Repair Procedure

This procedure involves installation of a new ESA/EFC module, choke assembly, solenoid kicker, coolant valve, thermal bowl vent valve, and choke pull-off delay valve. The choke cam index, vacuum kick, and fast idle speed must be adjusted.

1. INSTALLATION OF CHOKE HOUSING

a. Remove carburetor.

b. Disconnect choke operating rod lower end from the electric choke housing assembly.

c. Loosen the three screws holding electric choke housing assembly to the carburetor main body.

d. Remove electric choke housing assembly, taking care to disconnect the fast idle link to the throttle lever.

e. Install field fix electric choke housing, PN 4419638, making sure the fast idle link has been installed correctly. Tighten three (3) screws held in choke housing assembly.

f. Reinstall choke operating rod into rod retainer on fast idle cam lever.

9. Check vacuum kick adjustment. Reset to specification (.085") at upper edge of choke plate.

h. Check and reset cam index to specification, if necessary, to .095" for automatic transmissions and .080" for manual transmissions.

Cam Index Checking & Setting

Tools Required: Calibration Gauge .095" and .080" Bending Tool (needle nose pliers or equivalent)

FIGURE 1:

Procedure

a. Position fast idle adjusting screw on middle step of fast idle cam.

b. Insert calibration gauge between upper edge of primary choke blade and air horn (Figure 1).
c. While applying light closing pressure to top of choke blade, measure cam index setting.

d. Adjust cam index - open choke blade enough to install bending tool on index cam operating lever tang. Bend tang to obtain desired cam index setting (.095" for automatic transmissions and .080" for manual transmissions).

e. Reposition fast idle adjusting screw on middle step of fast idle cam.

f. Position calibration gauge and lightly close choke blade. Measure cam index setting.

2. INSTALLATION OF .070" SOLENOID KICKER

a. Remove the convolute tubing from the carburetor wiring harness and set aside.

b. Remove the red and violet wire from the 6-way electrical plug.

c. Remove the wiring harness stand-off clamp located on the top of the carburetor.

d. Remove the red and violet wire from the clamp.

e. Disconnect the vacuum line attached to the solenoid kicker.

f. Remove the solenoid kicker from the carburetor by removing the two attaching screws and set it aside.

9. Install the new solenoid kicker (with .070" stroke), PN 4342798, onto the carburetor using the same screws.

h. Attach the vacuum line to the new kicker.

i. Place the red and violet wires from the solenoid kicker into the stand-off clamp and secure the clamp to the carburetor.

FIGURE 2:

j. Install the spade end of the solenoid kicker wires into the 6-way connector by simply pushing them into the cavities until they snap into place. Be certain to place the proper wire into its proper cavity (Figure 2).

NOTE: IF EXISTING SOLENOID HAD ONLY ONE RED WIRE, TIE WRAP SECOND RED WIRE OF NEW SOLENOID ASSEMBLY BACK TO CONVOLUTE.

FIGURE 3:

k. Reinstall the convolute tubing around the wiring harness.

l. Reinstall the carburetor on the intake manifold using the new flange gasket provided. Replace the choke pull-off delay valve with the new one provided, PN 4300274 (Figure 3).

m. Proceed to the installation of the thermal bowl vent valve.
3. INSTALLATION OF THERMAL BOWL VENT VALVE

a. Remove the bowl vent hose from the carburetor.

b. Cut the rubber bowl vent hose 1-1/2" from the carburetor end.

c. Attach the 1-1/2" hose from Step 2 to the thermal bowl vent valve end marked "Carb" and reconnect it to the carburetor.

d. Attach the bowl vent hose to the other end of thermal bowl vent valve.

4. INSTALLATION OF THE COOLANT VACUUM SWITCH (STANDARD 2.2L ENGINE ONLY)

a. Locate the coolant vacuum switch which controls the air switching valve, PN 3870654, located in the vertical position at the water outlet connector.

b. Remove the coolant vacuum switch and replace it with the new switch provided, PN 4006587.

5. INSTALLATION OF ESA MODULE

a. Remove the ESA module. The battery will have to be moved to the right slightly to gain access to the ESA module. (See application list for the proper part number.)

b. Install the new ESA module, and reposition battery back into proper position.

6. SETTING FAST IDLE SPEED

Set fast idle on the slowest step of the fast idle cam (1950 rpm for vehicles with automatic transmissions and 1800 rpm for vehicles with manual transmissions). Refer to service manual for proper procedure.

FIGURE 4:

7. Type Authorized Modification Label, PN 4275086 (Figure 4), and attach near VECI label. On California vehicles clean the existing hose routing label and apply the appropriate hose routing label provided.
POLICY: Reimbursable within the provisions of the warranty

TIME ALLOWANCE:
Labor Operation No. 08-14-05-91 1.1 Hrs.

FAILURE CODE: AM - Authorized Modification