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GROUP 14

FUEL SYSTEM
CONTENTS
Pag e
AVS SERI ES CARBURETOR 26 HOLLEY 2200 SERI ES CARBURETOR
BBD SERI ES CARBURETOR 6 HOLLEY 4160 SERI ES CARBURETOR
FUEL PUMP 55 THROTTLE LI NKAGE
FUEL TANKS 57 SPECI FI CATI ONS
Page
14
37
63
64
GENERAL INFORMATION
SERVI CI NG CARBURETOR
Di r t , dus t , wat er and g u mmy depos i t s ar e s ome of
t he mai n c au s es f or poor c ar b u r et o r oper at i on. How-
ev er , p r o p er c l eani ng and t h e i ns t al l at i o n of new
par t s , wh er e r eq u i r ed , wi l l r et u r n t he c ar b u r et o r t o
i t s or i g i nal d es i g ned p er f o r manc e.
Wh e n o v er h au l i ng t he c ar b u r et o r , s ev er al i t ems of
i mpor t anc e s h o u l d be o b s er v ed t o as s u r e a good j ob:
(1) Al l par t s (ex c ept t he c h o k e d i ap h r ag m as s em-
bl y) s h o u l d be c ar ef u l l y c l eaned i n a s ui t abl e s ol v ent ,
t hen i ns p ec t ed f o r d amag e or wear .
(2) Us e ai r p r es s u r e onl y , t o c l ear t he v ar i o u s or i -
f i c es and c h annel s .
(3) Rep l ac e ques t i onabl e p ar t s wi t h NEW ones .
Wh en c h ec k i ng p ar t s r emo v ed f r o m t he c ar b u r et o r , i t
i s at t i mes r at h er di ffi c ul t t o be s u r e t hey ar e sat i s-
f ac t or y f or f u r t h er s er v i c e. It i s t h er ef o r e, r ec o m-
mend ed t hat i n s u c h c as e, NEW p ar t s b e i ns t al l ed .
(4) Al way s u s e a c ompl et e k i t wh en o v er h au l i ng
t he c ar b u r et o r . Us i ng t he c ode nu mb er s t amp ed on
t he ai r h o r n, ad j ac ent to t he f u el i nl et , r ef er t o t he
p ar t s c at al og and o r d er t he c o r r ec t r ep ai r k i t f o r t he
c ar b u r et o r bei ng wo r k ed on.
CLEANI NG CARBURETOR PARTS
Th e r ec o mmend ed s ol v ent f o r g u m depos i t s i s
d enat u r ed al c ohol wh i c h i s eas i l y obt ai nabl e. How-
ev er , t h er e ar e ot her c o mmer c i al s ol v ent s , ( s uc h as
Met al c l ene) wh i c h may b e u s ed wi t h s at i s f ac t or y r e-
s u l t s .
T h e c h o k e d i ap h r ag m c an be d amag ed by s ol v ent s .
Av o i d p l ac i ng t he d i ap h r ag m as s emb l y i n ANY l i q u i d .
Cl ean t he ex t er nal s u r f ac es wi t h a c l ean c l ot h o r soft
wi r e b r u s h . Sh ak e di r t or ot her f o r ei g n mat er i al f r o m
t he s t em s i de of t he d i ap h r ag m. Dep r es s i ng t he di a-
p h r ag m s t em t o t he r et r ac t ed pos i t i on, wi l l p r o v i d e an
addi t i onal hol e f o r t he r emo v al of di r t . Co mp r es s ed
ai r c an be u s ed t o r emo v e l oos e di r t , but should not be
connected to the vacuum inlet fitting.
I MPORTANT: If the commercial solvent or cleaner
recommends the use of water as a rinse, it should be
"HOT" After rinsing, all trace of water must be
bl own from the passages with air pressure. It is
further advisable to rinse all parts in clean gasoline or
kerosene to be certain no trace of moisture remains.
Never clean jets with a wire, drill or other mechanical
means because the orifices may become enlarged,
making the fuel mixture too rich for proper per-
formance.
