Assembly

1. Ensure that all holes in new gaskets have been properly punched and that no foreign matter has adhered to gaskets.
2. Ensure that accelerating pump diaphragm is not turned or cut.
3. Slide throttle shaft assembly into main body until it begins to enter high speed bleed cam slot in body.
4. Hold cam by edge of point in the slot and rotate throttle shaft until shaft passes through cam.
5. Rotate shaft clockwise until throttle lever clears boss for throttle solenoid positioner TSP OFF idle speed screw.
6. Continue inserting shaft into proper position, rotating as necessary to properly position cam.
7. Referring to lines scribed on throttle plates, install throttle plates in proper locations with screws snug but not tight. Always use new screws when installing throttle plates.
8. Close throttle plates, then invert main body and hold it up to light. Little or no light should show between throttle plates and throttle bores.
9. Tap plates lightly with screwdriver handle to seat them, then hold throttle plates closed and tighten and stake attaching screws. Stake hardened screws by crimping exposed threads with diagonal cutters.
10. If aneroid was separated from metering valve assembly position new gasket and the aneroid to the valve and install attaching screws, then, using new gasket, position aneroid valve assembly on carburetor and install four retaining screws. On newer aneroid valve, install and tighten three mounting screws.
11. On feedback carburetors, install new duty cycle solenoid gasket, solenoid and the three mounting screws.
12. On all models, install anti-stall dashpot, solenoid, or solenoid dashpot, solenoid diaphragm or vacuum kicker, if equipped.
13. On feedback carburetors, proceed as follows:
a. Install throttle positioner with throttle shaft in closed position.
b. Install throttle sensor over throttle shaft and flush to mounting surface with sensor rotated counterclockwise as far as possible.
c. Rotate sensor clockwise to align mounting holes and engage sensor to throttle shaft actuating pin, then install two mounting screws, torquing to 11 - 16 inch lbs.
d. Mount throttle position sensor connector bracket to choke shield with two mounting screws.
14. On all models, place fast idle adjusting lever assembly on throttle shaft and install retaining washer and nut, then install fast idle screw and spring.
15. Invert main body and install enrichment valve with new gasket, tightening valve securely.
16. Install idle mixture adjustment screws and springs, turning needles in gently with fingers until they just contact seat, then back off 11/2 turns. Do not install idle mixture adjustment limiting caps at this time.
17. Install enrichment valve cover and new gasket. The enrichment cover must be installed with limiter stops on cover in position to provide a positive stop engage in the plugs. When limiter cap is installed, simply position tang of cap outboard and press in position.
18. Apply suitable lubricant to tip of replacement Elastomer valve and insert tip into accelerator pump cavity center hole.
19. Using a suitable tool, reach into fuel bowl and grasp valve tip, then pull valve in until it seats in pump cavity wall.
20. Cut off tip of Elastomer valve forward of retaining shoulder, then remove tip from bowl.
21. Install accelerator pump diaphragm return spring on boss in chamber.
22. Insert diaphragm assembly in cover and place cover and diaphragm assembly into position on main body.
23. Install shorter right hand cover screws finger tight.
24. Install mechanical vent system by positioning vent valve actuating lever and install it with two longer cover screws finger tight, if equipped.
25. Push accelerator pump plunger the full length of travel and tighten cover screws.
26. Rotate pump link and rod assembly until keyed end of assembly is aligned with keyed hole in pump overtravel lever. Reposition rod and swivel assembly in specified hole, then reinstall pump link in accelerator pump cover and insert roll pin 27. Position booster assembly gasket and booster venturi, then drop accelerator pump discharge ball and weight into passage in main body.
28. Install booster venturi screw, filter screen and gasket.
29. Install main jets and fuel inlet seat, filter screen, baffle and new gasket.
30. Install fuel inlet needle assembly in fuel inlet seat.
31. Slide float shaft into float lever, then position float shaft retainer on float shaft.
32. Insert float assembly into fuel bowl and hook float lever tab under fuel inlet needle assembly.
33. Place float damper spring, if equipped, on left side of float shaft and insert float shaft into its guides at sides of fuel bowl.
34. Using screwdriver, position float shaft retainer in groove on fuel inlet needle seat, then check float setting, ensuring that float does not interfere with Elastomer valve.
35. On carburetors equipped with temperature compensated accelerator pump, install new TCP gasket, TCP valve and three mounting screws.
36. Position fast idle cam lever on thermostatic choke shaft and lever assembly, ensuring that bottom of fast idle cam lever adjusting screw rests against tang on choke lever.
37. Insert choke lever into rear of choke housing, positioning choke lever so that hole in lever is to left side of choke housing.
38. Install fast idle cam rod on fast idle cam lever, then place fast idle cam on fast idle cam rod and install retainer.
39. Place choke housing vacuum pick-up port to main body gasket on choke housing flange.
40. Position choke housing on main body and, at same time, install fast idle cam on hub on main body.
41. Position gasket and install choke housing attaching screws, then install fast idle cam retainer. Ensure that bi-metal spring tab is engaged in slotted choke shaft lever.
42. Position gasket on housing and install choke cap and retainer, tightening breakaway screws until breakaway heads snap off.
43. Install choke pulldown diaphragm assembly as follows:
a. Engage rod in diaphragm assembly link, then rotate assembly to align mounting bracket with main body casting.
b. On modulated systems, attach rod and install E-clip, then install two attaching screws.
c. Adjust choke pulldown and fast idle cam.
44. Position choke plate shaft in air horn, then install choke plate rod and lever on end of choke shaft.
45. On carburetors equipped with altitude compensation, install link to choke plate shaft levers and install link retainer.
46. On all models, insert choke plate into choke plate shaft.
47. Install choke plate screws snug but not tight.
48. Check for proper plate fit, binding in air horn and free rotation of shaft by moving plate from closed position to open position.
49. Remove choke plate and grind or file plate edge where it is binding or scraping on air horn wall, if necessary.
50. If choke plate and shaft moves freely, tighten choke plate screws while holding choke in fully closed position, then stake choke plate screws by crimping exposed threads.
51. Position main body gasket and choke rod plastic seal over choke rod.
52. Position air horn on main body and gasket so that choke plate rod fits through seal and the opening in main body.
53. Insert end of choke plate rod into automatic choke lever, then install air horn attaching screws and the carburetor identification tag.
54. Install choke plate rod retainer.
55. Install air cleaner anchor screw, then perform carburetor adjustments as required to meet specifications.