Assembly

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

Fig. 4 Air horn screw tightening sequence:

1. If removed, install curb or base idle screw and spring in throttle body and the fast idle adjustment screw and clip in primary throttle lever.
2. Hold primary throttle lever wide open and install lower end of pump rod in throttle lever by aligning squirt on rod with slot in lever. End of rod should face toward throttle lever.
3. If removed, install idle mixture needle, washer and spring with tool J-28706 or J-28030. Lightly seat needle, then back out four turns. Final adjustment is made on the vehicle. If a new float bowl assembly is used, stamp or engrave the model number on the new float bowl.
4. Install new throttle body to bowl insulator gasket over two locating dowels on bowl.
5. Hold fast idle cam so that cam steps face fast idle screw on throttle lever and install throttle body making sure throttle body is properly located over dowels on float bowl. Install throttle body to bowl screws and lockwashers and tighten securely. Inspect linkage to insure lockout tang is located properly to engage slot in secondary lockout lever and that linkage moves freely and does not bind.
6. Install fuel inlet filter spring, check valve-filter assembly, new gasket and inlet nut. Torque nut to 18 ft. lbs.
7. Install choke housing on throttle body, making sure raised boss and locating lug on rear of housing fit into recesses in float bowl casting. Install choke housing attaching screws and lock washers in throttle body. Tighten screws evenly and securely.
8. Install intermediate choke shaft and lever assembly in float bowl by pushing through from throttle lever side.
9. With intermediate choke lever in the ``UP'' position, install thermostatic coil lever inside choke housing onto flats on intermediate choke shaft. Coil is properly aligned when the coil pick-up tang is at the top position. Install inside lever retaining screw into end of intermediate choke shaft and tighten securely. Do not install thermostatic choke cover and coil assembly in housing until inside coil lever is adjusted.
10. Install pump discharge steel check ball and spring in passage next to float chamber. Insert end of new plastic retainer into end of spring and install retainer in float bowl, tapping lightly in place until top of retainer is flush with bowl casing surface.
11. Install main metering jet into bottom of float chamber with suitable tool. Tighten jet securely.
12. Install needle seat and gasket.
13. Install float needle onto float arm by sliding float lever under needle pull clip. Proper installation of the needle pull clip is to hook the clip over the edge of the float on the float arm facing the float pontoon.
14. Install float retaining pin into float arm with end of loop of pin facing pump well. Install float assembly by aligning needle in the seat and float retaining pin into locating channels in float bowl. Push down lightly on float arm at outer end against top of float valve. Adjust float lever as outlined under ``Adjustments.''
15. Install power piston spring into piston bore.
16. If removed, assemble metering rod to holder on power piston. Spring will be on top of arm when assembled correctly.
17. Install power piston and metering rod assembly into the float bowl and main metering jet. Use care installing the metering rod into the jet to prevent damaging the metering rod tip. Press down firmly on plastic power piston retainer to make sure the retainer is seated in recess bowl and the top is flush with the top of the bowl casting. If necessary, tap retainer lightly in place using a drift and small hammer.
18. Install plastic filler block over float needle, pressing downward until properly seated and flush with bowl casting surface.
19. Install air horn gasket on float bowl by carefully sliding slit portion of gasket over the two dowel locating pins on the float bowl.
20. Install pump return spring in pump well.
21. Install pump plunger assembly in pump well.
22. If removed, install choke shaft, choke valve, and attaching screws. Tighten screws securely and stake lightly in place. Check choke valve for freedom of movement and proper alignment before staking screws into place.
23. Install fast idle cam rod in lower hole of choke lever, aligning squirt on rod with small slot in lever.
24. On 4 cylinder models, if removed, install plastic bushing in hole in vacuum break lever making sure small end of bushing faces retaining clip when installed. Then, insert end of vacuum break rod through bushing in lever. Retain rod with new clip, pressing clip in place using needle nose pliers. Make sure clip has full contact on rod but is not seated tightly against the bushing. Rod to bushing clearance should be .030 inch. Retaining clip is ``dished.'' Install clip on rod with outward bend or self-locking lugs facing end of rod. Check that clip fully engages rod and is not distorted.
25. Rotate fast idle cam to the full ``UP'' position and tilt air horn assembly to engage fast idle cam rod in slot in fast idle cam. Hold down on pump plunger assembly and carefully lower air horn assembly onto float bowl, guiding pump plunger stem through hole in air horn casting. Do not force air horn assembly onto bowl.