AUTOMATIC CHOKE (Well Type)
A new des i g n wel l f or t he aut omat i c c h o k e h as b een
i nc o r p o r at ed i n al l eng i nes ex c ep t t he 440 c u . i n. t r i -
c ar b i ns t al l at i on and t he 426 c u . i n. Hemi . Th i s new
des i g n al l ows f as t er o p eni ng of t he c h o k e mec h ani s m
r es u l t i ng i n l eaner f u el mi x t u r es d u r i ng t he war m-u p
p er i o d f or r ed u c ed emi s s i o ns and f u el c o ns u mp t i o n.
( Fi g . 1).
To f u nc t i o n p r o p er l y , i t i s i mp o r t ant t hat al l p ar t s
be c l ean and mo v e f r eel y . Ot h er t h an an o c c as i o nal
c l eani ng , t he aut omat i c c hok e c o nt r o l r eq u i r es no
s er v i c i ng . Ho wev er , i t i s v er y i mp o r t ant t hat t h e c h o k e
c ont r ol u ni t wo r k s f r eel y at t he t her mos t at i c c oi l
s p r i ng h o u s i ng and at t he c h o k e s haf t . Mov e t h e c h o k e
r o d u p and d o wn t o c h ec k f or f r ee mo v ement i n t he
c oi l h o u s i ng . If u ni t b i nd s , a new u ni t s h o u l d be i n-
s t al l ed. The well type choke is serviced as an assembly.
Do not attempt to repair or change the setting, unless
authorized by s er v i c e l i t er at ur e. Ch ang es of t h e c h o k e
setting materially affect summer temperature cold
starting and seldom are a satisfactory correction of
drive-ability problems, which are generally associated
with carburetors or vacuum diaphragms.
Tw o t y pes of wel l s ar e i n g ener al u s ag e. One i s c as t
as an i nt eg r al p ar t of t he mani f o l d . Th e s ec o nd i s a
PY138
Fig. I Choke Control (Open Well) B-cy Under Engine
14-2 FUEL SYSTEM-
stai nl ess st eel cup f ast ened over a port i n t he ma ni -
f ol d (Fi g. 1).
The stai nl ess st eel we l l cups are he l d i n pl ace by
choke re t a i ne r bol t s. A steel-asbestos gasket seals t he
exhaust gas w i t hi n t he ma n i f ol d . Loosening or remov-
ing the choke retainer bolts will allow exhaust gases
to escape into the engine compartment. DO NOT RUN
THE ENGI NE WI THOUT THE CHOKE FI RMLY
BOL T ED T O T HE MAN I FO L D . FI RE OR HE AT DAM-
AGE MAY OCCUR.
Whe n i n s t a l l i n g t he st eel w e l l cup, make ce rt a i n t he
gasket i s i n good cond i t i on a nd i s i n pl ace t o pre ve nt
exhaust l eakage.
Do not l ubri ca t e any of t he choke pa rt s or t he con-
t r ol un i t . Thi s causes d i r t t o accumul at e, and woul d
re s ul t i n bi n d i n g of t he choke mechani sm.
The choke con t rol un i t i s accurat el y adj us t e d whe n
first assembl ed. Un d e r n orma l s e rvi ci ng do NOT
change t he s e t t i ng or di sassembl e t he con t rol un i t .
I f however, t he s e t t i ng has been d i s t urbe d , reset as
f ol l ows : Loosen l ock n ut and t ur n shaf t w i t h screw-
d ri ve r un t i l i nd e x ma r k on di sc i s i n a l i gnme nt w i t h
corre ct ma r k on t he f ra me . Hol d i n t hi s pos i t i on w i t h
s cre wdri ve r whi l e t i ght e n i n g n ut , (Refer t o Specifica-
t i ons f or i nde x i ng) .
A l l t he ca rbure t ors re f e rre d t o i n t he Fue l Syst em
are e i t he r e qui ppe d f or use w i t h a Cl eaner Ai r Syst em
(C.A.S.) or an Eva pora t i on Con t rol System, (E.C.S.) de-
pe nd i ng on t he area i n whi ch t he vehi cl e i s t o be used.
The s e rvi ci ng procedures cove ri ng these ca rbure t ors
are ne a rl y i d e n t i ca l . Di f f erences bet ween t he t wo
t ypes of ca rbure t ors are covered (where appl i cabl e)
i n t he servi ce procedures.
CLEANER AIR SYSTEM (C.A.S.)
