e) Thermo valve malfunction allowing (e) Check thermo valve as outlined
secondary throttle valve to open i n Group 25.
when cold.
(f) Dirty or clogged carburettor (f) Disassemble and clean carburettor.
passages.
(g) Fault in ignition system. (g) Check and repair ignition system
as necessary.

POOR IDLE (a) Idle speed incorrect. (a) Adjust to specifications.

(b) Idle CO concentration incorrect. ( b) Refer to procedures outlined in
Section 1.
(c) Fuel cut off solenoid faulty. (c) Check solenoid operation and
electrical circuit (including fuse).
(d) Idle discharge holes clogged. (d) Remove disassemble and clean
carburettor.
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 14-2-2
Condition Possible Cause Correction
POOR IDLE (Cont.) (e) Idle air bleed carbonized. (e) Remove and clean air bleed jets.
(f) Carburettor flooding. ( f7 Refer to possible causes (a) to (d)
listed under "CARBURETTOR
FLOODS OR LEAKS".
(g) Vacuum leakage from hose, intake (g) Locate and rectify leak.
manifold or carburettor.
(h) Worn throttle shaft. (h) Remove carburettor and check
throttle shaft wear. Replace
carburettor body if necessary.
(i) Hot idle compensator inoperative. (i) Check hoses for leaks, check
thermo sensor operation*, replace
i f faulty.

CARBURETTOR ( a) Float level high. (a) Set float level to specifications.

FLOODS OR LEAKS (b) Worn needle and seat. (b) Replace needle and seat. Set float
l evel to specifications.
(c) Fuel pump delivery pressure high. (c) Test pump pressure (refer
specifications). Replace pump if
pump pressure is incorrect.
( d) Leaking float. (d) Replace float and set float level to
specifications.
(e) Carburettor body cracked. (e) Replace carburettor body.
(f) Faulty carburettor gasket or (f) Replace as necessary.
1` 011
rrn2.
(g) Ruptured accelerator pump (g) Replace diaphragm.
diaphragm.
(h) Faulty bowl vent system. (h) Check valve operation* and hoses
for restrictions.

POOR ACCELERATION (a) Accelerator pump linkage worn. (a) Replace worn linkage.
(b) Accelerator pump diaphragm (b) Replace diaphragm.
hardened or deteriorated.
(c) Accelerator pump follow-up (c) Check spring. Replace if
spring weak. necessary.
(d) Float level low. (d) Adjust to specifications.

POOR PERFORMANCE
(i) Engine running rich** (a) Clogged air cleaner. (a) Clean or replace as necessary.
(b) Carburettor flooding. ( b) Refer to possible causes (a) to (d)
listed under "CARBURETTOR
FLOODS OR LEAKS".
(c) Damaged metering jet (c) Replace jet.
(d) Main jet loose. (d) Tighten jet.
' (e) Choke valve not opening fully. (e) Refer to possible causes (b) and
(c) listed under "ENGINE
RUNNING RICH AFTER COLD
STA RT ".

(ii) Engine running lean** (a) Vacuum leak at hose, inlet (a) Locate and correct leak.
manifold or carburettor.
(b) Main jet clogged. ( b) Remove and clean jets.
(c) Secondary throttle valve (c) Check operation of diaphragm
i noperative. and thermo valve*. Replace faulty
components.
(d) Fuel starvation. (d) Refer to possible causes listed
under "FUEL STARVATION".
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 14-2-3
Condition Possible Cause Correction
FUEL STARVATION (a) Fuel filter clogged. (a) Replace filter.
(b) Float level low. (b) Set float level to specifications.
(c) Fuel pump delivery pressure low (c) Test pump pressure, refer Sections
4 and 4A. Replace pump if
pressure is not within
specifications.
(d) Bowl vent valve faulty. (d) Test bowl vent valve*, replace if
necessary.
(e) Incorrect hose connection at Check and correct hose
vapour seperator tank (1986 connections as necessary, refer
models). Section 4A.

EXCESSIVE INTAKE (a) Air cleaner assembly loose. (a) Tighten air cleaner assembly.
NOISE (b) Air cleaner seal damaged or (b) Replace seals as necessary.
perished.
(c) Secondary air filter housing (c) Tighten housing.
(1986 models) loose.

