Getting it road worthy. Whats wrong with the carb.

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There is a little fuel coming through the primary. But not as much as the secondary. Maybe you're right.
Just for easier reference i took a video and I'm gonna upload it.

I can't see anything through that glass. It could be empty it could be full, it could be chocolate pudding behind there. No clue.
 
There is a little fuel coming through the primary. But not as much as the secondary. Maybe you're right.
Just for easier reference i took a video and I'm gonna upload it.

I can't see anything through that glass. It could be empty it could be full, it could be chocolate pudding behind there. No clue.

Give the vehicle a shake while you watch the sight glass. As it shakes you might see where the fill line of the fluid is...and be able to tell if it is too full or empty...
 
Yikes! That's a lot of fuel!

Yeah, that's not supposed to be happening...
 
Did you do the shake test to see if the level in the fuel bowl is overfilled or empty? If the float is not working properly, it will allow too much or not enough fuel to enter into the bowl...
 
I'm thinking:

1) float is either stuck or not set according to spec (gap between float tab and needle valve is not to spec - did you check this during rebuild?)
2) clog somewhere - and it is pushing the fuel through the secondary...

To diagnose #1:
1) do the shake test and confirm there is too much/too little fuel in fuel bowl (I'm guessing too much due to the amount of fuel flowing in that video...but we must rely on measurements...this is the scientific part of the process...)
2) remove air horn on carb and double check tolerance of the clearance between the tab on the float and the top of the needle valve

To diagnose #2:
1) remove the following: the Idle Mixture Screw, the two plugs at the base of the fuel bowl (below the sight glass) - note: when you do this, the fuel in the bowl will drain out!!!, and also remove the air cleaner cover so you have access to the throats of the carb
Then, with your carb cleaner in the can and that niffty red straw, blow carb cleaner:
- down the hole where the Idle mixture screw was
- insert the straw into each of the two holes at the base of the carb ALL THE WAY BACK INTO AND THROUGH THE MAIN JETS!!!! - this requires good aim but you can do it!! Blast away with that carb cleaner...you should see it coming out the venturis
-insert the straw down the venturis and blast away...you should see the carb cleaner coming out the base of the fuel bowl

and if you wanted to, you could also remove the 4 vac hoses that attach to the passenger side of the carb (use tape to mark their positions) and blast those ports as well...
...and the ports in the side walls of the carb itself.

Blast away!! Reassemble and retest!?!

I would do #2 first, then if that doesn't work, think about pulling the air horn to check the tolerance on that float (you can pull the airhorn with the carb installed, although I've never done it myself, but others on MUD have...)


....unless anyone else has a better idea of what this is happening!??
 
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NOTE: when you remove those two plugs at the base of the fuel bowl, you'll get a pretty good idea whether or not there is fuel in that bowl!!! Maybe catch it with a little bucket? cut off the bottom of a plastic bottle or something...
 
Alright, thanks so much for all the help and advice. I really appreciate it!

I guess I will get ready for some blasting this weekend.

Would you say for testing the carb, its mandatory to put the air cleaner on and hook up everything to it? Or as long as I have everything else hooked up its fine?
 
Alright, thanks so much for all the help and advice. I really appreciate it!

I guess I will get ready for some blasting this weekend.

Would you say for testing the carb, its mandatory to put the air cleaner on and hook up everything to it? Or as long as I have everything else hooked up its fine?

OK. Yeah, try blasting through everything, reassemble and test. Be sure to get the straw all the way into those main jets...

Not mandatory to reinstall the air cleaner while testing for idle/adjust idle mixture and idle speed screws...in fact, I do those adjustments with the air cleaner off. But those 4 hoses that connect to ports on the base of the carb on passenger side (the ones I recommend spraying carb cleaner through) will have to be connected to hold an idle...

Hit those circuits with carb cleaner and see if that dislodges anything, then repost. If I think of anything else I'll post...and maybe some smarter than I will post something here as well...
 
I'm fused about exactly where the two holes for the main jets are

The two plugs I'm referring to are located below the sight glass on the front of the carb. On the cross-section image below, they are to the right (see red arrow)...then you see the the fuel in the fuel bowl and then you see the main jet in line with that plug on the far side inside the fuel bowl. If you remove the two plugs, you can insert the plastic straw through the fuel bowl and into and through the hole in each of the main jets and then blow out the circuit behind them. If you don't get the plastic straw into that hole in the main jet, then you are just spraying carb cleaner into the fuel bowl...no bueno...

The red arrow points to the plug at the base of the fuel bowl that you must remove.

