Carburetor Removal

Figure 7:

1. Slowly and carefully remove the radiator pressure cap.

WARNING: Be aware of high coolant temperature and pressure. Do not allow the hot coolant to splash. Hot coolant will cause burns.

2. Drain cooling system.

3. To prevent excessive coolant leakage use smooth jaw hose shut-off pliers to pinch off the coolant hose from the intake manifold to the choke thermo wax housing (Figure 7). Then twist and disconnect the hose from the carburetor.

CAUTION: Avoid using standard locking clamp pliers (Vise-Grips) with serrated jaws as they may damage hoses.

4. Disconnect the accelerator cable and wire harness connector from the carburetor. Disconnect the fuel lines and hose connections.

Figure 8:

5. Remove the four carburetor through bolts, washers, and the nut and lock washer at the left rear corner of the carburetor near the sub-EGR valve (Figure 8).

Lift the carburetor off the intake manifold.

NOTE: Usually a quick, hard pull will separate the carburetor from the intake manifold. Cover the exposed intake manifold ports with a shop towel.

6. Support the carburetor in a vise using MIT209769 carburetor aligning pins.

CAUTION: Do not damage the throttle linkage that extends below the base of the carburetor.

Figure 9:

BEFORE INSTALLING THE CHOKE SHIM READ THROUGH THE FOLLOWING 3 PAGES.


7. Install the choke shim that is included in the emission kit as described in Figures 9, 10, 11, 12, and 13.


Shown in Figure 9 is a basic outline view of the choke mechanism.

NOTE: The area between the choke adjustment screw and the plunger is behind the choke linkage and is hidden from view.

Figure 11:

Figure 10:

7. Using the fast idle release driver special tool, insert the tool between the thermo wax element housing and the choke linkage (Figure 11).

Figure 12:

8. Spread the choke linkages to create a gap between the choke adjustment screw and the plunger of the thermo wax element. Make sure not to interfere with the throttle lever or other linkages.

Figure 13:

9. With the linkages spread, install the cap portion of the choke shim onto the threaded end of the choke adjustment screw. The cap portion of the shim should be inserted between the plunger and the choke adjustment screw (Figure 13). Remove the fast idle release driver. Carefully twist the handle of the choke shim and allow the handle to break off from the cap portion.