Disassembly

Fig. 2 Exploded view of Rochester Varajet 2SE carburetor:

Refer to Fig. 2 to aid in disassembly and assembly of carburetor.

1. Remove idle speed solenoid as follows:
a. Bend back lockwasher retaining tabs, then large solenoid retaining nut.
b. Remove lockwasher and solenoid from bracket. Do not place solenoid in carburetor cleaner.
2. Remove accelerator pump lever retaining screw from air horn, then rotate pump lever to remove from pump rod.
3. Remove vacuum break assembly hose.
4. Remove idle speed solenoid-vacuum break bracket attaching screws from air horn and throttle body.
5. On 4 cylinder models, rotate bracket to remove vacuum break rod and air valve rod from vacuum break diaphragm plunger. Remove bracket assembly from float bowl.
6. On 6 cylinder models, rotate vacuum break and bracket assembly to disengage rods from vacuum break and air valve levers. On V6 models, it is not necessary to remove the vacuum break or air valve rods from vacuum break plunger unless replacement of the rods or vacuum break units is necessary. If replacement is needed, remove and discard retaining clips from rod ends. Remove plastic bushings used on rods and retain for assembly.
7. If equipped, remove secondary side vacuum break bracket attaching screws from throttle body, then rotate bracket to remove vacuum break rod from vacuum break lever. Do not place vacuum break in carburetor cleaner. It is not necessary to remove the vacuum break rod from vacuum break plunger unless replacement of the rod or vacuum break units is necessary. If replacement is needed, remove and discard retaining clip from rod end. Remove plastic bushing used on rod and retain for assembly.
8. Remove and discard retaining clip from intermediate choke rod at choke lever. Remove choke rod and plastic bushing from choke lever and retain bushing for assembly.
9. If equipped, remove two hot idle compensator valve retaining screws, then the valve and seal from air horn. Discard the seal. The hot idle compensator valve must be removed to gain access to the short air horn to float bowl attaching screw.
10. Remove air horn to float bowl attaching screws and lockwashers. Remove vent and screen assembly.
11. Rotate fast idle cam to the full ``UP'' position and remove air horn by tilting to disengage fast idle cam rod from slot in fast idle cam. Do not remove the fast idle cam and screw from float bowl as these parts are not serviced separately.
12. Remove fast idle cam rod from choke lever by rotating rod to align squirt on rod with slot in lever. Further disassembly of the air horn is not required for cleaning purposes. If necessary for parts replacement, remove staking from choke valve attaching screws, then the screws, choke valve and shaft from air horn. The air valve screws are permanently staked in place. Do not attempt to remove the secondary metering rod from the air valve assembly. The secondary metering rod adjustment is performed at the factory and no attempt to change the setting should be made. If air horn replacement is required, the replacement air horn will include the secondary metering rod-air valve assembly and will the pre-set.
13. Remove air horn gasket and the accelerator pump plunger and pump return spring from the pump well.
14. Remove plastic filler block from float chamber, then the float and needle valve assembly by pulling up on retaining pin.
15. Remove needle seat and gasket.
16. Remove power piston and metering rod assembly by depressing piston stem and allowing to snap free. This may have to be repeated several times. Do not use pliers to remove power piston.
17. Remove power piston spring from piston bore. If necessary, remove metering rod from hanger by compressing spring on top of rod and aligning groove on rod with slot in holder. Use care not to damage metering rod.
18. Remove main metering jet with a suitable tool.
19. Using a small slide hammer or equivalent, remove plastic retainer holding pump discharge spring and check ball in place. Discard plastic retainer. Turn float bowl over and catch discharge spring and check ball. Do not attempt to remove the plastic retainer by prying out with a screwdriver or similar tool. This will damage the sealing beads on the bowl casting surface and will require float bowl replacement.
20. Remove attaching screws from choke cover, then pull cover and coil assembly from choke housing. If equipped with a tamper-resistant choke cover (secured with pop rivets), drill out the rivet heads with a No. 21 (.159 inch) drill. Use a suitable drift and small hammer to drive the remainder of the rivets from choke housing. Use care when drilling or hammering to prevent damage to choke cover or housing.
21. Remove screw from end of intermediate choke shaft inside housing, then the choke coil lever from shaft.
22. Remove intermediate choke shaft and lever assembly from float bowl by sliding rearward out throttle lever side.
23. Remove choke housing attaching screws and the choke housing.
24. Remove fuel inlet nut, gasket, filter and spring.
25. Remove throttle body to float bowl attaching screws, then the throttle body assembly.
26. Hold primary throttle lever wide open and disengage pump rod from throttle lever by rotating rod until squirt on rod aligns with slot in lever.
27. If replacement is necessary, remove fast idle screw and clip in primary throttle lever and the curb or base idle screw and spring in throttle body. Do not remove idle mixture needle unless replacement is necessary. To gain access to concealed idle mixture needle, refer to ``Concealment Plug Removal'' further on in this section.