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OEM Nikki Carb Repair


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EPU Before making any assumptions or checks a recent tune-up including air filter, pcv valve, pcv filter, fuel filte
spark plugs and wires, distributor cap, etc.. should be made. Check to make sure your base ignition timing i
1600 deg +/- 1 deg. There are many vacuum operated systems and often vacuum lines are hard and brittle, chec
vacuum routing using these vacuum diagrams and replace any lines that look suspicious.
1800
Assembly Diagram
2000

2200

2300

2500

2600i

3000

4000

13, 06
ate
ey 5200 Page changed to
layout!
1. Accelerator pump lever < 16. Accel pump inlet check ball
2. Connect Spring td>
3. Air vent solenoid valve 17. Primary slow jet
4. Choke Rod 18. Secondary slow jet
5. Air Horn 19. Primary main jet
6. Electric Choke 20. Secondary main jet
7. Float 21. Plug
8. Fuel Inlet Needle Valve 22. Primary booster
9. Accelerator pump plunger 23. Secondary booster
10. Sight Glass 24. Primary main air bleed
11. Idle Switch 25. Secondary main air bleed
12. Slow fuel cut solenoid 26. Main carb body
27. Vacuum diaphragm
13. Coasting richer solenoid
28. Throttle link
14. Dashpot
29. Throttle Body
15. Accel pump outlet check ball & spring
30. Mixture Adjust Screw

Tamper Pin

The Mazda carburetors are usually fitted with a Tamper resistant pin to prevent people from changing idle m
settings. To remove it you need to knock it out with a punch like shown below.

Choke Operation

The choke is electrically operated by regulated voltage at the back of the alternator. When cold the internal
is also cold which pushes the choke closed, in order to do this though there is a lock on the linkage which pr
it from doing so. To engauge the choke on startup you must pump the gas atleast once which will close the
Once the engine is started voltage output from the alternator starts going to the choke which causes the spr
inside to heat up, as it heats the choke will start to back off until open throttle while driving or when the gas
goosed will kick it open and idle normal.

Diagnosing: Take the lid off the air breather with the engine off and cold. Pump the gas once and make sure
choke closes. If the choke does not close it is either stuck or the mechanisms are damaged. If this is the cas
truck may not want to start unless you pump the gas several times before and after starting or it may not w
idle at all. If the choke is stuck you simply need to clean all the linkages, make sure the choke plates open a
close easily then spray some silicon lube on there. Heavier lubricants may attract dirt and make the linkages
again.

To check if the choke is opening warm up the truck. Once the truck is fully warmed up the idle should either
on it's own or kick down after you pump the gas once. If the idle drops down like it should the choke is likely
your problem. If the idle stays high the truck either isn't fully warmed up or it is staying closed, remove the
breather lid again and look at the choke, if not opening it will still be closed and you will not be able to see d
the barrel. The choke may be stuck, worn out, or not getting current from the alternator. Like above make s
the linkages and plates can freely move. There is an electrical connection sticking out the side, clean the
connection and make sure it is not loose, trace this wire to the next electrical connection and clean it, then g
the back of the alternator and remove that plug and clean it. To check the electrical connection with a multim
set it to read ohms, place one probe in the plug that goes into the alternator and the other on the connector
goes to the choke. If the resistance measured is less than .7 ohms you should be ok. Do not mix this up wit
Kohms as this is actually 700 ohms and not .7 if you get a high resistance check all of your electrical connec
again and clean if neccessary.

Accelerator Pump

Purpose:To provide fuel when pumping the gas on startup and to squirt gas into the carburetor during
acceleration.

Symptoms:Hard start, hesitation, slow acceleration, or stalling when accelerating.

Accelerator pump is damaged or passageways in the carb are plugged and need cleaning.

Air/Fuel Solenoid

Purpose: Located in the carburetor, controls air/fuel mixture based on ECU control output.

To test and diagnose the Air/Fuel Solenoid you will need a dwell meter and a digital multimeter, all tests will
performed with the engine warmed up and at idle.

Testing: To check the solenoid itself warm up the engine and let it run at idle, locate the white test connect
near the firewall on the passenger side of the engine compartment. Run a jumper wire from it to ground and
listen for the idle to drop. If the idle does not drop remove the air/fuel solenoid and clean it with carb cleane
replace it. Do not submerge the solenoid when cleaning.

