Author Topic: 22R Aisan Carb Refurb  (Read 33297 times)

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fireitup

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22R Aisan Carb Refurb
« on: May 17, 2017, 06:27:22 AM »
I needed to rebuild the Auxillary and Main Acceleration Pumps on my carb and just decided to break the whole thing down and give it a thorough cleaning. Figured I'd stash all the pictures here with an explanation of what was going on for all to enjoy. Also will help me remember what to do when it's time to put it all back together.

I plan to delete the EGR while the carb is off, but leave the rest of the vacuum system intact. First to document where all the spaghetti attaches...



Everything still attached but the AAP lines



Fuel Inlet Line



Misc Spaghetti



HAC Vacuum Line 1 (Red)



HAC Vacuum Line 2 (Red)



HAC Vacuum Line 3 (Red)



Choke Breaker/Choke Opener



Passenger Side Spaghetti



Passenger Side Spaghetti 2



Removed vacuum valve to reveal some more spaghetti/carb...



Same thing zoomed in



Detached float bowl vent and some other line.



Where'd the carb go!?!?!



Found it



All the choke opener crap that i plan to reinstall at this point.  If it becomes a huge pain or a bunch of it breaks then I may just go manual choke...


« Last Edit: May 18, 2017, 12:46:46 PM by fireitup »
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H8PVMNT

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Re: 22R Aisan Carb Refurb
« Reply #1 on: May 17, 2017, 07:40:53 AM »
Hey if it's OK I am going to post a link to your thread here in my carb thread.  I am lacking good carb rebuild pics.
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fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #2 on: May 17, 2017, 09:09:21 AM »
Hey if it's OK I am going to post a link to your thread here in my carb thread.  I am lacking good carb rebuild pics.

Sure thing man feel free to steal/reference whatever pics you like.

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fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #3 on: May 17, 2017, 09:47:11 AM »
Ordered my rebuild/repair kit from Rock Auto for $35.  It came with this nice "paint by number" breakdown sheet that I scanned/attached here.  I have found it to be a great reference during this process.  Not necessarily following it by the number for disassembly, but will likely come in handy for reassembly.





PM me if you want the pdf version as I cant attach it on the forum.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #4 on: May 17, 2017, 10:18:01 AM »
Carb off and in my "office" aka laundry room making my whole house smell like gas.  Termites are swarming outside and I don't have a closed in garage so was forced into here...



Lots of carbon in the primary barrel.





Metering needle assembly retaining screw removed and assembly being lifted out



Bowl Cover screw being removed



Retaining screws for this bracket (fuel union?) removed



Choke breaker/E-Choke retaining screws removed



E-Choke cover assembly removed.  Gasket looks shot...



E-Choke assembly looks fairly clean.





Choke axle tab where the E-Choke applies torque looks to be in good shape.



Needed to get a pic of this tiny  :moon: little spring in the secondary choke linkage

Four other main screws holding the float bowl cover to the bowl assembly and it popped right off





Everything looks to be fairly clean.  I was expecting it to be much worse.  Will need to check the medical records on this truck and see if the previous owner ever had the carb rebuilt.




82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #5 on: May 17, 2017, 06:54:55 PM »
Got everything broken down/cleaned (pics to come soon) and thought of a question.  Anyone use gasket sealant on the paper carb gaskets?  My only hesitation is that some of that stuff would squeeze out past the gasket perimeter and clog up one of these tiny carb passages...
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

Gnarly4X

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Re: 22R Aisan Carb Refurb
« Reply #6 on: May 17, 2017, 07:24:27 PM »
Got everything broken down/cleaned (pics to come soon) and thought of a question.  Anyone use gasket sealant on the paper carb gaskets?  My only hesitation is that some of that stuff would squeeze out past the gasket perimeter and clog up one of these tiny carb passages...

All the carbs I've rebuilt over the years... I don't remember using any kind of sealant on the gaskets.  BUT... I have not rebuilt a 22R Aisin carb.

Gnarls.
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

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Mudder

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Re: 22R Aisan Carb Refurb
« Reply #7 on: May 17, 2017, 07:27:03 PM »
I wouldn't use any type of sealant on a carb. One little piece gets in a passage and it won't be a fun time.

emsvitil

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Re: 22R Aisan Carb Refurb
« Reply #8 on: May 17, 2017, 07:35:45 PM »
I've used a very thin layer of hylomar on some paper gaskets so I could reuse them.............
Ed
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Re: 22R Aisan Carb Refurb
« Reply #9 on: May 17, 2017, 07:37:01 PM »
I wouldn't use any type of sealant on a carb. One little piece gets in a passage and it won't be a fun time.

