Chrysler Caravan/Voyager/Town n Country 1984-1995

Carburetor

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ADJUSTMENTS



Holley Carburetor

IDLE SPEED/SOLENOID KICKER CHECK

See Figure 1



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Fig. Fig. 1: Solenoid kicker system-2.2L engines

Vehicles equipped with the 2.2L engine and air conditioning are equipped with a solenoid kicker.

  1. Start engine and run until operating temperature is reached.
  2.  
  3. Turn air conditioning switch ON and set temperature control lever to the coldest position.
  4.  
  5. Notice the kicker solenoid for in and out movement as the compressor cycles on and off. If no movement occurred, check the kicker system for vacuum leaks. Check the operation of the vacuum solenoid. If no problems are found, replace the kicker.
  6.  
  7. If the kicker solenoid functions properly, turn off the air conditioning switch and shut engine OFF .
  8.  

SOLENOID KICKER ADJUSTMENT
  1. Check ignition timing and adjust if necessary.
  2.  
  3. Disconnect and plug vacuum connector at the Coolant Vacuum Switch Cold Closed unit (CVSCC).
  4.  
  5. Unplug connector at cooling fan and jumper harness so fan will run continuously.
  6.  
  7. Remove the PCV valve and allow it to draw under hood air.
  8.  
  9. Connect a tachometer to the engine.
  10.  
  11. Ground the carburetor switch with a jumper wire.
  12.  
  13. Disconnect the oxygen system test lead located on the left fender shield on vehicles equipped with 6520 carburetors.
  14.  
  15. Start the engine and run until normal operating temperature is reached.
  16.  
  17. Adjust idle speed screw to specification given on the underhood label.
  18.  
  19. Reconnect PCV valve, oxygen connector and CVSCC vacuum connector.
  20.  
  21. Remove the jumper from carburetor switch.
  22.  
  23. Remove the jumper from radiator fan and reconnect harness.
  24.  

After Steps 10, 11 and 12 are completed, the idle speed may change slightly. This is normal and engine speed should not be readjusted.

FAST IDLE ADJUSTMENT

See Figure 2



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Fig. Fig. 2: Fast idle adjustment-2.2L engines

Before adjusting the fast idle, check and adjust the ignition timing.

  1. Disconnect the electrical harness at the radiator fan and install a jumper wire so the fan will run continuously.
  2.  
  3. Remove the PCV valve and allow it to draw under hood air.
  4.  
  5. Disconnect and plug the vacuum connector at the Coolant Vacuum Switch Cold Closed unit (CVSCC).
  6.  
  7. Install a tachometer.
  8.  
  9. Ground the carburetor switch with a jumper wire.
  10.  
  11. Disconnect oxygen system test connector located on the left fender shield by shock tower.
  12.  
  13. Start engine and allow to reach normal operating temperature.
  14.  
  15. Open throttle slightly and place adjustment screw on the lowest step of fast idle cam.
  16.  
  17. Adjust the fast idle screw to specification shown on underhood VECI label. Return engine to idle and repeat Step 8, readjust if necessary.
  18.  
  19. Stop engine, remove jumper wire from radiator fan harness and reattach connector.
  20.  
  21. Reinstall PCV valve.
  22.  
  23. Reattach oxygen system test connector.
  24.  
  25. Reattach the vacuum connector at CVSCC.
  26.  

CHOKE VACUUM KICK ADJUSTMENT

See Figures 3, 4 and 5



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Fig. Fig. 3: Choke vacuum kick adjustment-2.2L engines



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Fig. Fig. 4: A/C kicker adjustment-2.2L engines



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Fig. Fig. 5: Vacuum kick adjustment specifications-2.2L engines

  1. Open the carburetor throttle and hold choke valve in closed position. While maintaining choke valve in closed position, release the throttle. Fast idle system should now be trapped at closed choke condition.
  2.  
  3. Disconnect carburetor vacuum source at carburetor.
  4.  
  5. Using light finger pressure, close choke valve to the smallest opening possible without disturbing linkage system.
  6.  
  7. Using the proper size drill or gauge, insert between choke valve and air horn wall at primary throttle end of carburetor. For more information, refer to the choke vacuum kick specification chart(fig 5).
  8.  
  9. Using an Allen head screw in center of diaphragm housing, adjust by turning clockwise or counterclockwise to obtain correct setting.
  10.  
  11. Reconnect vacuum hose to carburetor vacuum source.
  12.  