* Refer to Group 25-Emissions Control, for testing procedures.

** On vehicles equipped with a catalytic converter a blackened exhaust pipe is normal and does not indicate an
overrich mixture. To ascertain if the engine is running rich or lean it is necessary to remove and inspect spark
plugs.

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 1 4-2K-1

SECTION 2K - RESIN BODY CARBURETTOR

SPECIFICATIONS

1985 Models 1986 Models

Manual Automatic Manual utomatic
Model number ... ............ 32-35 DIDTA-263 32-35 DIDTA-264 32-35 DIDTA-256 3 -35 DIDTA-257
Throttle bore - primary ...... 32 mm 32 mm
- secondary ..... 35 mm 35 mm
Venturi bore - primary ....... 24 mm 24 mm
- secondary .....30 mm a- 30 mm
Main jet - primary . . . . . . . . . . # 113.8 # 113.8
- secondary ......... # 195 # 200
Main air jet - primary . . . . . . . # 105 # 75
- secondary ...... # 80 # 80
Pilot jet - primary ........... # 58.8 # 58.8
- secondary .........# 60 # 67.5
Enrichment jet ............... # 80 # 80
Dashpot ..................... Constant vacuum Conventional Conventional
Primary throttle valve angle when
secondary begins to open .... 45° ± 2° 45° ± 2°
Adjustments
Float level - off vehicle ..... 20 mm 20 mm `-
Idle speed (r.p.m.)........... 750 ± 50 800 ± 50 750 +_ 50 800 +_ 50
Idle COo7o (@a idle speed) .... 0.6 ± 0.4 Refer to Section 1 "Carburettor
Servicing and Adjustments"
Air conditioner idle up
speed (r.p.m.) ............. 750 800 850 900
Nominal setting of choke
valve pinion plate ......... Centre scribe mark on pinion Centre scribe mark on pinion
plate at 23°C plate at 21°C
Choke valve to bore gap ..... 0 to 0.5 mm 0 to 0.5 mm ''-
Choke breaker - valve to
bore gap ................. 1.6 ± 0.1 mm 1.8 + 0.1 mm
Fast idle throttle valve to
bore gap (primary bore) ... 0.7 mm 0.8 mm 0.7 mm 0.8 mm

NOTE: Specifications printed are correct at the time of publication. If these specifications differ from those
on the Vehicle Emission Control Information Label, use the specifications on the label.

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 1 4-2F-2
GENERAL INFORMATION The fuel cut solenoid cuts off the air/fuel mixture
The dual-throat down-draft t ype carburettor utilizes supplied through the pilot passage to rcduce the
four basic fuel metering systems. The Idling System possibility of engine run on when the ignition is
switched OFF and, on 1 986 models during closed
provides a mixture for idle and low speed performance;
the Main System provides an economical mixture for throttle coasting or deceleration to prevent the
normal cruising conditions; the Accelerator Pump i nduction of excessive quantities of raw fuel.
System provides additional fuel during acceleration; Main Metering System (Fig. 2)
and Enrichment System provides a richer mixture when As the throttle valve is opened, air velocity inside
high power output is desired. the venturi increases, forming a vacuum in the inner
In addition to the four basic systems, there is a fuel venturi (1). Utilizing this vacuum, the fuel is jetted from
inlet system that constantly supplies fuel to the basic the main nozzle (2) into the bore.
metering systems, an automatic choke system which The carburettor primary main circuit is used for
enriches the mixture to aid starting and cold running, medium-load operation. When the driver demands
a bowl vent system which allows the carburettor float more power, the secondary main circuit is brought into
bowl to vent to the canister with the ignition switched operation.
off and, on 1986 models, a mixture control system
which supplies air to below the throttle butterfly during Double Bleed Design (Fig. 2)
closed throttle deceleration. The double bleed design of the primary circuit inner
All 1985 models and 1986 models equipped with a venturi contributes to better atomization. Bleed pipes
manual transaxle are fitted with a dashpot to slow (3) and (4) are press-fitted into the inner venturi (1) and
down throttle return to idle. main air jets (5) and (6) provided. The fuel metered
A fuel cut solenoid shuts off the fuel supply through by the main jet (7) is bled with air metered by the main
the idling system when the ignition is switched OFF, air jets (5) and (6) through the bleed holes provided
reducing the possibility of engine run on. at the bleed pipes (3) and (4) and supplied from the
main nozzle (2) to the engine.
CARBURETTOR OPERATION The inner venturi of the secondary is a single bleed
Idling System (Fig. 1) design in which the flow of fuel and air is the same
This system controls the mixture during idle, off idle as in the double bleed system, the only difference being
and part load operation, ensuring smooth operation the single construction of the bleed pipe (3) and main
from idling to part load. air jet (6).
Fuel passes through the main jet (1) from the float Countermeasure against Percolation (Fig. 2)
chamber to passage (2) and is metered by the pilot jet
If percolation occurs in the main well (8), the
(3). vaporized fuel will pass outside the bleed pipe and
Air drawn through the venturi air passage (4) and escape from the main air jet (6). Therefore, there is no
pilot air No. 2 jet (5) is metered by the pilot air No. possibility of liquid fuel being discharged from the
I jet (6) and mixed with fuel in the well to produce an main nozzle (2). This assures stability during operation
air-fuel mixture. The air-fuel mixture is then sprayed and ease of restarting.
from the bypass (7) and pilot outlet (8) to mix with
air passing through the throttle valve gap prior to being
drawn into the engine.
The mixture screw (9) is used to adjust the air fuel
ratio mixture at idle.

