Disassembly

Fig. 3 Exploded view of Rochester Varajet E2SE Carburetor (Part 1 of 2):

Fig. 3 Exploded view of Rochester Varajet E2SE Carburetor (Part 2 of 2):

Refer to Fig. 3 to aid in disassembly and assembly of carburetor.

Fig. 5 Throttle position sensor seals. E2SE:

Fig. 6 Throttle position sensor removal. E2SE:

Fig. 7 Float bowl assembly. E2SE:

1. Remove idle speed solenoid, if equipped, 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. If equipped with idle speed control motor, remove motor as follows:
a. Remove idle speed control motor bracket to vacuum bracket attaching screws.
b. Remove idle speed control motor and bracket assembly.
3. Remove accelerator pump lever retaining screw or clip from air horn, then rotate pump lever to remove from pump rod.
4. Remove vacuum break assembly hose.
5. Remove idle speed solenoid-vacuum break bracket attaching screws from air horn and throttle body.
6. 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.
7. 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.
8. 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.
9. 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.
10. Remove mixture control solenoid screws in air horn. With a slight twisting motion, carefully lift solenoid out of air horn. Remove and discard solenoid gasket.
11. Remove seal retainer and rubber seal from end of solenoid plunger, being careful not to damage or nick end of solenoid plunger. Discard seal and retainer.
12. 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.
13. Remove air horn to float bowl attaching screws and lockwashers.
14. 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.
15. Remove fast idle cam rod from choke lever by rotating rod to align squirt on rod with slot in lever.
16. Remove Throttle Position Sensor plunger, if used, by pushing through seal in air horn. Use fingers only to remove plunger to prevent damage to sealing surface.
17. If used, remove throttle position sensor seal by inverting air horn and using a small screwdriver to remove staking holding seal retainer in place, Fig. 5. Remove and discard retainer and seal.
18. If used, remove pump plunger stem seal, Fig. 5, by inverting air horn and using a small screwdriver to remove staking holding the seal retainer in place. Remove and discard retainer and seal. Use care in removing the TPS plunger seal retainer and pump plunger stem seal retainer to prevent damage to air horn casting. New seals and retainers are required for assembly.
19. If necessary, remove screws and vent/screen assembly. 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 be pre-set.
20. Remove air horn gasket and the accelerator pump plunger and pump return spring from the pump well.
21. If used, push up from bottom on electrical connector and remove Throttle Position Sensor (TPS) and Connector Assembly from float bowl, Fig. 6. Remove spring from bottom of TPS well in bowl. Use care in removing sensor and connector assembly to prevent damage to this critical electrical part.
22. Remove plastic filler block from float chamber, then the float and needle valve assembly by pulling up on retaining pin.
23. Remove needle seat and gasket.
24. Using a wide-blade screwdriver that fully fits the slot in top of jet, remove the extended metering jet from the float bowl, Fig. 7. Do not remove or change adjustment of the small calibration screw located deep inside the metering jet during routine servicing. The adjustment screw is pre-set at the factory and no attempt should be made to change this adjustment in the field except during air horn or float bowl replacement at which time service instructions must be followed carefully.
25. 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.
26. Drill out the choke housing 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.
27. Remove screw from end of intermediate choke shaft inside housing, then the choke coil lever from shaft.
28. Remove intermediate choke shaft and lever assembly from float bowl by sliding rearward out throttle lever side.
29. Remove choke housing attaching screws and the choke housing.
30. Remove fuel inlet nut, gasket, filter and spring.
31. Remove throttle body to float bowl attaching screws, then the throttle body assembly.
32. Hold primary throttle lever wide open and disengage pump rod in throttle lever by rotating rod until squirt on rod aligns with slot in lever.
33. 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."