MIXTURE ADJUSTMENT (PROPANE ASSISTED)

The following procedures require the use of a propane cylinder, vacuum hose and a special control valve to provide proper enrichment. Any adjustments made other than those in the following procedures, may violate Federal and State Laws.

  1. Remove the mixture adjustment concealment plug. For more details, refer to Steps 18-20 in the carburetor disassembly procedure.
  2.  
  3. Set the parking brake and place the transaxle in neutral position. Turn off all accessories. Start engine and allow to idle on second highest step of fast idle cam until normal operating temperature is reached. Return engine to idle.
  4.  
  5. Disconnect vacuum connector at Coolant Vacuum Switch Cold Closed unit (CVSCC) and plug. Disconnect the vacuum hose to the heated air door sensor at the three way connector, and in its place, install the supply hose from the propane bottle.
  6.  
  7. Unplug the radiator fan connector and jumper harness so the fan will run continuously. Remove PCV valve and allow it to draw underhood air. Connect a jumper wire between the carburetor switch and ground. On vehicles equipped with 6520 carburetors, disconnect the oxygen test lead located on the left fender shield.
  8.  
  9. With the air cleaner installed. Open the propane main valve. Slowly open the propane metering valve until maximum engine rpm idle is reached. If too much propane is added engine rpm will decrease. Adjust metering valve for the highest engine rpm.
  10.  
  11. With the propane still flowing, adjust the idle speed screw on top of the solenoid to obtain specified rpm on underhood label. Again adjust the propane metering valve to get the highest engine rpm. If the maximum rpm changes, readjust the idle speed screw to the specified propane rpm.
  12.  
  13. Shut off the propane main valve and allow the engine to stabilize. With the air cleaner still in place, slowly adjust the mixture screws to obtain the specified set rpm. Pause for a few seconds after each adjustment to allow engine speed to stabilized.
  14.  
  15. Again turn on the propane main valve and adjust the metering valve to obtain the highest engine rpm. If the maximum speed differs more than 25 rpm, repeat Steps 5-8.
  16.  
  17. Shut off both valves on propane cylinder. Disconnect the propane vacuum supply hose and connect the vacuum hose to the heated air door sensor at the three way connector.
  18.  
  19. Install concealment plug. Proceed with fast idle adjustment starting at Step 7.
  20.  

ANTI-DIESELING ADJUSTMENT

Always check and adjust ignition timing before any idle speed adjustment is performed.

  1. Warm engine to normal operating temperature. Place transaxle in neutral position and set parking brake.
  2.  
  3. Turn OFF all accessories. Jumper wire between carburetor switch and ground.
  4.  
  5. Remove the RED wire from the 6-Way connector (carburetor side).
  6.  
  7. Adjust the throttle stop speed screw to obtain 700 rpm.
  8.  
  9. Reconnect RED wire and remove jumper from carburetor switch.
  10.  

Mikuni Carburetor

IDLE SPEED ADJUSTMENT

See Figure 6



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Fig. Fig. 6: Idle up adjustment-Mikuni carburetors

  1. Check and adjust ignition timing.
  2.  
  3. Set the parking brake and place transaxle in neutral. Turn off all accessories.
  4.  
  5. Disconnect the radiator fan.
  6.  
  7. Connect a tachometer to the engine.
  8.  
  9. Start engine and run until operating temperature is reached.
  10.  
  11. Disconnect cooling fan. Run engine at 2500 rpm for 10 seconds and return to idle.
  12.  
  13. Wait 2 minutes and record rpm. If rpm differs from VECI under hood specification label, turn idle speed adjusting screw until specification is obtained.
  14.  
  15. On air condition models, set the temperature lever to the coldest position and turn air conditioning switch ON . With the air conditioning running, set the engine speed to 900 rpm using the idle-up adjustment screw.
  16.  
  17. Shut engine OFF . Connect the cooling fan and remove tachometer.
  18.  