The cl eaner a i r syst em consi sts of a speci al a i r
cl eaner, bre a t he r cap, ve n t i l a t i on val ve, ca rbure t or,
d i s t ri but or and vari ous ot he r aut omat i c con t rol de-
CARBURETOR
CRANKCASE
VENTI LATI ON VALVE
AI R CLEANER BOWL VENT VALVE
CLEANER
TO CAP HOSE
VENT VALVE
TO CARBURETOR HOSE
BREATHER CAP
CRANKCASE
(VAPOR STORAGE AREA)
PY598
Fig. 2Cleaner Air System (C.A.S.J
vi ces, (Fi g. 2) as re q ui re d .
The f un ct i on of t he cl eaner a i r syst em i s t o reduce
t he un burn e d hydro- carbons e mi t t e d by t he vehi cl e' s
engi ne. Fre s h a i r i s d ra wn i n t o t he a i r cl eaner, f or con-
s umpt i on by t he engi ne. A port i on of t hi s f re s h a i r i s
d i ve rt e d t hrough a hose t o t he bre a t he r cap and i n t o
t he crankcase. Ma n i f ol d va cuum causes crankcase
vapors ( i ncl ud i ng f re s h a i r and un burn e d hydro- car-
bons) t o flow t hr ough t he crankcase ve n t i l a t i on val ve
t o t he base (or t hrot t l e body) of t he ca rbure t or. These
vapors are j oi n e d w i t h t he f ue l mi x t ur e i n t he i n t a k e
ma n i f ol d and are de l i ve re d i n t o t he combus t i on cham-
ber, f r om whi ch t he y are ej ect ed as essent i al l y com-
pl e t e l y burn e d exhaust product s .
EVAPORATION CONTROL SYSTEM (E.C.S.)
The e vaporat i on con t rol syst em consi sts of t he
C.A.S. syst em pl us , a speci al ve nt e d f ue l t a n k , sep-
arat or, f ue l t a n k vapor t ube , bre at he r cap, encl osed
bowl ve nt val ve, a va cuum pressure re l i e f f ue l t a n k
cap and hoses (Fi g. 3).
P Y 5 9 9
Fig. 3Evaporation Control System (EX.S.)
A
Th e f unc t i on of t he ev ap o r at i o n c o nt r o l s y s t em i s to
r ed u c e t he l os s of f u el f r o m t he f u el s y s t em t o t he
at mos pher e by ev apor at i on and r ed u c e t he u nb u r ned
hy dr o-c ar bons emi t t ed b y t he v eh i c l e' s eng i ne. Wh e n
f u el ev apor at es f r o m t he c ar b u r et o r or f u el t ank , i t
pas s es t hr oug h v ent hos es or t ubes t o t he c r ank c as e.
Wi t h t he eng i ne r u nni ng , v ap o r s ar e p u r g ed f r o m t he
c r ank c as e t h r o u g h t he c r ank c as e v ent i l at i on s y s t em,
as i n t he Cl eaner Ai r Sy s t em p r ev i o u s l y d es c r i b ed .
Th e f u el t ank c ont ai ns a one g al l on ov er f i l l l i mi t er
t ank. Wh en t he f u el t ank i s filled, t he ov er f i l l l i mi t er
t ank r emai ns es s ent i al l y empt y , t o al l ow f or t h er mal
ex p ans i o n. Ea c h c o r ner of t he f u el t ank i s v ent ed and
eac h of t he hos es f r o m t hes e v ent s ar e c o nnec t ed t o
t he s epar at or . A t ube f r o m t he s ep ar at o r l ead s t o t he
b r eat h er c ap. Th u s ev ap o r at ed f u el v ap o r f r o m t he
f u el t ank , flows t h r o u g h t he s epar at or , t o t he eng i ne
c r ank c as e and t h en t h r o u g h t he c r ank c as e v ent i l at i on
s y s t em. I n addi t i on, t he c ar b u r et o r f u el bowl v ent
v al v e i s al so i nc l u d ed , b y a t ube f r o m t he v ent v al v e
t o t he b r eat h er c ap , o r f u el p u mp . (6 Cy l i nd er en-
gi nes. ) Th i s c o mp l et el y s eal s t he f u el s y s t em.
