1985 Toyota Pickup DX

CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

CARBURETOR - AISAN 2-BBL

1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

DESCRIPTION
Carburetor is a 2-barrel downdraft design with primary and secondary venturi. An automatic choke containing a
bi-metallic spring, controlled by a ceramic heater, provides proper air/fuel mixture control during engine warm-
up.

Secondary throttle valve is actuated by a vacuum diaphragm unit with a kick-up (open) lever. Secondary valve
begins to open when primary throttle valve opening exceeds 50.

A thermostatic valve provides airflow under secondary throttle valve, when ambient air temperature is high, to
maintain proper combustion. Other features include a choke opener, a main and an auxiliary accelerator pump
(AAP), a secondary slow circuit fuel cut system, a fast idle cam breaker, a deceleration fuel cut system, outer
vent control valve and idle-up diaphragm.

CARBURETOR IDENTIFICATION
Application Carburetor No.
Calif.
Man. Trans. 21100-35310,
21100-35290
Auto. Trans. 21100-35390,
21100-35301

ADJUSTMENTS

NOTE: For all on-vehicle adjustments not covered in this article, see appropriate TUNE-
UP article in the TUNE-UP section.

NOTE: Manufacturer recommends using Carburetor Adjustment Kit No. 09240-00014

for carburetor measurements and adjustments.

FLOAT LEVEL

Remove air horn gasket, invert air horn, and allow float to hang by its own weight. Measure clearance between
top of float and air horn. Clearance should be .386" (9.8 mm). Adjust clearance by bending float arm at tab "A".
See Fig. 1 .

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Fig. 1: Float Level Adjustment Adjust by bending float arm at tab "A".

FLOAT DROP

Remove air horn gasket, position air horn right-side up, and let float hang down by its own weight. Measure
distance between bottom of float and air horn. Float drop measurement should be 1.89" (48 mm). Adjust
clearance by bending float tab "B". See Fig. 2 .

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Fig. 2: Float Drop Adjustment Adjust by bending float tab "B".

UNLOADER

Fully open primary throttle valve, insert angle gauge, and measure choke valve angle. Choke valve angle should
measure 45. Adjust by bending primary throttle arm. See Fig. 3 .

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Fig. 3: Choke Unloader and Throttle Valve Adjustment

THROTTLE VALVE OPENING

1. Invert carburetor and fully open throttle valves. Measure angle of primary and secondary throttle valves
using angle gauge.
2. Angle of throttle valves should measure 90. Adjust by bending the appropriate throttle arm. See Fig. 3 .

SECONDARY TOUCH ANGLE

Measure the primary throttle valve angle as secondary throttle valve just begins to open. Primary throttle angle
should measure 59.

FAST IDLE

Bench Adjustment

Set throttle lever to high (first) step of fast idle cam. Fully close choke valve, insert angle gauge, and adjust
primary throttle valve angle by turning fast idle adjusting screw. Angle adjustment is 23.

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

CHOKE BREAKER

Apply vacuum to choke breaker diaphragm. Close choke valve by hand, insert angle gauge, and measure choke
valve angle. See Fig. 4 . Choke valve angle should measure 42. Adjust by bending relief lever.

Fig. 4: Choke Breaker Adjustment Adjust by bending relief lever.

CHOKE OPENER

1. Apply vacuum to choke opener diaphragm. Check that fast idle cam is released to 4th step. If not, adjust
by bending choke opener lever.
2. Close choke valve and set fast idle lever to 1st step. Ensure there is clearance between choke opener lever
and fast idle cam.

IDLE-UP (THROTTLE POSITIONER)

Apply vacuum to idle-up diaphragm, insert angle gauge, and measure throttle valve opening. Adjust throttle
valve opening angle to 16.5 by turning adjusting screw.

SECONDARY THROTTLE VALVE LOCK SYSTEM

1. Hold throttle slightly open, and push choke valve closed. Hold it closed as you release throttle valve.
2. Lever "A" should be holding lever "B" locked. See Fig. 5 . Lever "A" should move smoothly at step 2 or
3 of fast idle cam. Adjust by bending top of lever "A".

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Fig. 5: Adjusting Secondary Throttle Valve Lock System

3. While holding throttle slightly open and choke valve closed, rotate lever "B" until it makes contact with
lever "A". Measure clearance between secondary valve and bore. Check for a maximum clearance
of .020" (.51 mm).
4. With choke valve opened above 52, check that lever "A" unlocks when throttle valve is opened. Repeat
step 1). Apply vacuum to choke opener and check that lever "A" withdraws and that lever "B" unlocks.

OVERHAUL
DISASSEMBLY

Air Horn

1. Use Driver Set SST 09860-11011. Remove metering needle, and disconnect fast idle link and air valve
connecting rod. Remove the 5 air horn screws, and lift air horn from body. Remove air horn gasket.
2. Remove float pivot pin and float with the needle valve. Remove needle valve seat. Loosen power piston
retaining screw. Hold piston, and rotate retainer. Remove piston and spring. Loosen the 3 screws, and

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

remove the outer vent control valve.

Main Body

1. Remove slow jet using Remover (SST 09922-00010). Remove power valve with jets, metering needle
guides, and secondary main jets.
2. Remove plug and primary main jets. Remove solenoid valve from body. Remove main and auxiliary
acceleration pump housings, springs, and diaphragms.
3. Disconnect idle-up diaphragm link and diaphragm. Disconnect choke opener link, and remove choke
opener. Remove 3 body-to-flange screws and remove flange from body.

CLEANING

NOTE: Do not immerse diaphragm valves, electrical components, or synthetic parts in

carburetor cleaner.

Clean cast parts in carburetor cleaner and blow dry. Do not clean jets or other passages with wire or similar
metal objects. Inspect all parts for wear or damage and replace necessary parts.

INSPECTION

Choke Heater

Measure choke heater resistance between terminal and housing. Resistance should measure 20-22 ohms.

Choke Breaker, Choke Opener & Idle-Up Diaphragm

Apply vacuum to diaphragm and check for leakage. Ensure link or valve moves as vacuum is applied.

Float & Needle Valve

Inspect pivot pin for scratches and wear. Check float for wear in pivot pin holes and for broken lips. Inspect
needle valve and seat for wear and damage and strainer for rust or breaks.

Primary Fuel Cut Solenoid

Connect battery voltage to solenoid terminals and feel solenoid for "click" as power is connected and
disconnected. Inspect "O" ring for damage.

Power Piston

Inspect power piston and piston bore for wear and damage. Check spring for distortion or breaks.

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Fig. 6: Exploded View of Carburetor

Vent Control Valve

1. Check valve and seats for damage. Check that valve rod moves smoothly. Connect valve terminal wire to
battery positive post. Jumper valve body to battery negative post.
2. You should feel a click from the control valve each time the valve wire is connected and disconnected to
the battery positive post.

REASSEMBLY

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 1985 Toyota Pickup DX
CARBURETOR - AISAN 2-BBL 1985 CARBURETORS Toyota Aisan 2-Barrel - 22R Engine

Reassemble carburetor by reversing disassembly procedure, using new gaskets where required. Check for
smooth operation of all valves and linkage.

ADJUSTMENT SPECIFICATIONS
CARBURETOR ADJUSTMENT SPECIFICATIONS
Application Specification
Float Level In. (mm) 0.386 (9.8)
Float Drop In. (mm) 1.89 (48)
Choke Opener In. (mm) n/a
Choke Breaker Angle 42
Throttle Positioner Angle 16.5

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