2X on that.

Gnarls.
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

God Bless Our Troops... Especially Our Snipers. The 2nd defends the 1st
MEMBER: WWP, T2T, VFW, NRA, GOA, SAF, Mammoth Nation, C2 Tactical, Hillsdale College, Humane Society of the U.S. - "We cannot solve our problems with the same thinking we used to create them." ~ Albert Einstein

Plainview

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Re: 22R Aisan Carb Refurb
« Reply #10 on: May 17, 2017, 09:17:58 PM »
The thieves who broke into my work van night before last left that exact same screw driver behind...   :shakehead:
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Re: 22R Aisan Carb Refurb
« Reply #11 on: May 18, 2017, 04:45:20 AM »
The thieves who broke into my work van night before last left that exact same screw driver behind...   :shakehead:

In the categories of bad people, I put thieves just above liars and stingy people. :thumbdown:

Remember Plainview.... if it weren't for those bad people, us good people wouldn't go to Heaven! :thumbs:

Gnarls.  :smokin:
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

God Bless Our Troops... Especially Our Snipers. The 2nd defends the 1st
MEMBER: WWP, T2T, VFW, NRA, GOA, SAF, Mammoth Nation, C2 Tactical, Hillsdale College, Humane Society of the U.S. - "We cannot solve our problems with the same thinking we used to create them." ~ Albert Einstein

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #12 on: May 18, 2017, 05:00:54 AM »
The thieves who broke into my work van night before last left that exact same screw driver behind...   :shakehead:

Damn plainview! Sorry to hear that. I hope those idiots get caught.

82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #13 on: May 18, 2017, 05:01:47 AM »
As for the gaskets i'm not going to worry about using any sealant.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #14 on: May 18, 2017, 06:11:34 AM »
Thought it would be a good place to stop and document what is going on in the float bowl.



Green: Primary Venturi
Red: Secondary Venturi

These are both held in by shims located on the back (right in this pic) side of the carb.



Green: Metering Needle Guide
Yellow: Slow Jet
Red: Power Valve and Jet Assembly

Underneath the Metering Needle Guide is where the Secondary Main Jet is installed.  It was difficult to get a good picture with everything installed.

To get to the primary main jet you have to remove a 14mm plug from the front of the carb, and feed a screwdriver through into the float bowl.  The following pics illustrate that sequence:











That last pic is the main jet itself after it was removed.

I need to get pics of the markings on all the jets while they are out for later reference.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

H8PVMNT

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Re: 22R Aisan Carb Refurb
« Reply #15 on: May 18, 2017, 07:22:31 AM »
In the categories of bad people, I put thieves just above liars and stingy people. :thumbdown:

Remember Plainview.... if it weren't for those bad people, us good people wouldn't go to Heaven! :thumbs:

Gnarls.  :smokin:

That's doctrinally incorrect unless you rely solely on karma and fruity feel good stuff but that is another discussion :).
« Last Edit: May 18, 2017, 08:36:12 AM by H8PVMNT »
“I would rather wake up in the middle of nowhere than in any city on earth.”
– Steve McQueen

"Except for maybe Seattle."  -H8PVMNT

"I plan to hit 300k in this truck"  :)bestgen4runner

 "I'm jealous of your shop. It has concrete and doesn't smell like pickles like the old shop  "  300K

H8PVMNT

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Re: 22R Aisan Carb Refurb
« Reply #16 on: May 18, 2017, 07:24:27 AM »
Got everything broken down/cleaned (pics to come soon) and thought of a question.  Anyone use gasket sealant on the paper carb gaskets?  My only hesitation is that some of that stuff would squeeze out past the gasket perimeter and clog up one of these tiny carb passages...

No just rub them down with some grease of some kind.  They will also come apart ad can be re-used if you grease them, say like if you want to change main jets like 30 times...   :yupyup:

111 is a pretty lean main jet!

Also I see you got your secondary jet out successfully.  I'm jealous.
« Last Edit: May 18, 2017, 07:45:09 AM by H8PVMNT »
“I would rather wake up in the middle of nowhere than in any city on earth.”
– Steve McQueen

"Except for maybe Seattle."  -H8PVMNT

"I plan to hit 300k in this truck"  :)bestgen4runner

 "I'm jealous of your shop. It has concrete and doesn't smell like pickles like the old shop  "  300K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #17 on: May 18, 2017, 09:58:31 AM »
111 is a pretty lean main jet!