Idle Speed Adjustment (Curb Idle)
To mak e t he i dl e s p eed ad j u s t ment on c ar b u r et o r s ,
s ec u r e an ac c u r at e i g ni t i on t ac h o met er and a Su n
El ec t r i c Co mb u s t i o n-Vac u u m Uni t , Model 80, Ex h a u s t
Co nd ens er , Model EC , and Ho s e 669-14 or equi v al ent .
( Th e above anal y zer i s r ec o mmend ed ; h o wev er , ot her
r el i abl e mak es of anal y zer s i n good c ondi t i on may b e
us ed). Pr o c eed as f ol l ows :
(1) Eng i ne r u nni ng at no r mal oper at i ng t emp er a-
t ur e, and t i mi ng c h ec k ed , (r ef er to Di s t r i b u t o r Sp ec i -
fications).
(2) Ai r Cl eaner i ns t al l ed .
(3) Au t o mat i c t r ans mi s s i o ns i n neu t r al pos i t i on (not
i n p ar k posi t i on).
(4) On ai r c ondi t i oned c ar s , t u r n ai r c ondi t i oni ng
off.
(5) Co nnec t i g ni t i on t ac h o met er .
(6) Ins er t pr obe of ex h au s t gas anal y zer i n t ai l
pi pe as f ar as pos s i bl e (2 ft . mi ni mu m di s t anc e). On
d u al ex h au s t c ar s u s e l ef t s i de t ai l pi pe (si de opposi t e
h eat v al v e) . It i s v er y i mp o r t ant t hat pr obe and c on-
nec t i ng t u b i ng be f r ee of l eak s t o p r ev ent er r o neo u s
r ead i ng . If a g ar ag e ex h au s t s y s t em i s u s ed t o c on-
duc t ex h au s t g as es away , a p l enu m c h amb er or ot her
means mu s t be u s ed t o r ed u c e v ac u u m or ex h au s t
s y s t em t o 1/2 i nc h wat er or l es s .
(7) Co nnec t ex h au s t gas anal y zer , w a r m u p and
c al i br at e ac c o r d i ng t o manu f ac t u r er ' s i ns t r u c t i o ns .
(8) Di s c o nnec t hos e b et ween di s t r i but or v ac u u m
c ont r ol v al v e and i nt ak e mani f o l d .
(9) Set i d l e s p eed t o s pec i f i ed v al u e f o r s pec i f i c
eng i ne-t r ans mi s s i o n c ombi nat i on.
(10) I MP ORT ANT : When adjusting mixture screws
FUEL SYSTEM 14-3
to obtain air/ fuel rati specified,'do not Turn
ture screw more than 1/ 16 turn at a time. The com-
bustion analyzer is so sensitive that the ratio must be
changed in very small increments if accurate readings
are to be obtained. The meters read in air/ fuel ratio
so that a higher reading indicates a leaner mixture
and vice versa.
(a) Ad j u s t eac h s c r ew 1/16 t u r n r i c h er (c ount er -
c l o c k wi s e) and wai t 10 s ec o nd s bef or e r ead i ng met er .
(b) If nec es s ar y , r epeat s t ep " a " u nt i l met er i ndi -
c at es a def i ni t e i nc r eas e i n r i c h nes s (l ower r ead i ng ) .
Th i s s t ep i s v er y i mpor t ant s i nc e met er r ev er s es i t s
r ead i ng s and i ndi c at es a r i c h er mi x t u r e as c ar b u r et o r
i s l eaned out i f c ar b u r et o r i s s et t oo l ean.
(c ) Wh e n i t has b een es t ab l i s h ed t hat met er i s i ndi -
c at i ng a l o wer r ead i ng ( r i c h er mi x t u r e) wh en i dl e
mi x t u r e s c r ews ar e t u r ned i n r i c h er d i r ec t i o n, pr o*
c eed t o ad j u s t c ar b u r et o r t o g i v e 14.2 a i r /f u e l r at i o,
t u r ni ng s c r ews c o u nt er c l o c k wi s e ( r i c her ) t o l o wer
met er r ead i ng and c l o c k wi s e (l eaner ) t o i nc r eas e
met er r ead i ng .
(d) If i dl e s p eed c h ang es as mi x t u r e s c r ews ar e
t u r ned , ad j u s t s p eed t o s pec i f i ed v al u e and r ead j u s t
mi x t u r e as r eq u i r ed so t hat 14.2 a i r /f u e l r at i o i s ob-
t ai ned at s pec i f i ed i dl e s p eed .
