Assembly

1. If throttle valve replacement is necessary, proceed as follows:
a. Remove staking from throttle valve attaching screws with suitable file.
b. Remove screws that secure throttle valves to throttle shaft.
c. Slide damaged throttle valves out of bores.
d. Slide new throttle valves into position with valve number on bottom and opposite vacuum port.
e. Install but do not tighten new screws, ensuring that fast idle adjusting screw is backed out. Hold valves in place with fingers pressing on high side of valves.
f. Tap valves lightly, then tighten screws securely and stake them. Support shaft when staking screws.
g. Operate throttle shaft from closed to open position, ensuring that it operates without dragging or sticking.
h. Hold throttle body up to strong light and ensure that the light visible around the outer diameter of valves on bores is uniform.
i. Install secondary throttle valves in same manner, ensuring that numbers stamped on valves are toward bottom rear.
2. Install idle mixture screws, and springs if used, in throttle body, ensuring that tapered portion is straight or smooth. Do not forget to install plastic caps or concealment plugs after carburetor has been installed and adjusted.
3. Inspect vacuum diaphragm piston to ensure that passage is not plugged with foreign matter.
4. Leak test diaphragm for internal leaks as follows:
a. Depress diaphragm stem.
b. Place finger over fitting to seal opening.
c. Release stem. If stem moves more than 1/16 inch in ten seconds, replace assembly.
5. Position diaphragm and bracket assembly on locating dowel on mounting surface, then install and tighten attaching screw.
6. Inspect rubber hose for cracks before installing on carburetor fitting next to diaphragm bracket. Do not connect vacuum hose to diaphragm fitting until after vacuum kick adjustment has been made.
7. Install step-up actuating lever with edges facing up.
8. Install throttle body gasket and main body.
9. Install primary metering jets in floor of main body and tighten securely.
10. Carefully install new primary O-ring seals, ensuring that they are centered over holes in main body.
11. Install secondary metering jets over bleed tubes and tighten securely.
12. Position accelerator upper spring on pump plunger with large diameter up.
13. Install spring and plunger in cylinder, compressing spring until rod extends through bowl cover, then install pump ``S'' link to retain assembly.
14. Position intake check seat, flange down, on a clean flat surface.
15. Position accelerator pump cylinder over assembly, then apply firm hand pressure to bowl cover to seat intake check seat in pump bore.
16. Install plastic accelerator pump passage tube.
17. Pour clean gasoline into clean container approximately 1/2 inch deep, then carefully lower pump housing into gasoline and raise plunger and press lightly on plunger shaft to expel air from pump passage.
18. Install accelerator pump discharge check needle in discharge passage.
19. Using small clean rod, hold discharge check needle firmly on its seat, then again raise plunger and press downward. If there is fuel leakage at discharge passage, clean again and install new check needle, then retest.
20. If discharge check needle still leaks, attempt to reseat as follows:
a. Insert a piece of drill rod down on needle, then lightly tap drill rod with hammer to form new seat.
b. Remove and discard needle and install new needle, then test as previously described. If leakage persists, replace carburetor.
c. Install accelerator pump jet housing, new gasket and adjusting screw, tightening screw securely.
d. Test operation. If identical clear straight streams are not emitted from jets, install new accelerator pump assembly. After test, remove bowl cover and the plastic accelerator pump passage tube from bowl cover.
21. If carburetor is equipped with bowl vent, install new grommet seal on bowl vent arm and install solenoid bowl vent valve assembly.
22. Install gaskets on fuel inlet needle seats, then install in bowl cover and tighten securely. When installing original needle seats and needles, ensure that they are installed in original position.
23. Place new bowl cover to main body gasket in position on bowl cover, then slide right and left floats into position in bowl cover and install float fulcrum pins. Ensure that marked float is installed on pump side of bowl cover.
24. Adjust float as described under ``On-Vehicle Adjustments''.
25. Install plastic accelerator pump passage tube.
26. Ensure that primary O-ring seals in bottom of main body are centered over holes, then carefully lower bowl cover down onto main body. The O-rings will hold the bowl cover up slightly until screws are installed.

Fig. 2 Float lever pins improperly placed:

27. Ensure that bowl vent operating lever engages bowl vent actuating lever, then install ten cover screws, torquing to 35 inch lbs. in two steps. When installing the bowl cover, it is important that the float lever pins are correctly positioned (centered in their supports). If the pins are not properly placed, they may be trapped between the gasket surfaces. When the bowl cover screws are tightened, the bowl will crack, Fig. 2.
28. Install fuel inlet fitting with a new gasket and tighten securely.
29. Install fuel line ``L'' hose and clamp securely.
30. Install solenoid bowl vent assembly and tighten securely.
31. Engage pump rod ``S'' link with hole in accelerator pump arm, then position arm on air horn and install pump arm screw. After tightening screw, operate lever to check for freedom of operation.
32. Engage throttle connector rod with hole in throttle lever and install other end in specified hole of accelerator pump arm, then install rod retainers.
33. Install step-up piston spring in piston cylinder, then the step-up rods and pistons and arm assembly.
34. Install cover plate and attaching screw, tightening securely.
35. Engage choke connector rod with hole in choke shaft lever, then swing rod at an arc until rod can engage choke countershaft and install rod retainer.
36. Engage choke diaphragm connector rod to air valve lever, then install washer and rod retainer.
37. Connect other end of rod to choke vacuum diaphragm plunger and install rod retainer.
38. Install duty cycle solenoid and gasket or oxygen feedback solenoid and gasket.
39. Install idle stop carburetor switch and bracket.