Removal and Disassembly

REMOVAL:

1. Disconnect the air intake hose.
2. Remove the butterfly nut for the air cleaner cap.
3. Disconnect the emission control hoses from the air cleaner.

Air Cleaner:

4. Remove the mounting bolt and vacuum switching valve.
5. Lift the air cleaner off the carburetor.
6. Disconnect the fuel hose from the carburetor inlet union.
7. Disconnect all vacuum hoses and label for correct reinstallation.
8. Disconnect electrical connectors.
9. Remove four base flange mounting nuts.
10. Lift carburetor from intake manifold.
11. Remove carburetor heat insulator and gaskets.
12. Cover opening with a rag to prevent dirt from entering the engine.

DISASSEMBLY:

1. Remove air cleaner support.

Removing Air Cleaner Support:

2. Remove throttle position switch.

Removing Throttle Position Switch:

3. Remove two wire clamps and disconnect the fuel-cut solenoid valve and throttle position switch wires from the clamps.
4. Remove the fuel-cut solenoid and gasket.

Removing Fuel-Cut Solenoid:

5. Remove the three screws, compensator and gasket.

Removing Compensator:

6. Install a 4mm bolt into the suction chamber adjusting pin plug.
7. Using two screwdrivers, pry the plug from the carburetor. Remove the O-ring from the plug.

Removing Suction Chamber Adjusting Pin:

8. Invert the carburetor and shake the pin out.

Removing Pin From Carburetor Body:

9. Remove the three suction chamber mounting screws.

Removing Suction Chamber:

10. Pull the suction chamber, spring and piston from the carburetor body.
11. Remove acceleration pump arm pin clip.
12. Remove the pump arm pivot screw and pump arm.

Removing Acceleration Pump Arm:

13. Remove the bushing and spring from the connecting rod.
14. Disconnect the fuel heater wire from the clamp.
15. Remove the five screws, union nipple clamp, throttle valve solenoid, wire clamp, washer, number plate, EGR vacuum modulator bracket and float bowl.

Removing Float Bowl Screws:

16. Remove the pump damping spring from float bowl.
17. Remove the float pivot pin, float and needle valve subassembly.
18. Remove float bowl gasket, needle valve seat and gasket.

Removing Float Needle Valve:

19. Remove pump plunger and boots.
20. Remove clip, two screws and throttle positioner.

Removing Throttle Positioner (TP):

21. Remove three screws, vacuum port adapter and gasket.