Also I see you got your secondary jet out successfully.  I'm jealous.

Yeah i remember in your research thread you were swapping in between 116-120 right?  Might need to get some of those Hitachi jets that you were using. (anyone who hasn't read H8PVMNT's Aisan 22r Carb Tech thread i recommend it here http://board.marlincrawler.com/index.php?topic=100917.0)

As for the secondary jet, I had to go buy a new flathead screwdriver to get it out with a fatter blade.  It was a tight fit but it popped loose without damaging anything.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #18 on: May 18, 2017, 10:36:31 AM »
Next up is the bowl cover assembly





Float is held in with this sliding retainer pin.  It was very easy to remove.



Red: Power piston and spring are held in by the small phillips retainer screw.
Yellow: Needle and seat assembly



Here you can see the needle and seat assembly removed (although in a different orientation).



I also disassembled the choke breaker diaphragm, but did not get more pics than the one above.  I will be replacing this part so will try to remember to snap some when it is going back in.

Bowl vent solenoid assembly came off as well but I couldn't find any pictures. It looked fairly clean...

I chose not to remove the fuel union before soaking.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #19 on: May 18, 2017, 10:40:41 AM »


Auxillary acceleration pump was removed and disassembled.  Here it is bagged and tagged.



Likewise for the main acceleration pump

82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

H8PVMNT

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Re: 22R Aisan Carb Refurb
« Reply #20 on: May 18, 2017, 11:06:06 AM »
I have noticed that the jets will be different depending on the year and I think what kinds of piggy back systems and emissions stuff were on the carb.  A lot of the extra stuff is kind of a controlled vac leak, so this would effect the jetting.  I would play with it but the 111 is going to be your base line.  My carb had a 116 originally, and it still likes the 116 with the stock air cleaner on.  It just likes more fuel when I add more air flow.

You are doing a great job on this thread.  Keep it up  :thumbs:!
“I would rather wake up in the middle of nowhere than in any city on earth.”
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"Except for maybe Seattle."  -H8PVMNT

"I plan to hit 300k in this truck"  :)bestgen4runner

 "I'm jealous of your shop. It has concrete and doesn't smell like pickles like the old shop  "  300K

Plainview

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Re: 22R Aisan Carb Refurb
« Reply #21 on: May 18, 2017, 07:29:21 PM »
In the categories of bad people, I put thieves just above liars and stingy people. :thumbdown:

Remember Plainview.... if it weren't for those bad people, us good people wouldn't go to Heaven! :thumbs:

Gnarls.  :smokin:

Damn plainview! Sorry to hear that. I hope those idiots get caught.

Since the cops have no time to really investigate this kind of stuff I'll have to be satisfied with the knowledge that their lives really can't be much fun.

Not to hijack your thread, I just had a really strong reaction when I saw that screwdriver - kinda surprised me.. LOL.
'84 Xtra Cab Project:
http://board.marlincrawler.com/index.php?topic=100651.new#new
Parts Wanted:

- Un-cracked dash pad (do they exist?)

H8PVMNT

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Re: 22R Aisan Carb Refurb
« Reply #22 on: May 19, 2017, 04:31:46 AM »

Not to hijack your thread, I just had a really strong reaction when I saw that screwdriver - kinda surprised me.. LOL.

Those guys probably stole the screwdriver from the last job.

“I would rather wake up in the middle of nowhere than in any city on earth.”
– Steve McQueen

"Except for maybe Seattle."  -H8PVMNT

"I plan to hit 300k in this truck"  :)bestgen4runner

 "I'm jealous of your shop. It has concrete and doesn't smell like pickles like the old shop  "  300K

Gnarly4X

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Re: 22R Aisan Carb Refurb
« Reply #23 on: May 19, 2017, 05:12:08 AM »
That's doctrinally incorrect unless you rely solely on karma and fruity feel good stuff but that is another discussion :).

H8PVMNT,

Since you characterized my comment…  I will characterize yours….

The statement is simply a play on words. It’s certainly not a doctrine, more accurately characterized as a euphemism.  There’s no fruit involved.  Although you could apply Karma as the effectual spiritual principle in human behavior.  The statement is a humorous way to acknowledge good and evil. The reference to Heaven, is the “feel good stuff” that can be any place defined by a philosophy or religion.

Conceptual semantics is always at play in textual communications.