ROUGH I DLE AND LOW SPEED SURGE
Ro u g e i dl e and l ow s p eed s u r g e on v eh i c l es ( us i ng
1-1/2" BED, AV S , and Ho l l ey 4160 c ar b u r et o r s ) may
be t he r es u l t of i mp r o p er i dl e s et t i ng b al anc e b et ween
t he r i g h t and l ef t c ar b u r et o r bor es . To c o r r ec t t hi s
c ondi t i on t he f ol l owi ng s t eps s h o u l d be f ol l owed.
(1) Remo v e t he pl as t i c c ap s f r o m t he t wo i dl e
s c r ews i n bas e of c ar b u r et o r ( 1-1/2" BED and AVS)
or c u p or i n t he s i des i f t he p r i mar y met er i ng bl oc k
(Hol l ey ). ( Fi g s . 1, BED, AV S , and Ho l l ey ) .
(2) Wi t h ex h au s t t hor oug hl y war med u p , i ns t al l an
ap p r o v ed ex h au s t gas anal y zer f or c ar b u r et o r i dl e
s p eed and mi x t u r e ad j u s t ment as d es c r i b ed u nd er
" Id l e Sp eed Ad j u s t ment " .
(3) Wi t h a nar r o w s c r ew d r i v er , t u r n t he t wo i dl e
s c r ews c l o c k wi s e u nt i l t hey ar e bot h s eat ed.
(4) T u r n bot h i dl e s c r ews 1-1/2 t u r ns c o u nt er c l o c k -
wi s e f o r 1-1/2" BBD c ar b u r et o r s and 2 t o 3 t u r ns
c o u nt er c l o c k wi s e f o r AV S c ar b u r et o r s as a s t ar t i ng
poi nt ( ex p er i enc e may di c t at e mo r e or l es s t u r ns as a
r o u g h s et t i ng but bot h s c r ews s h o u l d be t u r ned
equal l y ) .
(5) St ar t eng i ne and s et s pec i f i ed i dl e s p eed f o r en-
g i nes wi t h 300 or mo r e mi l es . Set 75 r p m b el o w s p ec i -
fications i f u nd er 50 mi l es or 50 r p m bel ow s pec i f i c a-
t i ons i f 50 t o 300 mi l es ar e on eng i ne.
(6) Ob s er v e a i r /f u e l r at i o r ead i ng of ex h au s t g as
anal y zer . T u r n eac h s c r ew 1/16 t u r n r i c h er (c ount er -
14-4 FUEL SYSTEM
A
c l o c k wi s e) and not e c h ang e i n ai r /f ue l met er r ead i ng .
F r o m t hi s poi nt on, f ol l ow i ns t r u c t i o ns f o r i dl e s et t i ng
u nt i l 14.2 a i r /f u e l r at i o i s obt ai ned at appr ox i mat e
i dl e s p eed . It i s v er y i mp o r t ant t hat bot h i dl e l i mi t er
s c r ews be t u r ned t he s ame amount on eac h adj us t -
ment so t hat as f i nal l y s et bot h s c r ews wi l l be t he
s ame nu mb er of t u r ns f r o m t he s eat ed pos i t i on.
(7) Ins t al l pl as t i c c ap s ov er i dl e s c r ews .
SERVICE DIAGNOSIS
Condition Possible Cause Correction
POOR IOLING
POOR ACCEL ERAT I ON
C ARB URET OR F L OODS
OR L EAK S
(a) Idl e ai r bl eed c ar boni zed or of i nc or -
r ec t s i ze.
(b) Idl e d i s c h ar g e hol es pl ugged or
g u mmed .
( c ) Thr ot t l e body c ar boni zed or wor n
t hr ot t l e s haf t .
(d) Damag ed or wor n i dl e mi xt ur e needl e.
(e) L ow gr ade f uel or i nc or r ec t fl oat l ev el .
(f) L o o s e mai n body t o t hr ot t l e body
s c r ews .
(g) Wor n or c or r oded needl e v al v e and
s eat .
(h) Inc or r ec t v al v e l as h .
(i ) Eng i ne mi s s (i gni t i on),
(j ) Inc or r ec t t i mi ng.