Fig. 2-Main metering system

Air Flow System (Fig. 3)
Air drawn through the air cleaner flows from the
choke bore (1) into the venturi (2). The amount of air
is controlled by the primary throttle valve (3) and
secondary throttle valve (7). When the engine is idling,
air is drawn through the slight clearance between the
Fig. 1-Idling system primary throttle valve (3) and throttle bore.
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 14-2K - 3
During off-idle to intermediate load operation, the Mixture Control System (1986 models)
air is metered by the primary venturi (2) and controlled
by the primary throttle valve (3) before being drawn The mixture control valve, mounted on the
i nto the engine. secondary bore side of the carburettor, responds to
i ntake manifold vacuum generated below the primary
As the load increases, vacuum produced by air flow
throttle valve to supply additional air to the intake
past the primary and secondary negative pressure
manifold during closed throttle coasting or
extraction orifices (4) is routed into the depression
deceleration. This ensures effective combustion of fuel
chamber (5) to operate the diaphragm (6) and open the
drawn into the manifold.
secondary throttle valve (7).
Under normal driving conditions the valve is kept
Vacuum to the depression chamber is connected to
a thermo valve which prevents the secondary throttle closed by spring (8) force. When the throttle is closed
valve opening when coolant temperature is below 55°C during deceleration qr when coasting, vacuum is
applied to chamber (1) through orifice (2) and acts on
by opening the chamber to atmosphere.
the diaphragm (3) to open the valve (4). At the same
ti me, vacuum is applied to chamber (5) through the
orifice (6). When the vacuum in chamber (5) reaches
a preset value, spring (8) force overcomes the vacuum
i n chamber (1) and the valve closes. Atmospheric
pressure is applied through orifice (7) to control the
speed of valve closure.

Fig. 3-Air flow system

Enrichment System (Fig. 4)

The carburettor embodies the diaphragm enrichment
system. Manifold vacuum is transmitted to the
diaphragm chamber through the channel illustrated in
the figure. When running at part throttle, the
diaphragm is drawn up, closing the enrichment valve. Fig. 5-Mixture control valve
As the throttle is opened widely, the drop in manifold
vacuum permits the diaphragm spring to force the Accelerator Pump System (Fig. 6)
diaphragm down opening the enrichment valve. This
allows extra fuel to pass through the enrichment jet into When the engine speed is increased suddenly, the air
the emulsion well, supplying the fuel required for high fuel mixture becomes excessively lean. To overcome this
load vehicle operation. condition, the carburettor is provided with an
accelerator pump circuit to provide an additional
quantity of fuel to the pump jet.
As the throttle is opened rapidly, the diaphragm (1)
is pushed by the pump lever (3), which is linked to the
throttle valve (2), to force the fuel through the outlet
check valve (4) and spray it toward the top of the
primary venturi. When the throttle is closed, the
diaphragm (1) is pushed back by the spring (5) to allow
fuel flow through the inlet check valve (6) into the
pump chamber. Fuel delivery decreases as the engine
speed increases.
Lock nut (7) is provided for adjusting the amount
of fuel to be injected. This quantity is set at the factory
and an adhesive applied to the lock nut.