FAST IDLE ADJUSTMENT

See Figures 7 and 8



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Fig. Fig. 7: Fast idle adjustment-Mikuni carburetors



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Fig. Fig. 8: Installing tool C-4812-Mikuni carburetors

  1. Connect a tachometer to the engine. Check and adjust ignition timing.
  2.  
  3. Set the parking brake and place transaxle in neutral. Turn OFF all accessories.
  4.  
  5. Start engine and run until operating temperature is reached.
  6.  
  7. Disconnect radiator fan. Remove and plug vacuum advance hose at distributor.
  8.  
  9. Open the throttle slightly and install Tool C-4812 (or the equivalent) on the cam follower pin.
  10.  
  11. Release throttle lever and adjust fast idle adjusting screw to specification shown on VECI under hood label.
  12.  
  13. Remove tool and shut engine OFF . Reconnect fan, unplug and reconnect vacuum hose, and remove tachometer.
  14.  

IDLE MIXTURE ADJUSTMENT (PROPANE ASSISTED)

The following procedures require the use of a propane cylinder, vacuum hose and a special control valve to provide proper enrichment. Any adjustments made other than those in the following procedures, may violate Federal and State Laws.

  1. Remove concealment plug. For more details, refer to the concealment plug removal procedure later in this section.
  2.  
  3. Check and adjust ignition timing.
  4.  
  5. Set the parking brake and place transaxle in neutral. Turn OFF all accessories.
  6.  
  7. Disconnect the cooling fan.
  8.  
  9. Connect a tachometer to the engine.
  10.  
  11. Start engine and run until operating temperature is reached.
  12.  
  13. Disconnect cooling fan. Run engine at 2500 rpm for 10 seconds and return to idle. Allow engine to idle for 2 minutes.
  14.  
  15. Remove the air cleaner fresh air duct. Place the propane bottle in a safe location and in an upright position. Insert the propane supply hose approximately 4 in. (10cm) into the air cleaner snorkel.
  16.  
  17. Open the propane bottle main valve. Slowly open the metering valve until the highest engine rpm is reached. If too much propane is added, the engine rpm will decrease. Fine tune the propane metering valve to obtain the highest engine rpm.
  18.  
  19. With the propane still flowing, adjust the idle speed screw to the specified rpm shown on VECI underhood label. Again fine tune the propane metering valve to get the highest engine rpm. If the rpm increases, readjust the idle speed screw to specification.
  20.  
  21. Shut OFF the propane main valve and allow the engine speed to stabilize. Slowly adjust the carburetor mixture screws to obtain the specified idle rpm. Pause between each adjustment to allow engine speed to stabilize.
  22.  
  23. Again turn ON the propane main valve, fine tune the metering valve to get the highest engine rpm. If the rpm changes, repeat Steps 8-10.
  24.  
  25. Shut OFF the propane main valve and metering valve. Remove the propane supply hose. Install the air cleaner fresh air duct. Install the concealment plug and impact plate.
  26.  

CONCEALMENT PLUG REMOVAL
  1. Remove the impact plate, if used.
  2.  
  3. Remove the vacuum connector from High Altitude Compensator (HAC) fitting on carburetor, if used.
  4.  
  5. With an 1 / 8 in. (3mm) long, 1 / 4 in. (6mm) diameter drill bit, drill out concealment plug at location show.
  6.  
  7. Remove the concealment plug.
  8.  