(a) Ac c el er at o r pump pi st on (or pl unger )
l eat her t oo har d, wor n, or l oose on
s t em.
(b) Faul t y ac c el er at o r pump d i s c h ar g e
bal l .
(c ) Faul t y ac c el er at o r p u mp i nl et c h ec k
bal l .
(d) Inc or r ec t f uel or f l oat l ev el .
(e) Wor n ac c el er at o r pump and t hr ot t l e
l i nkage.
(f) Mani f ol d heat v al v e s t i c k i ng .
(g) No power mi xt ur e.
(h) Inc or r ec t t i mi ng .
(i ) Inc or r ec t pump s et t i ng .
(a) Cr ac k ed body.
(a) Di s as s emb l e c ar bur et or . Th en, u s e
c o mp r es s ed ai r t o c l ear i dl e bl eed
af t er s o ak i ng i t i n a s ui t abl e s ol v ent .
(b) Di s as s emb l e c ar bur et or . Th en, u s e
c o mp r es s ed ai r to c l ear i dl e d i s c h ar g e
hol es af t er s o ak i ng mai n and t hr ot t l e
bodi es i n a s ui t abl e sol v ent .
(c ) Di s as s emb l e c ar bur et or . Ch ec k t hrot -
t l e v al v e s haf t for wear . If ex c es s i v e
wear i s appar ent , r epl ac e t hr ot t l e
body as s emb l y .
(d) Rep l ac e wor n or damag ed i dl e needl e.
Adj us t ai r mi xt ur e.
(e) Tes t f uel l evel i n c ar bur et or . Ad j u s t
a s nec es s ar y to obt ai n c or r ec t fl oat
l ev el .
(f) Ti g ht en mai n body to t hr ot t l e body
s c r ews s ec u r el y to pr event ai r l eak s
and c r ac k ed hous i ng s .
(g) Cl ean and i ns p ec t needl e v al v e and
s eat . If f ound to be i n ques t i onabl e
c ondi t i on, r epl ac e as s emb l y . Th en,
t es t f uel pump p r es s u r e. Ref er t o
Sp ec i f i c at i o ns for c or r ec t f uel p u mp
p r es s u r e.
(h) Adj us t v al v es .
(i ) Ch ec k i gni t i on s y s t em,
(j ) Res et t i mi ng.
(a) Di s as s emb l e c ar bur et or . Rep l ac e a c -
c el er at or pump as s emb l y if l eat her i s
har d, c r ac k ed or wor n. Tes t f ol l ow-up
s p r i ng for c o mp r es s i o n.
(b) Di s as s emb l e c ar bur et or . Us e c o m-
p r es s ed ai r to c l ean d i s c h ar g e nozzl e
and c h annel s af t er s o ak i ng mai n body
i n a s ui t abl e sol v ent . Tes t ac c el er at o r
pump c apac i t y .
(c ) Di s as s emb l e c ar bur et or . Ch ec k a c -
c el er at or pump i nl et c h ec k bal l for
poor s eat or r el eas e. If par t i s f aul t y,
r ep l ac e.
(d) Tes t f uel or fl oat l evel i n c ar bur et or .
Ad j u s t a s nec es s ar y to obt ai n c o r r ec t
fl oat l ev el .
(e) Di s as s emb l e c ar bur et or . Rep l ac e
wor n ac c el er at o r pump and t hr ot t l e
l i nkage and meas u r e for c or r ec t p o s i -
t i on.
(f) Fr ee up mani f ol d heat c ont r ol v al v e;
u s i ng r ec o mmend ed s ol v ent .
(g) Tes t power pi st on oper at i on.
(h) Res et t i mi ng .
(i ) Res et pump.
(a) Di s as s emb l e c ar bur et or . Rep l ac e
c r ac k ed body. Make s u r e mai n to
t hr ot t l e body s c r ews ar e t i g h t
Condition Possible Cause Correction
POOR P ERF ORMANC E
MI XTURE TOO RI CH
POOR COL D ENGI NE
STARTI NG I NCORRECT
P ROC EDURE
C HOK E VAL VE F AI L S
TO C L OS E
L OW ENGI NE OUTPUT
( 10 F or l ower)
(b) Faul t y body g as k et s .