NOTE: Do not tamper with this adjustment.

Spring (9) is provided to maintain fuel injection for

Fig.4-Enrichment system a period after the throttle valve has been opened.
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 14-2K-4
Fuel Return

Fuel is circulated through the accelerator pump body,

from the fuel pump (1985 models) or vapour seperator
tank (1986 models), and back to the fuel tank, this
reduces fuel temperature rise in the pump chamber so
that stable pump delivery characteristics can be
obtained without the generation of vapour.

Fig. 7-Bowl vent system

AUTOMATIC CHOKE (Fig. 8)

Fig. 6-Accelerator pump system
The choke valve is automatically operated by a
thermo-wax element which senses the coolant temper-
ature. The sensing element closes the choke valve at
Fuel Inlet System l ow coolant temperature and opens it as the coolant
temperature increases.
The fuel inlet system maintains a constant level of To prevent an over-rich mixture during cold starts,
fuel during engine operation. The fuel flows from the the choke valve is set initially to the partially open
fuel tank,'through the fuel filter, fuel pump, and the position by the choke breaker, which is actuated by
strainer where it is routed through the needle valve into i ntake manifold vacuum.
the float chamber. A fast idle cam is provided on the choke set lever,
As fuel enters the float chamber, the float moves and the cam controls the throttle valve opening.
upward to the prescribed level, where the needle valve When the vehicle is operated (the throttle valve
is closed. With the consumption of fuel, the float opened) immediately after cold starting (the choke
moves down to open the needle valve to permit fuel closed), the choke valve is forced to open by the choke
to flow into the float chamber, raising the float to the unloader to allow more air to enter and maintain a
prescribed level. This operation is repeated to maintain suitable air fuel mixture, refer Fig. 8.
a suitable level of fuel within the carburettor during
operation. Choke pinion
Choke
valve

Bowl Vent System ~, To intake

manifold
_ Coolant inlet
Strangler Thermo-
The bowl vent valve (1) opens when intake manifold spring wax
vacuum acting on diaphragm (2) exceeds a pre-set value element

after the ignition is switched ON (3). The valve is kept

open by the solenoid (4), regardless of vacuum/pressure
acting on the diaphragm, while ignition is switched ON
so that the carburettor float bowl (5) is vented through Throttle
the carburettor bore. valve

With the ignition switched off the valve is closed and

the carburettor float bowl is vented to the canister. Fig. 8-Automatic choke system
REV. APRIL 86
 1 4- 2K-5

Fig. 9-Choke unloader

Fast Idle Cam

The fast idle cam i s integral with the choke lever and
has a profile set to provide an optimum fast idle
opening through the cam follower depending on the
varying coolant temperature. Fig. 10--Strangler mechanism

Return Spring
The return spring assists tile thereto wax element rod
to retract as the engine coolant temperature falls and
also ensures that a throttle opening necessary for
starting can be automatically obtained against the
friction of t he throttle return spring and tile throttle
link system.

Strangler Mechanism (Fig. 10)

The choke valve (1) is mounted on the choke shaft
and is held shut by tile strangler spring (2). One end
of the strangler spring (2) is secured to the choke shaft
lever (3), and the other end is secured to the pinion (4).
The pinion is in mesh with the rack. The choke set lever
(5) is held in contact with tile thereto wax clement rod
(7) by the return spring (6). When the engine coolant Fig. 11-Choke breaker
temperature falls, tile thereto wax element rod (7)
retracts. As tile temperature rises, tile rod extends.
Extension or retraction of the rod rotates tile choke set CARBURETTOR DASHPOT (where fitted)
l ever (5) which rotates the pinion (4). Rotation of the
pinion twists the strangler spring (2) which provides Some carburettors are equipped with a dashpot to
the strongest choke valve closing pressure at the lowest delay throttle valve closure to normal idling position,
coolant temperature and the weakest pressure at the t hus reducing tile amount of' Hydro Carbon emissions.
highest coolant temperature.