REMOVAL & INSTALLATION



2.2L Engines

See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20



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Fig. Fig. 9: After disconnecting the air intake duct, disconnect the air heat tube to the air cleaner



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Fig. Fig. 10: Disconnecting the breather hose to the air cleaner-2.2L engines



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Fig. Fig. 11: Disconnecting the breather hose to the air cleaner-2.2L engines



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Fig. Fig. 12: Disconnect the carburetor inlet line-2.2L engines



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Fig. Fig. 13: Detach the electrical connector to the electric choke-2.2L engines



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Fig. Fig. 14: Disconnect the wiring harness and vacuum tube retaining bracket-2.2L engines



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Fig. Fig. 15: Unplug the main wiring harness connector-2.2L engines



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Fig. Fig. 16: Disconnect the throttle linkage from the carburetor-2.2L engines



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Fig. Fig. 17: Disconnect the vacuum tube-2.2L engines



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Fig. Fig. 18: Removing the carburetor mounting nuts-2.2L engines



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Fig. Fig. 19: Removing the carburetor mounting nuts (continued)-2.2L engines



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Fig. Fig. 20: Removing the carburetor assembly from the manifold-2.2L engines


CAUTION
Never remove a carburetor from an engine that has just been road tested. Allow the engine to cool down to prevent accidental fuel ignition or personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the fuel tank filler cap to relieve fuel system pressure.
  6.  
  7. Disconnect all carburetor electrical wiring.
  8.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Disconnect the carburetor inlet line and block off line to prevent fuel leakage.
  2.  
  3. Disconnect the throttle linkage. Label and remove all vacuum hoses.
  4.  
  5. Remove the carburetor mounting nuts and remove carburetor.
  6.  

To install:
  1. Inspect the mating surfaces of the carburetor and isolator for nicks, burrs, dirt or other damage. It is not necessary to disturb the isolator to intake manifold mounting screws, unless the isolator is damaged.
  2.  
  3. Carefully install carburetor on engine. Install nuts evenly and tighten them to 17 ft. lbs. (22 Nm). Make certain throttle plates and choke plate opens and closes properly when operated.
  4.  
  5. Connect the throttle linkage and fuel inlet line.
  6.  
  7. Connect the vacuum hoses.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Install the air cleaner and adjust the carburetor.
  12.  

2.6L Engines


CAUTION
Never remove a carburetor from an engine that has just been road tested. Allow the engine to cool down to prevent accidental fuel ignition or personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the fuel tank filler cap to relieve fuel system pressure.
  6.  
  7. Disconnect the carburetor protector and all carburetor electrical wiring.
  8.  
  9. Drain the cooling system. Label and remove the vacuum hoses and coolant hoses at carburetor.
  10.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the carburetor inlet line and block off line to prevent fuel leakage.
  2.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Disconnect the throttle linkage.
  2.  
  3. Remove the carburetor mounting bolts and nuts and remove carburetor.
  4.  

To install:
  1. Inspect the mating surfaces of the carburetor and intake manifold for nicks, burrs, dirt or other damage.
  2.  
  3. Install a new gasket on intake manifold.
  4.  
  5. Carefully install the carburetor on the engine. Install mounting bolts and nuts. Tighten evenly to 12 ft. lbs. (17 Nm). Make certain throttle plates and choke plate opens and closes properly when operated.
  6.  
  7. Connect the throttle linkage, fuel line and electrical connectors.
  8.  
  9. Install and tighten carburetor protector.
  10.  
  11. Fill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Install the air cleaner and adjust the carburetor.
  16.  

