Assembly

Fig. 6 Float needle pull clip installation:

Fig. 7 Air horn screw tightening sequence:

1. Reinstall idle mixture needles and springs, if removed. Lightly seat each needle, then back off number of turns counted during disassembly.
2. Install accelerator pump link, ensuring end of link points outward.
3. Install new float bowl gasket onto bowl, then assemble float bowl to throttle body and secure with attaching screws.
4. Support carburetor in a suitable holding fixture.
5. Install new intermediate choke shaft seal in choke housing shaft hole, if applicable. Lip of seal should face toward inside of housing.
6. Install fast idle cam assembly onto intermediate choke shaft, lever and link. Steps on cam should face downward.
7. Install intermediate choke shaft, lever and link assembly into choke housing.
8. Install choke coil lever onto flats of intermediate choke shaft. Inside and outside levers should face toward fuel inlet. Install coil lever attaching screw.
9. Install new intermediate choke shaft seal into float bowl insert, if applicable. Ensure lip of seal faces outward.
10. Install new choke housing to float bowl seal, if applicable.
11. Install secondary throttle lockout lever onto float bowl boss, ensuring recess in lever hole faces inward.
12. Install intermediate choke lever into float bowl cavity. Retain lever in position with tool No. J-23417 or equivalent.
13. Install choke housing assembly onto float bowl, ensuring that tang of intermediate choke shaft lever is positioned under fast idle cam. Install choke housing attaching screw and washer. Check linkage for freedom of movement.
14. Install pump well baffle, with slot facing downward.
15. Install accelerator pump discharge check ball, then the check ball retainer and primary metering jets.
16. Install float needle seat assembly and gasket, using suitable tools.
17. On M4MED models, install dual capacity pump valve assembly, using tool No. J-34928 or equivalent, then install solenoid assembly.
18. Install aneroid cavity insert, if equipped.
19. Insert float hinge pin into float arm, ensuring loop end of pin faces toward pump well.
20. Install float needle onto arm with pull clip positioned over edge of float arm, facing pontoon, Fig. 6. Do not insert pull clip into holes in float arm since flooding may result.
21. Install float assembly, aligning needle into seat and float hinge pin into locating channels in float bowl. Adjust float level as outlined under ``Adjustments.''
22. Install float bowl insert over float needle, pressing downward on insert until properly seated.
23. Install primary metering rod spring at top of each metering rod, then the power piston spring into piston bore.
24. Align pin on power valve piston with slot in bore, then insert primary metering rods into metering jets.
25. Press downward on power piston retainer until it is seated in bowl recess and flush with top of bowl. Using a small drift and hammer may facilitate installation.
26. Install pump return spring into pump well and new solenoid connector, if equipped, onto air horn gasket.
27. Slide tab of air horn to float bowl gasket around main metering rods and under power piston hanger. Position gasket over dowel pins on float bowl, then lift one corner of gasket and push pump plunger to bottom of well. Align pump plunger stem with hole in gasket, then press gasket into place.
28. Apply lithium based grease to air valve shaft pin at spring contact area.
29. Install new pump plunger stem seal and retainer, if used, ensuring seal lip faces toward outside of carburetor. Lightly stake seal retainer in several locations different from original stakings.
30. Install air horn assembly onto float bowl while holding gasket downward at pump plunger location. Ensure tubes and pump plunger stem are properly positioned through holes in gasket. Install air horn attaching screws and baffle, if used. Tighten attaching screws in sequence shown, Fig. 7.
31. Insert upper end of pump link into specified hole of pump lever. Align pump lever hole with hole in air horn casting, then install pump lever roll pin until end of pin is flush with casting bosses.
32. Install fuel filter spring, filter and fuel inlet nut with new gasket.
33. Connect choke link into intermediate choke lever, then install choke lever with flats positioned on choke shaft. Install choke lever attaching screw.
34. Install rear vacuum break assembly, if used, as follows:
a. Install vacuum break air valve lever link, then connect vacuum break to choke link.
b. Install vacuum break, then tighten attaching screws.
35. If used, install front vacuum break air valve link, then the vacuum break assembly. Tighten attaching screws.
36. Install idle speed solenoid or throttle kicker assembly.
37. Install secondary metering rods into secondary metering rod holder, ensuring upper ends of rods are facing each other.
38. Install holder and rods onto air valve cam follower, then install rod holder attaching screw. Operate air valves to ensure free movement in either direction.