Choke Breaker Mechanism (Fig. 11) Constant Vacuum Type

The choke breaker mechanism prevents an The dashpot is controlled by a servo valve. The servo
excessively rich mixture after cold starting. When the valve detects intake manifold vacuum and closes when
engine starts manifold vacuum is applied to the choke tile vacuum exceeds a pre-set value. When the servo
breaker diaphragm (3), through an internal passage on valve is closed, air in the diaphragm chamber of the
all 1985 models and 1986 manual models or an external dashpot cannot exhaust, the dashpot diaphragm is
passage 1986 -automatic models, overcoming spring l ocked and the throttle valve opening is maintained
force to pull the shaft (2) in the direction of the arrow, t hrough the carburettor linkage. The combination of
opening the choke a specified amount. dashpot and servo valve functions as a throttle valve
On 1986 automatic models, a valve fitted in the positioner. If tile manifold vacuum is below the preset
vacuum hose, delays the operation of the choke breaker value, the servo valve opens and the dashpot works
mechanism by approximately six seconds. normally.
REV APRIL 86
 1 4-2K- 6
(1) Disconnect the throttle dashpot lower link from
t he throttle linkage, remove two dashpot to float
chamber attaching screws and remove the dashpot and
servo valve assembly (where fitted) complete.
(2) Remove the choke unloader link retaining clip
and disconnect the choke unloader link.
(3) Disconnect the depression chamber to throttle
body vacuum hose.

Fig. 12-Constant vacuum throttle dashpot

Conventional Type
When the throttle is opened the dashpot rod moves
up, moving the diaphragm upward. This action forces
the air on the topside of the diaphragm out of the
chamber through a one way valve. When the accelerator
is released, air is drawn into the top chamber through
an orifice slowing the return of the throttle to idle.
Fig. 13-Removing choke unloader link

CARBURETTOR REMOVAL
(4) Disconnect the lower end of the depression
(1) Drain the engine coolant to a level below the
chamber link and remove the depression chamber. Do
thermostat housing.
(2) Remove the air cleaner. not immerse the depression chamber in solvent.
(3) Disconnect the accelerator cable.
(4) Disconnect the vacuum and fuel hoses and all
electrical connectors.
(5) Disconnect the coolant hoses.
(6) Remove the carburettor mounting bolts.
(7) Remove the carburettor assembly.
(8) Remove the carburettor gasket.
NOTE: Using suitable material, blank off the
carburettor mounting hole to prevent entry of
foreign material into the inlet manifold.

CARBURETTOR DISASSEMBLY

Disassemble the carburettor in a systematic order,

paying attention to the following:
• Use spanners and screwdrivers that fit the nuts,
screws and jets securely otherwise the
components may be burred or damaged. Fig. 14-Removing depression chamber
Where parts are disassembled place them on a
clean bench in the order of removal to aid in
reassembly.
• Do not remove the inner venturi assemblies. (5) Remove the mounting screws and remove the
• Do not disassemble the throttle shaft and throttle throttle position sensor (automatic models).
valve. (6) Disconnect the pump rod from the throttle shaft
Do not remove or dismantle the mixture control lever and remove the accelerator pump assembly.
valve (where fitted) or bowl vent valve unless (7) Remove the three screws and nuts and three
replacement is necessary or the float chamber screws securing the float chamber cover, main body and
cover is to be cleaned in solvent. throttle body, refer Fig. 15.
REV APRIL 86
 14-2K- 7
NOTE: The screws are secured with Loctite for
removal an impact screwdriver may be required.

(8) Separate the float chamber cover, the main body

and throttle body by tapping with a plastic hammer
or handle of a screwdriver.

NOTE: Do not pry the cover off with a screwdriver

blade.

Fig: 16-Primary and secondary main jets

(15) Remove the secondary pilot jets, refer Fig. 17.

Fig. 17-Secondary pilot jet

(16) Remove primary pilot jet, refer Fig. 18.