DISASSEMBLY



Holley Model 5220/6520

  1. Remove the carburetor from the engine as described in carburetor removal procedure.
  2.  
  3. Using a small prytool disconnect and remove choke valve operating rod and seal.
  4.  
  5. Remove the idle stop solenoid mounting screws and remove solenoid.
  6.  
  7. Remove the oxygen solenoid retaining screws and carefully remove the sensor.
  8.  
  9. Remove the retaining clip securing the vacuum diaphragm control rod, remove the vacuum diaphragm mounting screws and remove vacuum diaphragm assembly.
  10.  
  11. Make a mark, for proper alignment during assembly, on the air conditioning wide open throttle cut-out switch, and remove switch and wiring assembly.
  12.  
  13. Remove the (5) air horn screws and separate the air horn from carburetor body.
  14.  
  15. Invert the air horn and remove the float pin, float and inlet needle.
  16.  
  17. Remove the fuel inlet needle and seat.
  18.  
  19. Notice the size and position of the secondary main metering jets, and remove jets.
  20.  
  21. Notice the size and position of the primary main metering jets, and remove jets.
  22.  
  23. Using a small prytool remove the secondary high speed bleed and secondary main well tube. Note the size and position so it can be reinstalled in its proper location.
  24.  
  25. Remove the primary high speed bleed and primary main well tube. Note the size and position so it can be reinstalled in its proper location.
  26.  
  27. Remove the pump discharge nozzle retaining screw, nozzle and gasket. Invert the carburetor and remove the pump discharge weight ball and check ball. (Both are the same size).
  28.  
  29. Remove the accelerator pump cover retaining screws, cover, pump diaphragm and spring.
  30.  
  31. Remove the choke diaphragm retaining screws and remove cover and spring.
  32.  
  33. Rotate the choke shaft and lever assembly counterclockwise. Rotate choke diaphragm assembly clockwise and remove from housing. Remove end of lower screw from housing. If the choke diaphragm need replacement, the diaphragm cover must also be replaced.
  34.  
  35. To remove concealment plug, center punch at a point 1 / 4 in. (6mm) from the end of the mixture screw housing.
  36.  
  37. Drill through the outer housing with a 1 / 8 in. diameter drill bit.
  38.  
  39. Pry out the concealment plug and save for reinstallation.
  40.  
  41. Remove the idle mixture screws from carburetor body.
  42.  

Mikuni Carburetor

2.6L engines are equipped with a downdraft type two barrel carburetor, which can be identified with its black resin compound main body. The automatic choke is a thermowax type which is controlled by engine coolant temperature.

This carburetor also features a diaphragm type accelerator pump, bowl vent, fuel cut-off solenoid, Air Switching Valve (ASV), sub-EGR valve, Coasting Air Valve (CAV), Jet Air Control Valve (JACV) and a High Altitude Compensation (HAC) system. (California only).

  1. Grind head from screws of choke cover. Gently tap the remaining screw portions using a hammer and a pointed punch in a counterclockwise direction until screws are removed.
  2.  
  3. Take notice of the painted punch mark and scribed lines on choke pinion plate. During reassembly, these marks must be aligned.
  4.  
  5. Remove the E-clip from the throttle opener link. Remove the throttle opener mounting screws and set aside.
  6.  
  7. Remove the ground wire from the fuel cut-off solenoid, remove solenoid mounting screws, and remove solenoid.
  8.  
  9. Remove the throttle return spring and damper spring.
  10.  
  11. Remove the choke unloader E-clip from its link and remove choke unloader.
  12.  
  13. Remove vacuum hose and link from vacuum chamber. Remove vacuum chamber mounting screws and remove vacuum chamber.
  14.  
  15. Remove accelerator rod link from throttle lever.
  16.  
  17. Remove the air horn mounting screws (6) and carefully separate air horn from carburetor body.
  18.  
  19. Slide out float pivot pin and remove float assembly. Remove air horn gasket.
  20.  
  21. Unscrew needle/seat retainer, remove needle/seat, O-ring and screen.
  22.  
  23. Remove the primary and secondary venturi and O-rings. Mark both venturi for proper location during reassembly.
  24.  
  25. Remove primary and secondary main jets. Mark both jets for proper location during reassembly.
  26.  
  27. Remove primary and secondary pedestals and gaskets.
  28.  
  29. Remove bowl vent solenoid mounting screws, solenoid, bowl vent assembly, seal and gasket.
  30.  
  31. Remove the Coasting Air Valve (CAV) mounting screws and remove valve assembly from air horn. (California and Altitude models).
  32.  
  33. Remove enrichment valve mounting screws and remove enrichment valve assembly.
  34.  
  35. Remove Air Switching Valve (ASV) mounting screws and remove air switching valve assembly from air horn.
  36.  
  37. Remove the primary and secondary pilot jet set screw and lock. Remove pilot jet set assembly.
  38.  
  39. Remove primary and secondary air bleed jets from top of air horn. Mark both jets for proper location during reassembly.
  40.  
  41. Invert the air horn, carefully drop out and note pump weight, check ball and hex nut.
  42.  
  43. Remove accelerator pump mounting screws and remove pump cover, diaphragm, spring, pump body and gasket.
  44.  
  45. Remove jet air control valve mounting screws and remove JACV cover, spring, retainer and diaphragm seal.
  46.  
  47. Remove E-clip from sub-EGR lever. The sub-EGR valve is under pressure by a steel ball and spring. Care should be used when removing lever to prevent accidental lost of spring or ball. Carefully slide the pin from lever and sub-EGR valve. Remove the steel ball, spring, sub-EGR valve and boot seal.
  48.  