To diagnose the systems which control the A/F Solenoid warm up the engine and let it run at idle. Locate the
white test connector mentioned above. This is where you will connect the (+) lead of you're dwell meter, run
(-) lead to ground. The meter should now be swinging somewhere between 20 deg and 70 deg if it is not
swinging, or is swinging past this range use the checklist below to diagnose the system.

0 Degrees Dwell:

Ignition Signal
Vacuum Sensor
or Water Thermosensor

27 Degrees Dwell:
Air Thermosensor
Vacuum Lines
Oxygen Sensor

32 Degrees Dwell:

Water Thermosensor

More than a 20-70 degree swing:

Vaccum Lines
Oxygen Sensor
Air Fuel Solenoid and wires
Clogged carburetor jets and bleeds.

To check the solenoid itself warm up the engine and let it run at idle, locate the white test connec
listed above. Run a jumper wire from it to ground and listen for the idle to drop. If the idle does n
drop remove the air/fuel solenoid and clean it with carb cleaner or replace it. Do not submerge th
solenoid when cleaning.

Slow Fuel Cut Solenoid

Purpose: As the name says it cuts fuel during deceleration or when th


ignition is turned off. This helps fuel economy, reduces chance
poping noises from exhaust, and prevents dieseling when the k
is turned off and the engine is hot. If this solenoid is stuck or n
getting proper electrical connection the engine might not start
unless the gas is pumped several times or it may not start at a
once started it may only run for a few seconds. It is located
between Accelerator pump lever and choke. If stuck open the
truck may smell rich when letting off the gas, make poping fro
the exhaust, or start getting clogged cats. When the computer
goes into limp mode this solenoid is turned off and defaults to
open.
To test:

1. This solenoid should be heard or felt clicking when the ignition is turned off then back on.
2. You can disconnect the solenoid and connect it to 12v and make sure the plunger activates or
solenoid clicks.
3. Disconnect the Neutral Safty switch on the transmission (under the truck) while using a
screwdriver to your ear on the solenoid make sure you can hear it click when decelerating the en
from 3,000 rpm. Clean contacts and plunger if dirty or corroded.
4. With the engine running at idle it should stall when you disconnect the 8-pin carburetor conne
(Shown Below)

Servo Diaphragm ( A/C or A/T only )


Purpose: Uses vacuum from idle up solenoid to open throttle valve for increased load at idle. Migh
also be equipped on vehicles with power steering. Malfunction may lead to stalling or rough idle w
transmission is in gear, A/C is on, or making sharp turns during city driving. The truck may also n
more throttle then normal to prevent stalling when accelerating from a stop.

Coasting Richer Solenoid

Description: Solenoid on side of carb facing the valve cover, held in with three screws, and is
controlled by the computer using 2 wires. The purpose of this solenoid is to open the carburetor's
secondary stage fuel circuit during deceleration. There are no vacuum ports in or out of this devic
however there is a vacuum port located directly above it in the carburetor body.
Fuel Pressure

Fuel Pressure on carbureted Mazda 86-93 B2200s and B2000s should


between 3.7-4.7 psi (26-32 kPa). If fuel pressure is high the fl
level in the carb will also rise causing a rich condition. The
opposite goes for low fuel pressure. If fuel pressure is within s
fuel level is high or low then the float level needs to be adjuste
Fuel level in the carb can be seen in the sight glass facing the
front of the truck near the bottom of the carburetor. It is also
common for an internal diaphram in the fuel pump to go bad
leaking fuel into the crankcase, this may cause the truck to idl
run rough, because of this you should monitor you're oil more
frequently if you siddenly develop a drivability problem.

Rich Condition

A rich condition can becaused by many things believe it or not a clog


air filter will cause a rich fuel mixture because it increases
vacuum inside the carburetor. A bad or worn out O2 sensor is
common considering the age of the truck. If the ECU does not
the readings it likes it goes into limp mode and will not go into
closed loop operation, simply put it shuts off all the systems
which control fuel mixture and defaults to rich conditions to
prevent engine damage.
Last Updated 4/12/09