Fig. 15-Float chamber cover removal

Do not turn the carburettor upside down to remove

the float chamber cover-the discharge check ball and
accelerator pump weight housed in the main body may
fall out and become lost.
Remove the float chamber cover gasket.
(9) Remove the float lever pin and the float.
(10) Remove the needle valve assembly, gasket and
filter.
(11) Do not remove the automatic choke system
because the factory setting will be affected.
(12) Turn the main body upside down and remove the
pump discharge check ball and weight.
(13) Remove the fuel cut-off solenoid. Fig. 18-Primary pilot jet
(14) Remove the main jets and pilot jets, using a
screwdriver with a blade suitable for the jet groove, refer (17) Remove the primary and secondary main air jets,
Fig. 16. refer Fig. 20.
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(3) If 0-rings, gaskets and diaphragms are to be

reused, they should be cleaned with a clean cloth or

soft brush.
(4) Check the carburettor body and water passages
for cracks, scale and clogging.
(5) Check the needle valve and seat contact for
damage or wear, replace if defective.
(6) Check the filter for damage and clogging.
(7) Check the jets and air bleeds for damage and
clogging.
(8) Check each diaphragm for damage.
(9) Check the mixture screw contact surface for
damage.
(10) Check the throttle valve shaft and choke shaft
operation, if unsatisfactory clean the shaft and linkage
with solvent and lubricate with engine oil.
(11) Check the depression chamber diaphragm by
Fig. 20-Primary and secondary main air jets pushing the rod in, sealing off the nipple and releasing
the rod. It' the rod does not return, the chamber is
(18) On 1985 models remove the idle mixture good. If the rod returns when released, the diaphragm
adjusting screw, spring and O-ring from the throttle is defective and the assembly must be replaced.
body. (12) Check the fuel cut solenoid by connecting the
(19) On 1986 models remove the idle mixture black, white wire to the positive (+) terminal of a 12V
adjusting screw as follows: battery and-the other wire to the negative (-) side of
(a) Position the throttle body in a vice equipped the battery. The plunger should move in towards the
with soft jaws, with the idle mixture screw solenoid when the battery is connected and it should
concealment plug facing up. move out as soon as the battery is disconnected. If the
(b) Drill a 2 mm pilot hole in the casting, as solenoid is not satisfactory it must be replaced.
shown in Fig. 21, at a 45° angle towards the plug.
(c) Drill the hole out to 3 mm.
(d) Insert a blunt punch through the hole and
drive out the plug. DO NOT discard plug.
(e) Remove the idle mixture adjusting screw. CARBURETTOR ASSEMBLY

Assembly is a reversal of the disassembly procedure

noting the following:-
Drill hole here at a 45° angle
(1) Clean all parts prior to installation. Check to
t owards concealment plug ensure there is no clogging in the air and fuel passages.
( 2) Check for smooth operation of the throttle and
choke linkage.
(3) Adjust the float level as outlined in Carburettor
Adjustments, this Section.
(4) Use new O-rings and gaskets. If diaphragms are
damaged in any way, replace with a new diaphragm.
(5) When replacing a jet, ensure the new jet is the
correct size (a number is stamped on each jet).

Fig. 21-Removing concealment plug

CARBURETTOR INSTALLATION

Cleaning and Inspection (1) Inspect the mating surfaces of the carburettor
and intake manifold. Ensure both surfaces are clean
(1) Clean the disassembled parts with clean and free of nicks, burrs and other damage.
methylated spirits or a suitable solvent. (2) The carburettor gasket can be installed upside
down or backwards. Ensure the holes in the gasket
NOTE: Do not clean 0-rings, diaphragms or
plastic parts with any cleaning solvent as match the holes in the bottom of the carburettor.
(3) Ensure the carburettor attaching bolt holes in the
damage may result.
i ntake manifold are free of water and apply a thin
(2) Clean out fuel passages and jets with compressed smear of grease to the bolt threads.
air, DO NOT use wire or drills to clean jets as the (4) Place the carburettor on the intake manifold and
orifices may be enlarged and thus affect the i nstall the mounting bolts. Tighten the bolts alternately
performance of the carburettor. and in stages to 15-22 Nm.
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 1 4- 2K - 1 0

White
Delay valve

From secondary throttle

valve depression chamber

White

Black

862512

Fig. 22-Vacuum hose connections (1986 models)

(5) Connect all fuel and vacuum hoses and electrical (I1) Adjust the throttle position sensor (automatic
connectors. models), accelerator cable, idle CO concentration, idle
speed and dashpot (where fitted).
NOTE: To provide catalyst protection and ensure (12) On 1986 models, install the idle mixture screw
correct emissions levels it is essential that concealment plug after adjustments have been
vacuum hose connections are correct, refer Fig. completed.
22.