CLEANING AND INSPECTION



Efficient carburetion depends greatly on careful cleaning and inspection during overhaul, since dirt, gum, water, or varnish in or on the carburetor parts are often responsible for poor performance. There are many commercial carburetor cleaning solvent which can give satisfactory results.

Avoid placing any seals, O-rings, float, choke and vacuum diaphragm in cleaning solvent. Such components can be damaged if immersed in cleaning solvent. Clean the external surfaces of these parts with a clean, lint-free cloth or brush.

Soak carburetor parts in cleaning solvent, but do not leave parts in solvent any longer than necessary to loosen deposits. Remove parts and rinse with clean hot water. Blow out all passages and jets with compressed air. Blow dry all parts. Inspect the following:

  1. Check the float needle and seat for wear. If wear is found, replace the needle/seat assembly.
  2.  
  3. Check the float pin for wear and the float for damage, replace if necessary.
  4.  
  5. Check the throttle and choke shaft bores for wear or an out-of-round condition. Damage or wear to the throttle arm, shaft, or shaft bore will often require replacement of the throttle body. These parts require a close tolerance fit. Wear on these parts may allow air leakage, which could affect starting and idling.
  6.  
  7. Inspect the idle mixture adjusting needles for burrs or grooves, any such condition requires replacement of the needle, since you will not be able to obtain a satisfactory idle.
  8.  
  9. Check the bowl cover with a straight edge for warped surfaces .
  10.  

ASSEMBLY



Holley Model 5220/6520
  1. Install the choke shaft, while rotating counterclockwise. Install the diaphragm with a clockwise motion. Position spring and cover over diaphragm, and install retaining screws. Be certain fast idle link has been properly installed.
  2.  
  3. Install the accelerator pump spring, diaphragm cover and screws.
  4.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Install the accelerator pump discharge check ball in discharge passage. Check the accelerator pump and seat operation before complete reassembling as follows:
    1. Fill the fuel bowl with clean fuel.
    2.  
    3. Hold the discharge check ball down with a small brass rod and operate the pump plunger by hand. If the check ball and seat is leaking, no resistance will be felt when the plunger is operated. If the valve is leaking, use the old ball and carefully stake the ball using a suitable drift punch. Avoid damaging the bore containing the pump weight.
    4.  
    5. After staking the old ball, remove and replace with the new ball. Recheck for leaks.
    6.  

  2.  
  3. Install a new gasket, discharge nozzle and nozzle retaining screw.
  4.  
  5. Install the primary main well tube and primary high speed bleed.
  6.  
  7. Install the secondary main well tube and secondary high speed bleed.
  8.  
  9. Install the primary main metering (smaller size number) jet.
  10.  
  11. Install the secondary main metering (larger size number) jet.
  12.  
  13. Install the needle and seat assembly with a new gasket.
  14.  
  15. Invert the air horn and install float, inlet needle and float lever pin. Reset "dry float setting'' and "float drop.'', according to the following adjustment procedures.
  16.  
  17. Install a new gasket on air horn, and install choke rod seal and choke rod.
  18.  
  19. Carefully position the air horn on carburetor body.
  20.  
  21. Install a new retainer on choke shaft lever and fast idle cam pick-up lever and connect choke rod.
  22.  
  23. Install air horn retaining screws and tighten to 30 inch lbs. (3 Nm).
  24.  
  25. Install idle stop solenoid, and reinstall anti-rattle spring.
  26.  
  27. Install the air conditioning wide open throttle cut-out switch and align it with mark previously made. The switch must be positioned so that the air conditioning clutch circuit is open 10° before wide open throttle position.
  28.  
  29. Install the oxygen solenoid gasket on air horn. Install new O-ring seal on oxygen solenoid. Coat the new O-ring seal with petroleum jelly and install solenoid in carburetor body. Tighten solenoid mounting screws and secure wiring and clamps.
  30.  
  31. Install the vacuum solenoid.
  32.  
  33. Install the vacuum control valve.
  34.  

