Assembly

MAIN BODY
1. Install the throttle stop adjusting screw in the main body (if equipped).
2. Install the accelerator pump cam, flat washer, lockwasher and nut on the primary throttle shaft. Tighten to 15 lb-in.
3. Install the idle mixture adjusting needle and spring. Turn it in until it lightly bottoms. Back out the screw the exact number of turns recorded at disassembly. Install a new steel replacement plug in the fuel/air extension housing slightly below the outer edge and stake in three places.
4. Install the idle jet and retainer assembly on the secondary side of the carburetor body, tighten to 10 lb-in. Check carefully for the correct secondary size.
5. Install the enrichment valve, needle, seat and spring as an assembly, tighten to 15-in.
6. Install the primary and secondary main jets, tighten to 10 lb-in. Be sure the correct sizes are installed.
7. Install the primary and secondary main well tubes and high speed bleeds. Be sure the correct sizes are installed.
8. Install the throttle actuator device and bracket and tighten to 60 lb-in.

ACCELERATOR PUMP
1. Install the pump discharge check balls. Install the pump discharge nozzle with a gasket on top and bottom. Install the pump discharge nozzle screw. Tighten to 15 lb-in.
2. Install the pump return spring and pump diaphragm assembly. Start the four pump cover screws. Hold the pump operating lever partially open to align the diaphragm gasket. Tighten the four cover screws evenly to 8 lb-in.

AUTOMATIC CHOKE
1. Install the diaphragm adjusting screw. Initially adjust the screw so that the threads are flush with the inside of the cover.
2. Install the choke diaphragm and rod assembly. Install the diaphragm return spring.
3. Install the new choke pulldown diaphragm cover using the three retaining screws and tighten to 7 lb-in. Install the fast idle adjusting screw and spring to the fast idle arm.
4. Install the choke housing shaft into the housing and position the fast idle cam on the choke housing shaft.
5. Install the choke lever, lockwasher and nut. Install the choke housing shaft overcenter spring.
6. Install the O-ring on the vacuum passage. Install the fast idle rod with the end with one tab in the fast idle adjusting lever and the end with two tabs in the primary throttle lever.
7. Position the choke housing against the main carburetor body and install the long attaching screw in the long leg of the housing. Install the other screws. Tighten the three housing screws evenly to 10 lb-in.
8. Install choke cap per the following procedure:
a. Use Marson Rivet Gun HP-2 with nosepiece Tool D80P-53700-A or equivalent.
b. Use Ford rivet Part No. 388299 (1/8 inch diameter)
c. Determine that the choke cap spacer is installed properly.
d. Install choke cap after engaging bimetal loop on choke housing shaft lever pin and nylon bushing and rotate to engage plastic spacer index tab.
e. Install choke cap retainer over cap and loosely retain with the standard screw.

Rivet choke cap assembly as follows:
1. Place rivet in rivet gun and trigger lightly to retain rivet.
2. Press rivet fully into casting after passing through retaining clamp.
3. Trigger lightly the two rivets until sufficient pressure is obtained to hold cap temporarily.
4. Reposition rivet gun on mandrel and trigger until rivet is popped (mandrel breaks off).
5. Repeat previous steps for remaining rivet.
6. Tighten the standard screw 6 lb-in.

AIR HORN
1. Install bowl vent diaphragm, vent valve, spring, retainer and E-clip.
2. Install vent valve cover/solenoid with three screws and tighten securely to 8 lb-in.
3. Install the inlet needle seat and gasket. (On turbocharged engines the needle and seat are installed as an assembly.)
4. Install the power valve vacuum diaphragm. Depress the spring and install the screws and washers finger tight. Hold the stem so that the diaphragm is horizontal and tighten the screws evenly to 8 lb-in. (On turbocharged engines, install inlet needle and seat baffle and retainer at this time)
5. Install the float needle clip on the float tab and position the float and needle. Install the float shaft.
6. Hold the bowl cover in an inverted position and adjust the dry float setting.
7. Hold the cover in its normal position and adjust the float drop.
8. Install the choke rod seal. Install the choke rod through the seal and hook it into the choke lever. Install the retaining clip.
9. Install bowl cover gasket, choke link into the choke lever, and the retaining clip. Install the five bowl screws and tighten evenly to 20 lb-in.