Repair Procedure

This procedure involves installing a manifold purge orifice, choke pull-off delay valve, ESA module, solenoid kicker*, EGR valve*, and choke assembly*. The choke cam index, vacuum kick, and fast idle must also be adjusted.

*On certain engine packages only.

1. INSTALLATION OF ESA MODULE (ALL ENGINE PACKAGES)

a. Remove the ESA module. The battery will have to be moved to the right slightly to gain access to the ESA module.

b. Install the new ESA module and reposition battery back into proper position.

FIGURE 1:

2. CHOKE PULL-OFF DELAY VALVE (ALL ENGINE PACKAGES)

a. Remove choke pull-off delay valve (if so equipped) and install provided choke pull-off delay valve, PN 4300273 (Figure 1), into the vacuum line to the choke pull-off.
3. MANIFOLD PURGE ORIFICE (ALL ENGINE PACKAGES)

a. The manifold purge orifice can be found connecting two hoses in the vacuum harness below the PCV module. Remove the existing purge orifice and install the provided purge orifice, PN 4300907.

4. INSTALLATION OF .070" SOLENOID KICKER (MANUAL TRANSMISSION EQUIPPED VEHICLES ONLY)

a. Remove the convolute tubing from the carburetor wiring harness and set aside.

b. Remove the red and violet wire from the 6-way electrical plug.

c. Remove the wiring harness stand-off clamp located at the top of the carburetor.

d. Remove the red and violet wire from the clamp.

e. Disconnect the vacuum line attached to the solenoid kicker.

f. Remove the solenoid kicker from the carburetor by removing the two attaching screws and set it aside.

g. Install the new solenoid kicker (with .070" stroke), PN 4342798, onto the carburetor using the same screws.

h. Attach the vacuum line to the new kicker.

i. Place the red and violet wires from the solenoid kicker into the stand-off clamp and secure the clamp to the carburetor.

FIGURE 2:

j. Install the spade end of the solenoid kicker wires into the 6-way connector by simply pushing them into the cavities until they snap into place. Be certain to place the proper wire into its proper cavity (Figure 2).

k. Reinstall the convolute tubing around the wiring harness.

1. Reinstall the carburetor (on California and High Altitude vehicles only) on the intake manifold, using the new flange gasket provided.
5. EGR VALVE (ALL ENGINE PACKAGES EXCEPT CALIFORNIA AND HIGH ALTITUDE WITH MANUAL TRANSMISSION)

a. Remove the existing EGR valve and install the provided EGR valve and gasket.

6. INSTALLATION OF CHOKE HOUSING (FOR CALIFORNIA AND HIGH ALTITUDE ENGINE PACKAGES ONLY)

a. Remove carburetor.

b. Disconnect choke operating rod lower end from the electric choke housing assembly.
c. Loosen the three screws holding electric choke housing assembly to the carburetor main body.

d. Remove electric choke housing assembly, taking care to disconnect the fast idle link to the throttle lever.

e. Install the new electric choke housing, PN 4419638, making sure the fast idle link has been installed correctly. Tighten three (3) screws held in choke housing assembly.

f. Reinstall choke operating rod into rod retainer on fast idle cam lever.

g. Check vacuum kick adjustment. Set to .085" (manual transmission) or .060" (automatic transmission) at the top edge of the choke blade.
h. Check and reset cam index specification (automatic transmission is .095", manual transmission is .080"), if necessary, at the top edge of the choke blade. Use the following procedure:

Cam Index Checking and Setting

Tools Required: Calibration Gauge .095" (automatic) .080" (manual)
Bending Tool (needle nose pliers or equivalent)

Procedure:

^ Position fast idle adjusting screw on middle step of fast idle cam.

FIGURE 3:

^ Insert calibration gauge between upper edge of primary choke blade and air horn (Figure 3).

^ While applying light closing pressure to the top of the choke blade, measure the cam index setting.

^ Adjust the cam index - open the choke blade enough to install the bending tool on the cam index operating lever tang. Bend, the tang to obtain the desired setting (noted above).

^ Reposition the fast idle adjusting screw on the middle step of the fast idle cam.

^ Position the calibration gauge and lightly close the choke blade to measure the cam index setting.
7. FAST IDLE ADJUSTMENTS (FOR CALIFORNIA AND HIGH ALTITUDE ENGINE PACKAGES ONLY)

a. Referring to the service manual for proper procedure, set the fast idle speed on the slowest step of the cam to the following specifications:

Automatic Transmission 1850
Manual Transmission 1700

FIGURE 4:

8. Type Authorized Modification Label, PN 4275086, as shown in Figure 4 and attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 08-14-05-92 With Automatic Transaxle 1.1 Hrs.
08-14-05-93 With Manual Transaxle 0.8 Hrs.


FAILURE CODE: AM - Authorized Modification