SETTING THE FLOAT
  1. Invert the air horn. With gasket removed, insert a 0.480 in. (12.2mm) gauge or drill between air horn and float.
  2.  
  3. To obtain proper dry float level bend adjusting tang with a small prytool.
  4.  

FLOAT DROP

See Figures 21 and 22



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Fig. Fig. 21: Measuring the float drop-2.2L engine shown



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Fig. Fig. 22: Float drop adjustment-2.2L engine shown

  1. With the air horn upright, check float drop with a depth gauge.
  2.  
  3. To obtain proper float drop adjustment, hold float assembly securely with one hand. Using a small prytool, carefully bend adjusting tang to obtain a float drop of 1.87 in. (47.6mm).
  4.  

Mikuni Carburetor

  1. Install the sub-EGR valve to throttle valve and check for proper operation.
  2.  
  3. Assemble the Jet Air Control Valve (JACV) to throttle body and secure with mounting screws.
  4.  
  5. Assemble the accelerator pump to throttle body and secure with mounting screws.
  6.  
  7. Install the primary and secondary air bleed jets. The secondary air bleed jet has the largest number.
  8.  
  9. Position new O-ring seals on primary and secondary pilot jet side. Slide assembly into place and install lock and screw.
  10.  
  11. Assemble the Air Switching Valve (ASV) to air horn and secure with mounting screws.
  12.  
  13. Assemble the enrichment valve to air horn.
  14.  
  15. Assemble the coasting air valve to air horn.
  16.  
  17. Position a new O-ring and gasket on bowl vent assembly and install on air horn.
  18.  
  19. Position a new gasket on air horn and install primary and secondary pedestals.
  20.  
  21. Install primary and secondary main jets in their pedestals. The secondary main jet has the largest number.
  22.  
  23. Position new O-rings on both primary and secondary venturi. Install primary and secondary venturi and retainers.
  24.  
  25. Position a new O-ring on needle seat. Install a new screen on needle seat. Install shim and needle seat into air horn. Install retainer and screw.
  26.  
  27. Position the float on air horn and install float pivot pin. Refer to the following Float Level Adjustment procedure.
  28.  
  29. Position a new gasket on throttle body. Install main body to throttle and install nut, check ball and weight in main body.
  30.  
  31. Position a new gasket on main body and carefully assemble air horn to main body.
  32.  
  33. Install vacuum hoses to air horn.
  34.  
  35. Connect accelerator rod link to throttle lever.
  36.  
  37. Install vacuum chamber to air horn. Connect vacuum hose and secondary throttle lever link.
  38.  
  39. Connect choke unloader link and install E-clip.
  40.  
  41. Position a new O-ring on fuel cut-off solenoid. Install the solenoid to main body and connect ground wire.
  42.  
  43. Install throttle opener to air horn. Connect throttle opener link and install E-clip.
  44.  
  45. Replace tamper-proof choke cover screws. Align the punch mark with the painted mark on gear.
  46.  
  47. Install the choke cover and peen over screws. Tighten the remaining screw using a pointed punch and a small hammer.
  48.  
  49. Install the choke water hose and clamp.
  50.  

FLOAT LEVEL ADJUSTMENT

See Figure 23



Click image to see an enlarged view

Fig. Fig. 23: Measuring the float level-Mikuni carburetor

  1. Remove air horn from carburetor main body.
  2.  
  3. Remove air horn gasket and invert air horn.
  4.  
  5. Using a gauge measure the distance from bottom of float to air horn surface. The distance should be 0.78 in. (20mm) plus or minus 0.039 in. (1mm). If distance is not within specification, the shim under the needle and seat must be changed. Shim pack MD606952 or equivalent has three shims: 0.3mm, 0.4mm, or 0.5mm. Adding or removing one shim will change the float level three its thickness.
  6.  

 
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