Disassembly

1. Position carburetor on a suitable holding fixture.
2. Remove screws attaching wide open throttle switch and/or idle speed solenoid and bracket to float bowl. Remove switch or solenoid and bracket as an assembly.
3. Remove attaching screw, then remove upper choke lever from end of choke shaft. Rotate upper choke lever to remove choke rod from slot in lever.
4. While holding lower lever outward with a small screwdriver, twist choke rod counterclockwise and remove from lower lever.
5. Using a suitable punch, carefully drive accelerator pump lever pivot pin inward until pump lever can be removed from air horn. Note location of pump rod in hole in pump lever, then remove pump lever from pump rod. When removing pump lever pivot pin, use care not to damage casting on air horn.
6. Note location, then remove front vacuum break hose.
7. Remove seven air horn to bowl attaching screws, then remove the two countersunk screws located next to the venturi.
8. Lift straight upward on air horn, then remove air horn from float bowl. When removing air horn from float bowl, use care not to damage throttle position sensor adjustment lever, solenoid connector and pull over enrichment tubes, if equipped.
9. Remove front vacuum break and bracket assembly.
10. Push throttle position sensor plunger up through seal in air horn, if equipped. Use care not to damage sealing surface.
11. With air horn inverted, drive out lean mixture screw plug from bottom side, using a suitable punch. Do not turn rich mixture stop screw in air horn, unless screw or solenoid check are to be replaced.
12. With air horn inverted, use a small screwdriver to remove stakes holding accelerator pump stem and throttle position sensor seal retainers, if equipped. Remove and discard seal and retainer. Use care not to damage air horn casting when removing seal retainers.
13. Further disassembly of the air horn for cleaning purposes is not necessary, providing a low volatile cleaning solvent is used. Do not use carburetor cleaner, as damage to idle air bleed valve O-rings will result.
14. If it is necessary to replace the idle air bleed valve or to immerse air horn assembly in carburetor cleaner, proceed as follows:
a. Support air horn, then align a #35 drill on head of rivet holding idle air bleed valve cover in position. Drill only enough to remove rivet head, then using a suitable punch, drive remainder of rivet out of air bleed tower on air horn casting. Use care not to damage air horn casting when removing rivet.
b. Lift cover from idle air bleed valve and remove remainder of rivets from inside tower on air horn casting. Discard cover after removing. If cover is missing, this indicates idle air bleed valve setting has been changed from original factory setting.
c. Using a suitable screwdriver, turn idle air bleed valve counterclockwise to remove from air horn. Remove and discard idle air bleed valve O-rings. Do not remove covers from rich mixture stop screw or throttle position sensor adjustment screw.
15. While holding accelerator pump plunger downward, raise corner of air horn gasket and remove pump from pump well in float bowl.
16. Remove solenoid metering rod plunger from bowl by lifting straight upward.
17. Remove rubber seal from mixture control solenoid plunger.
18. Remove accelerator pump spring from well.
19. If equipped, remove staking holding throttle position sensor to bowl as follows:
a. Position a flat tool or metal piece across bowl casting to prevent damage to gasket surfaces.
b. Using a small screwdriver, lightly depress throttle position sensor, then using a small chisel, pry upward to remove bowl staking. Prying force should be exerted against flat tool or metal piece, not bowl casting.
c. Remove throttle position sensor and connector assembly from bowl.
d. Remove throttle position sensor spring from fuel bowl well.
20. Remove filler block located over float valve.
21. Remove metering rods from metering jets, then slide springs from rods.
22. Remove mixture control solenoid as follows:
a. Remove screws attaching solenoid connector to float bowl. Do not remove connector from bowl.
b. Using tool No. BT-7928 or equivalent, turn lean mixture screw clockwise until lightly bottomed, noting the number of turns for reassembly. Turn screw counterclockwise and remove from float bowl.
c. Carefully lift mixture control solenoid and connector assembly from float bowl. Do not remove plunger return spring or connector and wires from solenoid, as they are serviced as an assembly.
d. Remove plastic aneroid cavity insert from cavity in float bowl, if equipped.
e. Remove lean mixture tension spring, located next to float hanger pin.
23. Pull up on retaining pin and remove float assembly and float needle.
24. Using tool No. BT-3006M or equivalent, remove float needle seat and gasket.
25. Remove mixture control large tension spring from boss located between metering jets at bottom of float bowl.
26. If necessary, use tool No BT-7928 or equivalent to remove main metering jets.
27. Remove accelerator pump check ball and retainer.
28. If necessary, remove baffle from accelerator pump well fill slot.
29. Note location of vacuum hose, then remove rear vacuum break from float bowl.
30. Support float bowl and throttle body, then using a #21 drill, remove rivet heads attaching choke cover to choke housing. Using a suitable punch, drive remainder of rivets out of choke housing.
31. Remove choke cover from choke housing. On hot air choke models, do not remove baffle plate from choke cover.
32. From inside choke housing, remove attaching screws and washers, then slide choke housing from float bowl.
33. Remove lower choke rod lever from inside of float bowl.
34. Detach rear vacuum break rod from intermediate choke lever.
35. Remove choke coil lever retaining screw from end of shaft in choke housing, then remove choke coil lever from shaft.
36. Remove intermediate choke shaft from choke housing, then remove fast idle cam from intermediate choke shaft.
37. On models equipped with hot air choke, remove cup seal from choke housing shaft bore, if choke housing is to be placed in carburetor cleaner. Also remove cup seal from float bowl insert. Do not remove insert from float bowl.
38. Remove fuel filter and filter spring from housing bore.
39. Remove four float bowl to throttle body attaching screws, then remove throttle body and gasket.
40. Position throttle body on a suitable holding fixture to prevent damage to throttle valves.
41. Align tang on pump rod with slot on throttle lever, then remove pump rod. Do not remove throttle valve attaching screws, as they are permanently staked in position. The throttle valve is serviced as an assembly.