In the today’s world of chaos, can we have too much “feel good stuff?..... but that is another discussion. :D

Gnarls.
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

God Bless Our Troops... Especially Our Snipers. The 2nd defends the 1st
MEMBER: WWP, T2T, VFW, NRA, GOA, SAF, Mammoth Nation, C2 Tactical, Hillsdale College, Humane Society of the U.S. - "We cannot solve our problems with the same thinking we used to create them." ~ Albert Einstein

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #24 on: May 20, 2017, 07:43:13 PM »
No real action on the carb today. I pulled the trigger on some hitachi main jets and plan to open up the main jet from the 111 that is currently installed before I put it back together. Waiting on those to get in.

I went ahead with the EGR delete though and am pretty happy about that.  The EGR was disgusting and like 95% plugged with carbon, as expected...  :shake:









Blocked off with some shiny new LCE plates.





Now i need to crawl the forums/FSM and figure out what to do with this guy.



He's all lonely now that the EGR is gone.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

emsvitil

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Re: 22R Aisan Carb Refurb
« Reply #25 on: May 20, 2017, 07:49:59 PM »
Just remove the EGR vacuum modulator and hoses; then cap the vacuum nipples......
Ed
SoCal
86 SR5 XtraCab
22RE  W56B
31x10.50R15

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #26 on: May 20, 2017, 08:13:43 PM »
Just remove the EGR vacuum modulator and hoses; then cap the vacuum nipples......

Easy enough! Thanks.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #27 on: May 21, 2017, 05:27:01 AM »
Checked out the secondary main jet this morning and there are no markings on it anywhere. Since my baseline there is  :confused: i'll probably just leave it be for the moment until I can do some more research.
82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

fireitup [OP]

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Re: 22R Aisan Carb Refurb
« Reply #28 on: May 22, 2017, 05:05:20 AM »
Started putting this majestic thing back together yesterday. Tried to get into a little more detail on parts I skimmed over during the disassemble. Here comes a waterfall of carb pics!



Had to trim the throttle body gasket a bit as it was interfering with the carb on the right hand side (in this pic).  Gave a little rub down with some multi-purpose grease as suggested by H8PVMNT.



AAP Parts about to go on, with a little Great Smoky Mountains Natn'l Park plug.



Brass side out on the pump diaphragm.

[/url]

AAP Assembled



Hot Idle Compensator stack ready to be assembled.



1) New O-Ring Gasket



2) Bracket thing



3) Shorter blade



4) Longer blade with sealing surface screwed down, ready for cover to be installed.



Float level sight assembly.  O ring first, then glass, then retainer.



Main acceleration pump. Long brass pushrod comes out and through the boot.



make sure that the cam and rocker line up right and that rotating the throttle causes the pump to engage.



Power valve assembly.  Little red guy clips onto the valve pushrod and retains the spring to keep it closed.



044 Jet on the power valve



Assembled



Installed (reminder to use 9mm socket)



Slow jet with new O-Ring.



Installed.  Markings indicate 050 jet.

[/url]

Secondary Venturi/Retaining shim with improvised O-Ring



Primary venturi/retaining shim with O-Ring.  The O-Ring in this pic is actually the O-Ring for the secondary venturi.  I ended up finding the O-Ring for the primary later and was able to remove the improvised one listed above.  All probably would have worked out ok though...



Both Venturi's installed.

Moving on to the bowl cover



Power piston/retaining screw installed.



+Gasket and Needle seat



Needle assembly. I replaced all of these components.



Needle assembled and hung from float.



Float installed and adjusted per FSM spec. 



Choke breaker assembly



Installed and ready for a lifetime of abuse from the E-Choke.

Thats all for now until the Jets come in later today  :smokin:







82 Pickup - 22R : OME NitroChargers/Springs : Timing Chain @ 180K

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Re: 22R Aisan Carb Refurb
« Reply #29 on: May 22, 2017, 06:07:22 AM »
Excellent thread!  Great job!  Awesome photos!!  :beerchug:

I'm not sure I'd use the word "majestic" to describe that carb.  A bull Elk with a big rack is majestic.  A carburetor is a technological "marvel".... or depending on your experience.... a challenging mystery.

Gnarls.  :biggthumpup:
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

God Bless Our Troops... Especially Our Snipers. The 2nd defends the 1st
MEMBER: WWP, T2T, VFW, NRA, GOA, SAF, Mammoth Nation, C2 Tactical, Hillsdale College, Humane Society of the U.S. - "We cannot solve our problems with the same thinking we used to create them." ~ Albert Einstein

 
 
 
 
 

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