Service Procedure
A. Install carburetor choke adjustment shim:1. Drain about one gallon of engine coolant from radiator and save for later use.
2. Remove air cleaner assembly.
3. Remove carburetor assembly following Service Manual procedures.
4. Remove throttle return spring.
5. Insert the provided tool (fast idle release tool) between the fast idle cam lever and wax element housing.
Note: Insert tool such that there is no interference with throttle lever movement.
Service Procedure
A. 6. Turn tool counterclockwise (about 45 degrees) until the tool is wedged in position as shown.
This will provide the needed clearance between the choke adjusting screw and plunger.
Note: Rotate throttle lever to a fully open position for easier installation of shim.
7. Use needle nose pliers to install the provided choke adjusting shim onto the choke adjusting screw.
8. Rotate tool clockwise and remove.
Service Procedure
A. 9. Insure that the choke adjusting shim is securely installed between the plunger and the adjusting screw.
10. Reinstall throttle return spring
B. Clean the sub-EGR valve plunger:
1. Locate the sub-EGR valve on the carburetor underthe accelerator pump housing.
2. To disassemble valve, remove and discard the snap ring from the sub-EGR control valve pin as shown.
Remove the pin and separate the throttle linkage from the-plunger. Be careful not to lose the spring and small steel ball located in the plunger beneath the throttle linkage. They are needed for reinstallation later.
Remove the steel ball and spring from the end of the plunger.
To remove the plunger from the carburetor throttle body, insert an Allen wrench through the plunger pin holes and gently twist out.
3. Use a wire wheel to remove carbon deposits from the plunger.
4. Spray the sub-EGR passages of the carburetor with Mopar Brake and Carburetor Cleaner or equivalent and remove any carbon deposits.
5. Reassemble the sub-EGR control valve in the reverse order of the disassembly procedure in Step B-2 using a new snap ring.
6. Insure that the sub-EGR control valve operates smoothly. If the operation is not smooth, check and clean the throttle and choke linkages as necessary.
Service Procedure
C. Adjust sub-EGR valve:
1. Locate sub-EGR valve adjusting screw on carburetor underthe accelerator pump housing and beside the sub-EGR valve lever.
2. Turn sub-EGR valve adjusting screw in (clockwise) 1-1/2 turns.
3. Reinstall the carburetor using the new carburetor flange gasket provided.
D. Modify the vacuum harness:
1. Locate and remove the white striped hose (including check valve) connecting the secondary air control valve and the 5-port connector. Also remove the green striped hose teed into the white striped hose and connected to the secondary air control solenoid valve.
Service Procedure
D. 2. Install the provided hose between the secondary air control valve and the 5- port connector using the original clamps.
3. Locate and remove the blue striped hose connecting the secondary air control valve and the secondary air control solenoid valve.
4. Install the provided rubber cap over the secondary air control valve nipple.
5. Reinstall the air cleaner.
E. Modify the Carburetor Control Unit (CCU) harness:
1. Disconnect the positive terminal of the battery.
2. Locate and disconnect the 13-pin CCU connector (17-pin for 4-speed manual transmission vehicles) from the carburetor control unit. The connector is located under the heater assembly in the passenger compartment.
3. Cut the red with blue tracer wire at the connector.
4. Since the wire leads to the battery positive, wrap it with at least three turns of electrical tape to insure that it is well insulated.
5. Reconnect the CCU connector and the positive terminal of the battery.
6. Wipe existing hose routing label clean. Affix the supplied new label to cover the original label.
7. Reinstall coolant removed in Step A-1. Start engine and check for leaks.