(c ) Hi gh fl oat l ev el .
(d) Worn needl e v al v e and s eat .
(e) Ex c es s i v e f uel pump p r es s u r e.
(a) Res t r i c t ed ai r c l eaner .
(b) L eak i ng fl oat .
(c ) Hi gh fl oat l ev el .
(d) Ex c es s i v e f uel p u mp p r es s u r e.
(e) Worn met er i ng j et .
(a) ( See owner ' s Manual . )
(b) Di s as s emb l e c ar bur et or . Rep l ac e d e-
f ec t i v e g as k et s and t es t for l eak ag e.
B e s u r e s c r ews ar e t i ght ened s e -
c ur el y .
(c ) Tes t f uel l evel i n c ar bur et or . Mak e
nec es s ar y ad j u s t ment to obt ai n c or -
r ec t f l oat l ev el .
(d) Cl ean and i ns p ec t need l e v al v e and
s eat : If f ound t o be i n a ques t i onabl e
c ondi t i on, r ep l ac e c o mp l et e as s emb l y
and t es t f uel pump p r es s u r e. Ref er
t o Sp ec i f i c at i o ns for c o r r ec t f uel
pump p r es s u r e.
(e) Tes t f uel pump p r es s u r e. If p r es s u r e
i s i n ex c es s of r ec o mmend ed p r es -
s u r e (r ef er t o Sp ec i f i c at i o ns ) , r ep l ac e
f uel pump.
(a) Remov e and c l ean ai r c l eaner .
(b) Di s as s emb l e c ar bur et or . Rep l ac e
l eak i ng fl oat . Tes t fl oat l evel and c or
r ec t a s nec es s ar y , t o pr oper l ev el .
(c ) Adj us t fl oat l evel a s nec es s ar y t o s e
c u r e pr oper l ev el .
(d) Tes t f uel pump p r es s u r e. Ref er t o
s pec i f i c at i ons for r ec o mmend ed pr es -
s u r e. If p r es s u r e i s i n ex c es s of r ec -
o mmend ed p r es s u r e, r epl ac e f uel
pump as s emb l y .
(e) Di s as s emb l e c ar bur et or . Rep l ac e
wor n met er i ng j et , u s i ng a new j et of
c or r ec t s i ze and t ype.
(a) Inst r uc t owner .
(a) Chok e t her mos t at ad j u s t ment l eaner (a) Adj us t ,
t han s p ec i f i ed .
(b) Ch o k e t her mos t at c or r oded s u c h t hat (b) Rep l ac e as s emb l y ,
it h as c r ac k ed and di st or t ed l ean.
(c ) Chok e l i nkage, s haf t or r el at ed par t s (c ) Repai r , c l ean or r ep l ac e,
c or r oded, bent or di r t y s u c h t hat s y s -
t em i s not ent i r el y f r ee t o move f r om
open to c l o s ed posi t i on.
(d) Chok e v al v e i mpr oper l y s eat ed . (d) Res eat v al v e.
(e) Ai r c l eaner i nt er f er s wi t h c h o k e s h af t (e) Rot at e c l eaner t o c o r r ec t posi t i on,
i ns t r uc t owner ,
i nt er f er s wi t h (f) Rei ns t al l g as k et pr oper l y.
or l i nkage.
(f) Ai r c l eaner g as k et
c hok e v al v e or l i nkage.
(g) Sp r i ng s t ag i ng s p r i ng di st or t ed or (g) Rep l ac e or i nst al l new s pr i ng ,
mi s s i ng .
(a) Eng i ne l ubr i c at i ng oi l i nc or r ec t v i s - (a) Rec o mmend 5W-20.
c os i t y .
(b) Ch o k e t her mos t at ad j u s t ment i nc or - (b) Adj us t t o c or r ec t s et t i ng ,
r ec t , r i c h.
ENGI NE RUNS LEAN, FI RST HALF MI LE
CHOK E L EAN (a) Rev i ew i t ems under (Poor St ar t i ng).
(b) Di aphr agm ad j u s t ment l ean.
(a) See " Ch o k e Val v e Fai l s t o Cl o s e. "
(b) Read j u s t t o s p ec i f i c at i o n.
ENGI NE RUNS LEAN AFTER HALF MI LE
ENGI NE HEAT (a) Heat v al v e s t u c k o p en. (a) Fr ee wi t h s ol v ent .
