Carburetor Assembly

Throttle Body Mounting Screws:

1. Install a new gasket between the float bowl and throttle body, over the locating dowels on the bottom of the float bowl.
2. Install the throttle body over the dowels on the float bowl. Install the three throttle body mounting screws and tighten securely.

Fuel Inlet Nut With Filter:

3. Install the fuel inlet filter spring, a new filter element, a new gasket and the inlet nut. Torque the nut to 24 Nm (18 lb-ft).

Choke Assembly:

4. Install a new cup seal into the insert on the side of the float bowl for the intermediate choke shaft. The lip on the seal faces outward.
5. Install the secondary throttle valve lockout lever onto the boss of the float bowl with the recess in the hole of the lever facing inward.
6. Install the choke coil lever onto the flats of the intermediate choke shaft, install the retaining screw, and tighten securely. The lever is properly aligned when both the inside and the outside levers face the fuel inlet.
7. Install the vacuum kick link in the hole of the intermediate choke shaft lever. The end of the link faces toward the choke housing when it is installed correctly. Install the lower inner choke rod lever into the cavity in the float bowl.

Choke Lever Installation:

8. Install the choke housing to the float bowl, sliding the intermediate choke shaft into the lever. A pair of needle nose pliers may be used to hold the lower lever in the correct position while installing the choke housing. The intermediate choke shaft lever and the fast idle cam are in the correct position when the tang on the lever is beneath the fast idle cam. Install the choke housing retaining screw and washer, and tighten securely.
9. If previously removed, install the air baffle in the secondary side of the float bowl, with the notches toward the top. If previously removed, install the baffle inside of the pump well with its slot toward the bottom.

Primary And Secondary Jets:

10. Install the accelerator pump discharge ball and the retainer screw and tighten securely. If previously removed, install the primary metering jets in the float bowl, using care to avoid overtightening.

Float Assembly Removal/Installation:

11. Install the float needle and seat assembly with its gasket. To make adjustment simpler, carefully bend the float arm upward at the notch in the arm before assembly. Install the float needle onto the float arm by sliding the float lever under the needle pull clip. Proper installation of the needle pull clip is to hook the clip over the edge of the float on the float arm, facing the float itself.
12. Install the float hinge pin onto the float arm with the end of the loop of the pin facing the accelerator pump well. Install the float assembly by aligning the needle in the seat, and the float hinge pin into the locating channels in the float bowl. Do not install the float needle pull clip into the holes in the float arm. Perform float adjustment, refer to Powertrain Management/Fuel Delivery and Air Induction/Carburetor/Adjustments.

Plastic Filler Block:

13. Install the plastic filler block over the float needle.
14. Install the power piston spring into the power piston well.

Power Piston Assembly:

15. If previously removed, install the metering rods to the hanger, making sure the tension spring is attached to the top of each of the rods, in the same position as when it was removed.

Power Piston Removal/Installation:

16. Install the power piston assembly into its well, making sure the metering rods are properly positioned in the metering jets. Press the plastic retainer down firmly until the retainer seats. If necessary, use a small drift punch and a small hammer to lightly tap the retainer into place. Install the accelerator pump return spring into the well.

Air Horn Gasket:

17. Install the air horn gasket by sliding the tab of the gasket around the metering rods and beneath the power piston hanger. Position the gasket over the two dowel pins on the float bowl. Carefully lift the corner of the air horn gasket and install the accelerator pump plunger into the pump well. Push the plunger to the bottom of the well against the spring and place the gasket over the plunger stem.

Air Horn Removal/Installation:

18. While holding down the air horn gasket at the pump plunger location, carefully lower the air horn onto the float bowl. Ensure that the bleed tubes, accelerator well tubes, and the accelerator pump plunger are positioned through the holes in the air horn gasket. Do not force the air horn onto the float bowl, instead lower it lightly into place.

Air Horn Mounting Screws:

19. Install the secondary air baffle deflector and the air horn mounting screws. Tighten the screws evenly and securely, in numerical sequence.
20. Install the vacuum kick air valve rod into the air valve lever, and install the other end of the rod into the diaphragm plunger. Install the vacuum diaphragm to the float bowl.
21. Connect the upper end of the accelerator pump rod to the pump lever by placing the rod in the hole in the lever noted during disassembly. Align the hole in the accelerator pump lever with the hole in the air horn casting using a punch or drift. Push the lever roll pin into the casting until the pin is flush with the casting boss. Use a small screwdriver if necessary to align the roll pin.

Metering Rod Hanger Removal:

22. Install the metering rod hanger and the metering rods and tighten the screw securely. Work the air valves up and down several times to check their operation.

Choke Rod Removal/Installation:

23. Connect the choke rod into the lower choke lever inside the float bowl cavity. Install the choke rod in the upper choke lever and install the choke lever.

Choke Cover Installation:

24. Place the choke linkage cam follower on the highest step of the fast idle cam. Install the thermostatic cover and the coil assembly into the choke housing, making sure the coil tang engages the inside coil pick up lever. Reinstall the choke cover, retainers and rivets using a suitable rivet tool.
25. If previously removed, install the solenoid idle stop. Install the choke diaphragm hose.
26. Install the carburetor, refer to Powertrain Management/Fuel Delivery and Air Induction/Carburetor/Service and Repair for procedure.