Assembly

1. Place idle mixture adjusting screw and O-ring assembly through spring and install in throttle body.
2. Lightly seat needle, then back needle out number of turns recorded during disassembly.
3. Install idle channel restrictor and O-ring assembly into throttle body by gently pressing with a flat ended punch, ensuring that top of restrictor is flush with top of throttle body casting.
4. Snap small diameter end of WOT throttle pullover enrichment valve spring over shoulder on large end of pintle and insert pintle into the valve body from the threaded end.
5. Install valve body, pintle and spring in main body, torquing to 20 inch lbs. with suitable tool. Valve must be installed carefully so that spring is vertical and not misaligned against side of casting. Work pintle down to ensure freedom of movement.
6. Snap small end of main system feedback valve spring over shoulder on large end of pintle and insert pintle into valve body from threaded end.
7. Install valve body, pintle and spring in main body and torque to 20 inch lbs. with suitable tool. Valve must be carefully installed so that spring is vertical and not misaligned against side of casting. Work pintle up and down to ensure freedom of movement.
8. Using suitable tool, install main metering jet on main body, torquing to 15 inch lbs.
9. Install main nozzle to main body as follows:
a. Coat new O-ring with light oil and position on nozzle.
b. Insert .003 inch feeler gauge at main well mating surface of main body to prevent tearing O-ring during installation.
c. Install nozzle and O-ring between feeler gauge at main well end and main body slot at fuel inlet end of main body.
d. Press squarely on nozzle with slow, uniform pressure until top of each nozzle strut is flush with top of main body.
e. While holding nozzle in position, slowly pull feeler gauge out from between main well end of casting and nozzle.
10. Install throttle position sensor on main body, torquing attaching screws to 45 inch lbs.
11. Install pulldown diaphragm and linkage assembly on main body, install exhaust gas oxygen sensor wire clip in its original position, torque two attaching screws to 45 inch lbs. and install pulldown vacuum hose.
12. Install float shaft in float and bushing assembly and lower entire assembly into position in main body, then install shaft retainer.
13. Install fuel inlet valve assembly and gasket, torquing fuel inlet fitting to 150 inch lbs.
14. Adjust float level as described under ``On-Vehicle Adjustments.''
15. Install accelerator pump check ball and weight.
16. Install hot idle compensator gasket and cover, torquing retaining screws to 20 inch lbs.
17. Install mechanical bowl vent arm grommet on air horn, then position mechanical bowl vent paddle and seal assembly in air horn.
18. Align bowl vent arm and spring assembly with paddle, then, matching flat on arm with flat in paddle bore, firmly press bowl vent arm into paddle until it seats.
19. Install main system feedback diaphragm seat O-ring and diaphragm seat on air horn.
20. Install diaphragm return spring on shoulder of feedback adjustment screw that protrudes into diaphragm cavity. The top of the feedback adjustment screw must be no less than 11/64 inch below top of air horn screw boss before assembly. Install main system feedback diaphragm and actuator assembly to diaphragm seat. Apply suitable locking compound to first three threads of three retaining screws and torque screws to 4---5 inch lbs. If main system feedback diaphragm and actuator assembly has been replaced with new assembly, set diaphragm adjustment screw to specifications as described under ``On-Vehicle Adjustments.''
21. Install accelerator pump operating rod on air horn, torquing attaching screw to 20 inch lbs.
22. When installing new cup, push accelerator pump cup over retaining tab on end of piston/bracket assembly.
23. Install auxiliary main jet/pullover valve operating rod spring and auxiliary main jet/pullover operating rod on air horn.
24. Install accelerator pump piston/bracket assembly on air horn, positioning slot in bracket to tab on air horn casting, then torque return spring to 20 inch lbs.
25. Install choke bi-metal assembly as follows:
a. Ensure choke bi-metal assembly spacer is properly installed.
b. Install choke bi-metal assembly after engaging bi-metal loop on choke housing shaft lever and rotate to engage plastic spacer index tab.
c. Install choke bi-metal assembly retainer over cap and loosely retain with standard screws.
d. Using suitable rivet gun with adapter No. T81P-53700-A or equivalent, install rivet No. E1PZ-95510-F or equivalent, placing rivet in rivet gun and triggering lightly to retain rivet.
e. Press rivet fully into casting until rivet protrudes from back of casing.
f. Lightly trigger rivet until enough pressure is obtained to temporarily hold assembly.
g. Reposition rivet gun on mandrel and trigger gun until mandrel breaks off.
26. Position air horn gasket over alignment pins on air horn and carefully lower air horn into place on main body. Do not force. Ensure auxiliary main jet/pullover valve pickup lever properly contacts auxiliary main jet/pullover valve operating rod and fast idle adjustment screw is not bound on edge of fast idle cam. Ensure mechanical bowl vent operating lever on throttle body is positioned outboard of mechanical bowl vent arm on air horn. Ensure throttle position sensor actuating pin properly contacts throttle return spring lever/position sensor cam.
27. Torque three long black throttle body to main body screws to 95 inch lbs. and the short blue screw to 45 inch lbs.
28. Invert carburetor and attach choke pulldown lever to pulldown diaphragm linkage, then install pulldown lever, lock washer, and nut to choke shaft, torquing nut to 18 inch lbs. Choke pulldown lever must be installed with stamped number facing outboard from carburetor body.
29. Install solekicker on main body, torquing attaching screws to 95 inch lbs.
30. Install throttle position sensor to throttle body attaching screw, torquing to 45 inch lbs.
31. Actuate throttle from idle to WOT with choke plate both open and closed to ensure there is no binding.
32. Ensure auxiliary jet/pullover valve pickup lever and operating rod operate freely. The auxiliary jet/pullover valve operating rod must not remain in full up position. The auxiliary jet/pullover valve pickup lever must return the auxiliary jet/pullover valve operating rod to full up position when throttle is returned to idle position.
33. Ensure throttle position sensor actuating pin operates freely within position sensor housing and is pushed into sensor body as throttle is opened to WOT and returns as throttle is returned to idle.