Assembly

1. Ensure that all holes in new gaskets have been properly punched and that no foreign matter has adhered to gaskets. Ensure that accelerating pump and secondary operating diaphragms are not cut or torn.
2. Drop accelerator pump discharge needle or ball into its well and lightly seat needle or ball with brass drift and light hammer.
3. Clean gasket mating surfaces on nozzle and main body.
4. Position accelerator pump nozzle and gasket in main body and install retaining screw. Pump discharge gaskets, nozzle and screw must be installed before any other parts are installed to main body.
5. Using flat punch, stake nozzle screw in position. Do not use excessive force when staking nozzle screw. Ensure that any chips from nozzle screw during staking are cleaned from carburetor throttle openings before continuing assembly. Also, the secondary diaphragm housing must be installed before the choke housing.
6. Drop vacuum ball check into vacuum port of secondary diaphragm housing, then position secondary diaphragm in housing and place spring in cover.
7. Install cover and tighten screws finger tight.
8. Ensure that diaphragm is seated evenly on housing and that vacuum opening is aligned.
9. Install and tighten cover attaching screws. The diaphragm housing must be removed from the main body to install the cover.
10. Place gasket on secondary vacuum passage opening on main body, then place diaphragm housing in position on main body and install lock washers and retaining screws.
11. Position choke plate shaft in air horn and install choke plate in shaft.
12. Install rod seal on choke rod.
13. Slide U-shaped end of choke plate rod through opening in main body and insert rod end through inner side of bore in choke lever with rod end facing outward.
14. Push rod seal into retaining grooves on underside of air cleaner mounting flange.
15. On all 1982 - 84 models with V8-460 engine, proceed as follows:
a. Position choke thermostat lever link and piston assembly in choke housing.
b. Position fast idle cam assembly on choke housing and install choke housing shaft and lever assembly.
c. Position lever and piston assembly on choke housing shaft and lever assembly, then install spacer, lock or star washer and nut.
16. On 1984 models with V8-351 engine and 1985 - 86 models with V8-351 engine under 8500 GVW applications, proceed as follows:
a. Position split lever and piston assembly in choke housing, then install thermostatic lever and choke housing shaft assembly into choke housing.
b. Position fast idle cam assembly and the choke lever on the choke housing shaft, then install spacer, star washer and retaining nut on choke housing shaft.
c. Install over-center spring between thermostatic lever and the boss in the choke housing.
17. On 1985 - 86 models with V8-460 engine or 1985 - 87 models with V8-351 engine over 8500 GVW applications, proceed as follows:
a. Slide nylon choke modulator bushing onto the choke diaphragm shaft, then install choke modulator spring perch, spring, spring seat and retaining clip.
b. Position above assembly into choke housing, rotating choke modulator bushing until it slides securely into place.
c. Install choke diaphragm spring and diaphragm cover, torquing cover screws to 13 - 17 inch lbs.
d. Install choke housing shaft and lever assembly together with over-center spring.
e. Install fast idle cam, spring perch, spring, lever, spacer, star washer and nut.
f. Position choke housing assembly onto main body, pushing choke rod into retainer on choke housing shaft lever.
g. Install choke housing screws, torquing to 20 - 30 inch lbs.
h. Install choke cap gasket, then install choke cap by engaging bi-metal loop on choke thermostatic lever.
i. Install retaining ring, then loosely install two new breakaway screws and standard screw.
j. Align choke cap to proper index mark.
k. Tighten breakaway screws until heads snap off and torque standard screw to 16 - 18 ft. lbs.
18. On all models, lay main body assembly on its side and position choke housing gasket on main body.
19. Insert choke rod in choke housing shaft lever as choke housing is placed into position on main body. Ensure that projection on choke rod is placed under fast idle cam so that cam will be lifted when choke plate is closed.
20. Install choke housing lock washers and screws, then the choke rod cotter pin.
21. On 1982 - 84 models, proceed as follows:
a. Place thermostatic spring housing gasket into position on choke housing, engaging thermostatic spring on spring lever, then install housing, clamp and screws.
b. Adjust thermostatic spring housing by aligning index mark on cover with specified mark on choke housing.
22. On all models, invert main body and position throttle body gasket on main body.
23. Slide secondary diaphragm rod onto operating lever as the throttle body is placed into position.
24. Install throttle body to main body screws and lock washers.
25. Secure secondary diaphragm rod with retainer.
26. Install air cleaner anchor stud.
27. Place accelerating pump diaphragm spring and diaphragm in accelerating pump chamber, ensuring that diaphragm is positioned so that large end of rivet is against operating lever.
28. Install cover and tighten retaining screws finger tight.
29. With diaphragm centered, compress diaphragm with pump operating lever and tighten cover screws.
30. Install filter spring, filter, gasket and fuel inlet fitting.
31. Install fuel level sight plug and gasket.
32. Slide baffle plate onto ridges in fuel bowl.
33. Install float spring on float and slide float onto shaft, ensure that float spring is between ridges on boss on floor of fuel bowl and install float retainer.
34. Apply petroleum jelly to a new O-ring seal and slide seal on fuel inlet needle and seat assembly.
35. Position fuel inlet needle and seat assembly in fuel bowl through top of bowl, then position adjusting nut gasket and nut on fuel inlet needle and seat assembly.
36. Align flat on I.D. of nut with flat on O.D. of fuel inlet needle and seat assembly, then install fuel level adjustment lock screw and gasket.
37. Perform ``Float Level (Dry)'' adjustment as described under ``Adjustments.''
38. Using suitable tool, install power valve and gasket in metering block. Install only the correct power valve. The identification number is stamped on a flat on the base of the valve.
39. Install pump transfer tube and new O-rings in the metering block.
40. Using suitable tool, install jets in metering block.
41. On 1982 - 86 models, proceed as follows:
a. Position metering block gasket on dowels located on back of metering block, then the metering block and gasket on the main body.
b. Position gasket on metering block, then place retaining screws and new compression gaskets in fuel bowl.
c. Position bowl in place on metering block and tighten retaining screws.
42. Apply petroleum jelly to fuel line tube O-ring seal.
43. Place seal against flange on one end of fuel line tube, then install this end of fuel line tube into recess in primary fuel bowl. Inspect O-rings to ensure that they are not pinched.
44. Assemble secondary fuel bowl and perform ``Float Level (Dry)'' adjustment as described under ``Adjustments.''
45. On 1982 - 83 models, slide metering body gasket on balance tube and into position on main body, then position metering plate, gasket and metering body on main body and install retaining screws.
46. On 1984 - 87 models, slide metering plate gasket on balance tube and into position on main body, then position metering plate and gasket on main body and install retaining screws.
47. Adjust balance tube so that distance from metering body to end of balance tube is one inch.
48. Apply petroleum jelly to fuel line tube O-ring seal and position seal against flange on fuel line tube.
49. Position fuel bowl on main body, guiding fuel line tube into recess in bowl, then install retaining screws with new compression gaskets.