(6) Reconnect coolant hoses.

CARBURETTOR ADJUSTMENTS
(7) Reconnect the accelerator cable.
(8) Fit the air cleaner.
Float Level Adjustment
(9) Top up the cooling system with rain or "deminer-
alized" water and the recommended concentration of (1) Remove the carburettor from the engine.
Mitsubishi Coolant/Inhibitor, refer Group 7. (2) Remove the float chamber cover (see Carburettor
(10) Start the engine and run until normal operating Disassembly).
temperature is reached. (3) Tilt the carburettor top to the position shown
i n Fig. 23 and measure dimension `H'. (if the carburet-
NOTE: On 1986 models do not "prime" the engine tor top is turned upside down to check this measure-
by pouring fuel down the throttle bore. This ment, a false reading will be obtained due to
practice may result in catalyst damage. compression of the needle spring).
REV APRIL 86
 1 4 - 2K - 1 1
(5) If shim adjustment is required remove the float
by withdrawing the pin and remove the seat retainer.
(6) Carefully pull out the needle valve seat, using
pliers to grip the larger diameter of the assembly.
(7) Remove the strainer and replace the shims as
required.

Choke Valve and Fast Idle Adjustment

NOTE: The following method of choke valve
adjustment will only be effective if instructions
are carefully followed in the listed sequence and
with accurate temperature measurements.
(1) Remove the carburettor from the vehicle (this is
mandatory).
(2) Leave the carburettor to stabilize in the workshop
Fig. 23-Checking float level for a MINIMUM of 1.5 firs, preferably 2 firs. Ensure
that the carburettor is free from any heating or cooling
(4) Position special tool E14M17 or a suitable source during stabilization.
alternative, manufactured to the dimensions shown in (3) Measure the ambient air temperature with a
Fig. 24, on the float chamber cover adjacent to the known good t hermometer and record.
float. If the float level is low to the gauge add shims. (4) Loosen the lock nut at the choke adjustment
if the float level is high to the gauge, reduce the shims. screw and turn the screw to line up the scribed line on
the cam lever with the punch mark on the cam follower,
NOTE: A change in thickness of shim results in a refer Fig. 26.
threefold change of float level height.

s---20 mm

50 mm

Fig. 24-Float gauge tool

Fast idle throttle

valve to bore gap

Fig. 26-Fast idle adjustment

(6) Set the fast idle throttle valve to bore gap (see
specifications) by turning the fast idle adjustment
screw, refer Fig. 26.
(7) Referring to Chart-choke valve adjustment and
the previously recorded ambient air temperature, note
the number of turns of the choke adjustment screw
needed to correctly set the choke.
(8) Turn the adjusting screw by the amount shown
on the chart noting that this adjustment will result in
misalignment between the punch mark and the scribed
line for ambient temperature other than 23°C on 1985
Fig. 25-Float level adjustment models or 21°C on 1986 models.
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 1 4 - 2K - 1 2

Choke Choke Choke

Ambient Adjustment Ambient Adjustment Ambient Adjustment
Temp °C Screw Turns Temp °C Screw Turns Ternp °C Screw Turns
1 986 1 985 1 986 1 985 1 986 1 985
models models models models models models
0 -2.3 -2.5 15 -0.7 -0.9 29 + .9 +0.7
1 -2.2 -2.4 16 -0.6 -0.8 30 + 1.0 +0.8
2 -2.1 -2.3 17 -0.4 -0.7 31 + 1.1 +0.9
3 -2.0 -2.2 18 -0.3 -0.6 32 + 1.2 + 1.0
4 -1.9 -2.1 19 -0.2 -0.4 33 + 1.3 + 1.1
5 -1.8 -2.0 20 -0.1 -0.3 34 + 1.5 + 1.2
6 -1.7 -1.9 21 0 -0.2 35 + 1.6 + 1.3
7 -1.5 -1.8 22 + .1 -0.1 36 + 1.7 + 1.5
8 -1.4 -1.7 23 + .2 0 37 + 1.8 + 1.6
9 -1.3 -1.5 24 +.4 +0.1 38 + 1.9 + 1.7
10 -1.2 -1.4 25 + .5 +0.2 39 +2.0 + 1.8
II - 1.1 -1.3 26 +.6 +0.4 40 +2.1 +1.9
12 -1 .0 -1.2 27 + .7 +0.5 41 +2.2 +2.0
13 -0.9 -1.1 28 + .8 +0.6 42 +2.3 +2.1
14 -0.8 -1.0
Note: + = turns clockwise - = turns anti-clockwise