The yellow arrow points to the main jet #17 (this one #17 is the main jet on the primary barrel - if you remove the second plug on the fuel bowl, you will have the same type of access to the main jet #10 on the secondary barrel)

Carb Cirucits 2f Aisin FJ60_main jets_arrows.jpg
 
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Okay well found part of the problem. I sprayed(I think) into the main jet(also in all the other areas). Closed it all back up. and Start it up. I got someone to watch the bowl to see what happens. Lo' and behold, it fills right up and keeps going. I opened up the blow horn(is that what y'all call it?) of the carb and the bowl is filled to the max and the place where that plunger pump(1) thingy is filled too. I looked at the Float and it looks fine. I know I checked the needle or whatever it is that the float hits and it was fine as well when I put it on.
 
Okay well found part of the problem. I sprayed(I think) into the main jet(also in all the other areas). Closed it all back up. and Start it up. I got someone to watch the bowl to see what happens. Lo' and behold, it fills right up and keeps going. I opened up the blow horn(is that what y'all call it?) of the carb and the bowl is filled to the max and the place where that plunger pump(1) thingy is filled too. I looked at the Float and it looks fine. I know I checked the needle or whatever it is that the float hits and it was fine as well when I put it on.

Hmmm...so the fuel bowl is overfilling...and filling...and filling...

I wonder if the needle valve isn't closing correctly and is letting all the fuel come in that the fuel pump can give??

I'm trying to remember all the little parts that go into that needle valve assembly...

Did you replace that needle valve with a new one when you did the rebuild?

BTW it's called and air horn
 
Is the air horn off right now?

Did you take the needle valve assembly apart during carb rebuild? Could it be missing a piece?

The needle valve assembly should have all these little bits in it (don't loose the little spring):

Needle valve Aisin Carb.jpg
 
verify the float level settings. remove the needle and seat and inspect. replace if needed. before replacing the needle valve assy into the airhorn, blow thru the inlet backwards with carb cleaner. Does your fuel pump have 2 or 3 nipples? if it only has 2 lines to/from it, then that's your problem. it needs to have a supply, feed and return line for these set-ups to work right. if the return line is clogged, that could also be your problem- too much pressure for the needle valve. use an air compressor set to 14psi to blow out the fuel tank lines backwards towards the tank, replace the filter(s); remove gas cap first. inspect the gasket and airhorn for interferrence with the float- sometimes they just stick, but if it happens routinely, then there is an issue. if there are no obstructions from the floats opening and closing the needle valve, and the float levers are set correctly, and there is a clear path for excess fuel to return to tank thru, then you will not have this problem...
 
Right, so the working principle here is that fuel being pumped into the fuel bowl on the carb is regulated by the float and needle valve assembly (they work together...as a team...).
As the level of fuel in the fuel bowl rises, the float rises with it (because it is floating on top of the fuel...which is why it is called a float...I think...).
When the float reaches a certain level, the tab at the base of the float (the one which you adjust to set the specs outlined in the FSM so that the fuel level in the bowl remains at 1/2 up in the sight viewing window) pushes down on the needle valve assembly, closing the needle valve and preventing the further flow of fuel into the bowl.

So, either:
1) float is not set correctly...so it is not shutting off the needle valve assembly
2) the needle valve assembly is not working correctly and does not close
3) the fuel pump is forcing fuel into the bowl, over riding the float/needle valve

Do this:
1) Replace needle valve or if the needle valve was replace during carb rebuild, double check and make sure all the parts are present and assembled correctly
2) Recalibrate the float setting as per FSM
3) Reinstall air horn and test
4) check your fuel pump. As Lambcrusher says, you should see 3 leads coming from the pump. One is a return line to the tank, so that when the needle valve closes, fuel being pumped is directed back to the gas tank. Remove the gas cap on the gas tank (where you add gas during fill up) and remove that return hose at the fuel pump and blow into hose - it should be clear and someone should hear the air coming out the filler cap- if it's not clear then you won't be able to blow. Put hose back on fuel pump and reinstall gas tank cap. EDIT: maybe try this last, since you probably don't have access to air...
 
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Gallego, if you have that air horn off (or the next time you do while trouble shooting this carb), be sure to spray carb cleaner into those main jets...with the air horn off you should be able to see down into the fuel bowl and tell if the straw is getting into those holes in the main jets...
 
Anytime the fuel bowl is overflowing out of the vent tubes, either the float is stuck down or the inlet needle valve does not shut off. Remove, inspect and repair or replace as necessary.
 

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