Rebuilding the Toyota Aisan carburetor

[Gokhan]

In this post, I am providing the repair-manual pages, actual photos, and a few warnings if you intend to rebuild your carburetor.

Here is the Fuel System chapter from the 1985 Toyota Corolla FWD Repair Manual for the Aisan carburetors, including 16030.

IMPORTANT: In order for the pages to display correctly, use View --> Page Display --> Two-Up in Adobe Acrobat Reader.

Toyota Corolla 1985 FWD Repair Manual Fuel System (Aisan carburetor, including 16030)

Here are the photos of the rebuild of the 4A-LC Aisan 16030 carburetor of my 1985 Corolla LE (FWD) with US Federal emissions:

Toyota 4A-LC Aisan 16030 carburetor rebuild -- complete teardown

Good luck rebuilding the carburetor.

A few warnings:

• Get a Great Neck impact drive from Autozone to be able to remove the flange screws without damaging them.
• Use a quarter-dollar coin in the needle-valve strainer and turn it with pliers.
• A sawed-off flat screwdriver may be useful for removing jets.
• You need a very thin-walled 9 mm drive to be able to remove the power piston.
• Take a photo at every step so that you can put things back correctly.
• Larger jet is the secondary jet, smaller is the primary.
• Be very careful not to drill into the idle-mixture screw. Go very slowly. Punch a dot in the exact center of the MAS plug first so that the drill bit will be stable. The screw is only 2 mm under the plug.
• Use goggles when you use compressed air with carb cleaner so that you don't get it in your eyes.
• You can use short teflon-tubing pieces to replace broken plastic bushings.
• Don't damage the cold-mixture heater. They don't make it anymore. It only makes a complete circuit when it's installed and don't incorrectly assume that the heater wire is broken -- it's not.
• Get the correct flange gaskets if they don't come with the kit. Chances are that they won't. You can also make your own gasket from FEL-PRO sheet gasket material -- readily available and cheap at auto stores -- probably much higher quality than aftermarket gaskets in the kits.
• Don't overtighten any mounting bolt or screw. if you tighten the gaskets too much, they can start leaking in a few years.