Chart-choke valve adjustment

(9) Refit the carburettor using a new carburettor to Choke Breaker Adjustment
manifold gasket.
(10) If the vehicle still runs rich or lean after the Push the choke valve in the direction that it closes
adjustment, a fine adjustment can be performed with and push the vacuum operated choke breaker shaft to
the carburettor in place on the vehicle. Loosen the screw check the specified clearance between the choke valve
at the pinion plate and move the plate down for richer and choke bore wall. If necessary, adjust the clearance
operation or upwards for leaner operation, refer by inserting a screwdriver in the adjusting groove at
Fig. 27. t he end of the shaft.

Punched mark
Set temperature
raised (leaner) Unloader Adjustment

Push the choke valve in the direction that it closes

and fully open the throttle valve. Check the clearance
between the choke valve and choke bore wall. The
Inscribed line
normal clearance is 1.5 nun. If adjustment is necessary,
bend the rod.

Dashpot Adjustment (where fitted)

With the engine at normal operating temperature

Fig. 27-Choke valve adjustment and idle speed and idle mixture set to specification,
proceed as follows:-
Fast Idle Adjustment
(1) Back off the dashpot link screw so that it is not
( On Vehicle) contacting the dashpot link.
The engine fast idle speed is dependent on a number (2) Adjust the screw so that it just contacts the link,
of factors (engine coolant and ambient air temperature i.e. engine speed just starts to increase, then back off
etc.). Unless the conditions are ideal, the fast idle speed the screw half a turn.
will vary depending on the above mentioned factors. (3) Lift the dash pot link so that it contacts the
The fast idle speed is set at the factory to be dashpot speed screw and adjust the screw to achieve
approximately 1100 r.p.m., and it is recommended that the specified dashpot speed.
it is only adjusted as outlined in "Choke Valve and Fast (4) Release the link, the engine should return to idle
I dle Adjustment". speed within the specified time.
REV APRIL 86
 1986 Automatic Vehicles
1985 Models
(1) Ensure that the engine is at normal operating
temperature and idle speed is set to specifications.
Engine speed, Manual 2100 ± 100 r.p.m. (2) Switch on the air conditioner and check that
dashpot compressor clutch is actuated.
bottomed (3) Adjust engine speed to maintain the specified
Auto 1500 ± 200 r.p.m. speed, using the idle up adjusting screw, refer Fig. 29.

Idle speed within

Manual
Engine speed, 1.5 to 4.5 sees
rod released Idle speed within
Auto
3 to 6 sees

1986 Models
Engine speed,
dashpot Manual 1500 ± 200 r.p.m.
bottomed
Engine speed I dle speed within
Manual
rod released 3 + 1.5 sees

Air Conditioner Idle Up Adjustment

Fig. 29-Idle up adjusting screw (1986 automatic)
All Manual Vehicles and 1985 Automatic Vehicles

Adjust the dashpot as previously described and Throttle Position Sensor (T.P.S.) Adjustment
proceed as follows:- (Automatic Models)
(1) Switch on the air conditioner ensuring the For full i nspection and test procedures refer to Group
compressor is activated. 21 - Transaxles.
(2) Adjust the idle up screw to maintain the specified
speed with the compressor on. Anti-clockwise rotation ELECTRICAL COMPONENT TESTING
i ncreases speed.
Air Temperature Sensor (Vehicles with fan run-on
NOTE: Rotation of the idle up screw is difficult system)
when vacuum is applied to the idle up diap-
hragm. Disconnecting the vacuum supply hose An engine bay air temperature sensor is fitted to the
will facilitate idle up screw rotation. carburettor adjacent to the fuel inlet pipe.
Disconnect the sensor at the double connector and
heat the sensor bulb with a hot air gun to 70°C or more.
Check the sensor continuity. Allow the sensor to cool
and check for open circuit.
I dling A/C Idling A/C
off on

Fig. 28-Dashpot and idle up adjusting screws Fig. 30-Carburettor electrical components