26. Install vent and screen assembly on air horn assembly located in area between the primary and secondary bores. Install air horn to bowl attaching screws and lock-washers. Tighten air horn screws in sequence, Fig. 4, evenly and securely. Four long air horn screws are located in the primary and secondary venturi area of which two (2) longer screws hold the vent and screen assembly in place, and on V6 models, one larger head screw goes next to the choke valve on the primary side. 2 short screws are located on the fuel inlet side and 1 short screw is located in the area beneath the hot idle compensator valve.
27. If equipped, install new seal in recess of float bowl. Install hot idle compensator valve and retain with screws. Tighten screws securely.
28. Install plastic bushing in hole in choke lever, making sure small end of bushing faces retaining clip when installed. With inner choke coil lever at 12 o'clock position, install intermediate choke rod in bushing. Retain rod with new clip using Tool J-28697 or needle nose pliers. Make sure clip has full contact on rod but is not seated tightly against bushing. Rod to bushing clearance should be .030 inch.
29. On V6 models, if removed, install plastic bushing in hole in secondary side vacuum break plunger, making sure small end of bushing faces retaining clip when installed. Install secondary side vacuum break rod and secure new clip to rod using Tool J-28697 or needle nose pliers. Make sure clip has full contact on rod but is not seated tightly against bushing. Rod to bushing clearance should be .030 inch. Retaining clip is ``dished.'' Install clip on rod with outward bend of self-locking clip facing end of rod. Check that clip fully engages rod and that clip is not distorted.
30. On V6 models, rotate bracket and insert end of secondary side vacuum break rod into upper slot of vacuum break lever. Install bracket on throttle body and install countersunk screws. Tighten screws securely.
31. On all models, if removed, install solenoid in hole on bracket, large lock washer and retaining nut. Tighten nut securely. Bend back two (2) retaining tabs on lockwasher to fit in slots in bracket. Use care in tightening to avoid damaging vacuum break diaphragm plunger.
32. On 4 cylinder models, rotate solenoid bracket and insert end of vacuum break rod into inner slot and end of air valve rod into outer slot of vacuum break diaphragm plunger. Install bracket over locating lugs on air horn and install countersunk screw in air horn and screw with lockwasher in throttle body. Tighten screws securely.
33. On V6 models, if removed, install plastic bushing in holes in primary side vacuum break plunger, making sure small end of bushings, face retaining clips when installed. Install vacuum break rod in upper hold of plunger and air valve rod in lower hole of plunger and secure new clips to rod using Tool J-28697 or needle-nosed pliers. Make sure clips have full contact on rods but are not seated tightly against bushings. Rod to bushing clearance should be .030 inch. Rotate primary side vacuum break bracket to engage vacuum break and air valve rods in vacuum break and in air valve lever, positioning bracket over locating lug on air horn. Install countersunk screws and tighten securely. Retaining slips are ``dished.'' Install clip on rod with outward bend of self-locking clip facing end of rod. Check that clips fully engage rods and clip is not distorted.
34. Install pump rod in hole in pump lever by rotating lever. Installing retaining screw in pump lever, then washer. Hold pump plunger stem down and install pump lever on air horn. Make sure shoulder on screw seats in hole in lever and washer is located between lever and air horn casting. Tighten screw securely. The vacuum break and choke rod (fast idle cam) adjustments must be performed, and the thermostatic coil lever inside the choke housing has to be indexed properly before installing the choke thermostatic coil and cover assembly.
35. Install the choke cover and coil assembly in choke housing as follows:
a. Start the three (3) self-tapping screws in the choke housing, checking to be sure screws start easily and are aligned properly. Then, remove screws.
b. Place fast idle screw on highest step of fast idle cam.
c. Install the thermostatic cover and coil assembly in the choke housing, aligning notch in cover with raised casting projection on housing cover flange. Make sure coil pick-up tang engages the inside choke coil lever. On V6 models, the tang on the thermostatic coil is the ``trapped stat'' design. The coil tang is formed so that it will completely encircle the coil pick-up lever. Make sure the choke coil lever is located inside the coil tang when installing the choke cover and coil assembly.
d. Install three (3) cover retainers and self-tapping screws and tighten screws tightly. Ground contact for the electric choke is provided by a metal plate located at the rear of the choke assembly. Do not install a choke cover gasket between the electric choke assembly and the choke housing. Choke will not operate unless properly grounded.