Carburetor Disassembly

Choke Rod Removal/Installation:

1. Remove the upper choke lever retaining screw and remove the choke lever.
2. Remove the choke rod lower lever inside the float bowl casting. Remove the rod by holding the lever outward with a small screwdriver and twisting the rod counterclockwise.

Metering Rod Hanger Removal:

3. Remove the small torx head screw from the metering rod hanger and remove the hanger and metering rods.

Accelerator Pump Lever Roll Pin:

4. Utilizing a small punch and hammer, drive the accelerator pump rod roll pin inward until the pump lever can be removed. Remove the choke vacuum hose from the tube on the throttle body.

Air Horn Mounting Screws:

5. Remove the air horn mounting screws and the secondary air baffle deflector.

Air Horn Removal/Installation:

6. Remove the air horn from the throttle body by lifting it straight up. The air horn gasket should remain on the float bowl. Be careful not to damage the tubes permanently attached to the air horn.

Accelerator Pump Plunger And Seal:

7. Invert the air horn and use a small screwdriver to remove the staking holding the accelerator pump plunger stem seal in place. Remove and discard the retainer and seal.

Air Horn Gasket:

8. Remove the air horn gasket by lifting it off the locating pins, and lifting the gasket tab from under the power piston hanger, and discard the gasket. Be careful not to damage the metering rods or springs. Remove the accelerator pump plunger and plunger spring from the well.

Power Piston Removal/Installation:

9. Remove the power piston assembly by depressing the piston stem and allowing it to snap up. This procedure may have to be repeated several times to free the piston retainer. Do not use pliers on the metering rod hanger to remove the power piston. This will cause the hanger to separate from the piston. After removing the piston, remove the piston spring from the well.

Metering Rod Adjustment Screw:

10. Do not remove the metering rod adjustment screw, it is set at the factory and no adjustment is required.

Power Piston Assembly:

11. Separate the metering rods from the power piston by removing the tension spring from the top of each rod, noting the position of the spring for reinstallation. Remove the power piston assembly.

Plastic Filler Block:

12. Remove the plastic filler block from the float bowl.

Float Assembly Removal/Installation:

13. Remove the float assembly by pulling carefully in an upward motion on the retainer pin. Set the float assembly aside in a manner to avoid bending the float arm.

Primary And Secondary Jets:

14. Using an appropriate size screwdriver loosen and remove the primary main metering jets. Do not attempt to remove the secondary metering jets, they are a permanent part of the float bowl assembly.
15. Remove the accelerator pump discharge check ball retainer, and invert the bowl to remove the check ball. Catch and retain the check ball as it falls clear.
16. Remove the accelerator pump well fill slot if necessary. Remove the vacuum diaphragm hose, and mounting screws. Rotate the diaphragm assembly to remove the vacuum kick link from the slot in the plunger head.

Fuel Inlet Nut With Filter:

17. Remove the fuel inlet nut, gasket, and filter assembly with spring, and discard the filter and gasket.

Throttle Body Mounting Screws:

18. Remove the three throttle body to float bowl assembly mounting screws and remove the throttle body assembly. Remove and discard the old throttle body to bowl gasket.

Choke Cover Removal:

19. Put the carburetor in a holding fixture to avoid throttle plate damage. Drill out the three choke cover retaining rivets using a number 21 (.159 in.) drill. Only drill deep enough to remove the rivet heads.
20. Remove the choke cover by pulling it straight out, and drive out the remainder of the old rivets with a suitable punch and small hammer.

Choke Housing Removal:

21. Remove the choke housing mounting screw from inside the housing, and slide the choke assembly out of the float bowl. Remove the secondary throttle valve lock out lever from the float bowl, and remove the vacuum kick link from the lever.
22. Remove the accelerator pump rod from the throttle lever by rotating the rod until the tang on the rod aligns with the lever.
23. Remove the concealment plugs, refer to Powertrain Management/Fuel Delivery and Air Induction/Carburetor/Service and Repair.