Assembly

1. Ensure all holes in new gaskets have been properly punched and that no foreign matter has adhered to gaskets. Ensure accelerator pump and secondary operating diaphragms are not cut or torn.
2. Drop accelerator pump discharge needle into its well, then lightly seat needle using 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, then install retaining screw, torquing to 27 - 43 inch lbs. Pump discharge gaskets, nozzle and screw must be installed before any other parts are installed on main body.
5. Using flat punch, stake nozzle screw in position. Do not use excessive force when staking nozzle screws. Ensure any chips from nozzle screw during staking are cleaned from carburetor throttle openings before continuing assembly.
6. Drop vacuum check ball in vacuum port of secondary diaphragm housing, then position secondary diaphragm in housing and place spring in cover. The secondary diaphragm housing must be installed before the choke housing.
7. Install cover and tighten retaining screws finger tight, ensuring that diaphragm is seated evenly on housing and that vacuum openings are aligned.
8. Install cover attaching screws, torquing to 13 - 17 inch lbs. The diaphragm housing must be removed from the main body to install the cover.
9. 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, torquing screws to 20 - 31 inch lbs.
10. Position choke plate shaft in air horn, then install choke plate in shaft and torque screws to 6 - 8 inch lbs.
11. Install rod seal on choke rod.
12. 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, ensuring that rod end faces outward.
13. Push rod seal into retaining grooves on underside of air cleaner mounting flange.
14. On 1984 models, proceed as follows:
a. Position choke thermostat lever link and piston assembly in choke housing and install retaining pin.
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.
d. Install spacer, lock washer and nut. Torque nut to 16 - 20 inch lbs.
e. Lay main body assembly on its side and position choke housing gaskets on main body.
f. Insert choke rod in choke housing shaft lever as choke housing is placed into position on main body, ensuring projection on choke rod is placed under fast idle cam so that cam will be lifted when choke plate is closed.
g. Install choke housing lock washers and screws. Torque screws to 20 - 30 inch lbs.
h. Install choke rod cotter pin, using suitable tool.
i. Place thermostatic spring housing choke cap gasket into position on choke housing, engaging thermostatic spring on lever, then install housing, clamp and screws. Torque standard screws to 16 - 18 inch lbs. and breakaway screws until ends break off.
j. Adjust thermostatic spring housing by aligning index marks on cover with specified mark on choke housing.
15. On 1985 - 86 models, proceed as follows:
a. Install new O-ring on choke housing.
b. Slide nylon choke modulator bushing into choke diaphragm shaft, then install choke modulator spring perch, spring, spring seat and retaining clip.
c. Position assembly into choke housing, then rotate choke modulator bushing until it slides into place.
d. Install choke diaphragm spring and diaphragm cover. Torque screws to 13 - 17 inch lbs.
e. Install choke housing shaft, lever assembly and over-center spring.
f. Install fast cam, spring perch, spring, lever, spacer, star washer and nut.
g. Install choke housing assembly onto main body. Torque screws to 20 - 30 inch lbs.
h. Install choke cap and index spacer.
16. On all models, invert main body and position throttle body gasket on main body, then place throttle body on main body.
17. Slide secondary diaphragm rod onto operating lever as throttle body is placed into position.
18. Install throttle body to main body attaching screws and lock washers, torquing screws to 20 - 31 inch lbs.
19. Secure secondary diaphragm rod with retainer.
20. Install air cleaner anchor stud.
21. Place accelerator pump diaphragm spring and diaphragm in accelerator pump chamber. The diaphragm must be positioned so that large end of rivet is against operating lever.
22. Install cover and tighten retaining screws finger tight, ensuring that diaphragm is centered, then compress diaphragm with pump operating lever and torque cover screws to 10 - 14 inch lbs.
23. Install filter spring, filter, gasket and fuel inlet fitting, torquing fitting to 22 - 26 ft. lbs.
24. Install fuel lever sight plug and gasket, torquing to 19 - 24 inch lbs.
25. Slide baffle plate onto ridges in fuel bowl.
26. Install float spring on float and slide float onto shaft, ensuring that float spring is between ridges on the boss on floor of fuel bowl.
27. Using suitable tool, install float E-clip.
28. Apply petroleum jelly to new O-ring seal and slide seal on fuel inlet needle and seat assembly.
29. Position fuel inlet needle and seat assembly in fuel bowl through top of bowl.
30. Position adjusting nut gasket and the nut on fuel inlet needle and seat assembly.
31. Align flat on inside diameter of nut with flat on outside diameter of fuel inlet needle and seat assembly, then install lock screw and gasket.
32. Adjust float level as described under ``On-Vehicle Adjustments.''
33. Using suitable tool, install power valve and gasket in metering block, torquing power valve to 9 - 12 ft. lbs.
34. Install pump transfer tube and new O-rings in metering block.
35. Using suitable tool, install jets in metering block, torquing to 18 - 20 inch lbs.
36. Position metering block gasket on dowels located at rear of metering block, then position metering block and gasket on main body.
37. Position gasket on metering block, then place retaining screws and new compression gaskets in fuel bowl.
38. Position bowl in place on metering block and torque retaining screws to 50 - 60 inch lbs.
39. Assemble secondary fuel bowl, then adjust float level as described under ``On-Vehicle Adjustments.''
40. Slide metering body gasket into position on main body, then position metering plate, gasket and metering body on main body and install retaining screws.
41. Apply petroleum jelly to fuel line tube O-ring seal and position it into secondary fuel bowl recess.
42. Position fuel bowl on main body, guiding fuel line tube with O-ring into recess in primary fuel bowl, then install retaining screws with new compression gaskets. Inspect O-rings to ensure they are not pinched.