Disassembly

1. Remove fuel inlet fitting, fuel filter, gasket and spring.
2. Remove ``E'' rings on accelerator pump rod and choke control rod and disengage rods.
3. Remove air cleaner stud.
4. Remove seven upper body assembly retaining screws, then remove upper body and place it inverted on clean work surface, noting position of two long attaching screws.
5. Remove float hinge pin and float assembly.
6. Remove float bowl gasket.
7. Remove fuel inlet valve, seat and gasket.
8. Remove accelerator pump link retaining screw and nut, accelerator pump adjusting nut, accelerator pump link, overtravel spring, ``E'' clip and washer.
9. Remove accelerator pump rod and dust seal.
10. Remove cold enrichment rod (CER) adjusting nut by turning counterclockwise. If choke control rod breaks, a new service swivel assembly must be installed.
11. Remove choke control rod, then the dust seal by lifting retainer carefully and sliding seal out.
12. Remove ``E'' ring on choke hinge pin and slide pin out of casting.
13. Remove cold enrichment rod, lever adjusting swivel, control vacuum regulator, and adjusting nut as an assembly.
14. Slide cold enrichment rod out of upper body casting.
15. Remove two screws securing venturi valve cover in place, then invert carburetor assembly, holding venturi valve cover in place, and remove venturi valve cover, gasket and bearings as an assembly.
16. Using tool T77L-9928-A or equivalent, press tapered plugs out of venturi valve pivot pins.
17. Push venturi pivot pins out and slide venturi valve to rear until it is free of casting.
18. Remove venturi valve pivot pin bushings.
19. Remove metering rod pins, metering rods and springs, identifying rods for proper assembly. Always block venturi valve wide open when working on jets.
20. Using tool T77L-9533-B or equivalent, remove cup plugs recessed in upper body casting.
21. Using suitable tool, turn each main metering jet clockwise, counting number of turns, until they bottom in casting and record number of turns to nearest 1/4 turn.
22. Turn jet assembly counterclockwise to remove, then remove O-rings and identify jets for proper assembly.
23. Remove accelerator pump plunger assembly.
24. Remove venturi valve limiter adjusting screw from throttle side of venturi valve.
25. Remove 1/8 inch pipe plug from fuel inlet boss.
26. Remove venturi valve diaphragm cover retaining screws, cover, spring guide and spring tapping lightly to loosen cover.
27. Carefully loosen diaphragm and slide it out of main body.
28. Place carburetor inverted on clean surface, catching accelerator pump check ball and weight.
29. Remove five screws retaining throttle body and remove throttle body and gasket.
30. Remove feedback stepper motor, gasket pintle valve, and pintle spring.
31. Remove throttle return control device sol-a-dash, solenoid, dashpot and bracket, disengaging kickdown return spring.
32. Center punch choke cap retaining screw heads.
33. Using 1/4 inch drill, drill screw heads deep enough to remove retainer from choke cap.
34. Carefully remove cap.
35. Using suitable tool, remove remaining portion of choke cap screws.
36. Remove choke thermostatic lever screw and lever.
37. Slide choke shaft lever and pin assembly out of casting and remove fast idle cam and E-clip, then the fast idle cam adjusting screw.
38. Remove choke diaphragm rod E-clip which attaches to fast idle intermediate lever.
39. Remove fast idle intermediate lever.
40. Remove choke control diaphragm cover screws, cover and return spring, then the choke control diaphragm and rod. The choke housing bushing is pressed into the casting and staked in place on all models. If replacement is required, it will have to be carefully pressed out. While pressing, the casting must be supported to prevent damage. Before pressing, file or grind off staked areas.
41. Remove TSP Off idle speed adjusting screw.
42. Remove throttle shaft retaining nut, and spring if equipped, the fast idle adjusting lever, nylon bushing if equipped, fast idle lever and fast idle adjusting screw.
43. Remove deloading lever and large ``E'' clip as equipped.
44. Scribe a mark across the throttle position sensor and throttle body, then remove sensor attaching screws, throttle position sensor and roll pin.
45. Lightly scribe a line along throttle shaft and mark throttle plates for proper installation. The throttle plate screws are staked at assembly. Staked ends should be filed before removal and old screws should be discarded.
46. Remove throttle plate screws and the plates.
47. Drive limiter level stop pin down until it is flush with throttle shaft.
48. Remove ``E'' clip next to venturi valve limiter lever.
49. Slide throttle shaft assembly out of casting and remove transmission kickdown adjusting screw.
50. Remove venturi valve limiter lever and bushing.