I NSUF F I CI ENT (b) Heat v al v e t her mos t at di s t or t ed. (b) Rep l ac e t her mos t at .
14-6 F UEL SYSTEMB B D-
Condition Possible Cause Correction
CARBURETOR
MI XTURES LEAN
(c) Heat v al v e f ai l ed wi t hi n ex h au s t Se e
engi ne s ec t i o n for pr oper di ag nos i s .
(d) Wat er t emper at ur e s u b no r mal .
(a) Ai r l eak b y p as s i ng t he c ar bur et or .
(b) Car bur et or h as ec o no my met er i ng
s y s t em.
ENGINE RUNS EXCESSIVELY RICH AFTER COLD START
CHOKE SYSTEM RICH
CARBURETOR RICH
(a) Ch o k e t her mos t at ad j u s t ment r i c her
t han s p ec i f i ed .
(b) Ch o k e v ac u u m di aphr ag m i noper at i ve
or mi s ad j u s t ed .
(c ) Chok e v ac u u m p as s ag e bl oc k ed or
l eaki ng.
(a) Inc or r ec t g as k et or g as k et i nst al l at i on
bet ween c ar bur et or and i nt ake mani -
f ol d.
(c ) Rep l ac e h eat v al v e.
(d) Ch ec k t her mos t at .
(a) Repai r .
(b) Inf or m c u s t o mer .
(a) Cor r ec t .
(b) Cor r ec t or r ep l ac e.
(c ) Cor r ec t .
(a) Rep l ac e or c or r ec t .
EXCESSIVE STALLS AFTER COLD START
CHOKE SYSTEM LEAN
ENGI NE OUTPUT LOW
CARBURETOR LEAN
(a) Rev i ew i t ems under " Poor St ar t i ng-
Ch o k e Val v e Fai l s t o Cl o s e. "
(b) Ch o k e v ac u u m di aphr ag m ad j u s t ment (b) Adj us t t o Sp ec i f i c at i o n,
l ean.
(a) Fas t i dl e s p eed l ow. (a) Ad j u s t t o Sp ec i f i c at i o n.
(b) Fas t i dl e c a m posi t i on ad j u s t ment (b) Adj us t t o Sp ec i f i c at i o n,
i nc or r ec t .
(c ) Eng i ne l ubr i c at i on oi l of i nc or r ec t (c ) Rec o mmend ed 5W-20.
v i s c os i t y .
(d) Inc or r ec t t i mi ng. (d) Res et t i mi ng.
(a) Cu r b i dl e s et ver y l ean. (a) Adj us t .
(b) Ai r l eak b y p as s i ng t he c ar bur et or . (b) Repai r .
BBD SERIES CARBURETORS (W*)
INDEX
Pag e
Aut omat i c Ch o k e (wel l t ype) 1
Car bur et or Ad j u s t ment s . . . . . . 11
Ac c el er at or Pu mp and B owl Vent 11-13
Ch o k e Unl o ad er (Wi de Open K i c k ) 12
Ch o k e Vac u u m K i c k 12
Fas t Idl e Ca m Posi t i on . 11
Fas t Idl e Sp eed (On Veh i c l e) 14
GENERAL INFORMATION
Pag e
Idl e Sp eed Adj us t ment 13
Cl eani ng Car bur et or Par t s 1
Cl o s ed Cr ank c as e Vent Sy s t em . . . ( Eng i ne Gr oup)
Di s as s emb l i ng Car bur et or 7
Ins pec t i on and Reas s emb l y 9
Sp ec i f i c at i o ns . . . . 65
Th e B a l l and B a l l d u al t hr oat 1-1/2 i nc h Car b u r et o r
Model C. A. S. ( Cl eaner Ai r Sy s t em) B B D-4725S, B B D-
4726S and B B D-4894S ar e u s ed on t he 383c u . i n. En -
g i nes wh en t he v eh i c l es ar e eq u i p p ed wi t h manu al o r
aut omat i c t r ans mi s s i o ns r es p ec t i v el y ( Fi g . 1). B B D-
4726S i s u s ed onl y on v eh i c l es wi t hout ai r c ondi t i on-
i ng wh i l e B B D-4894S i s u s ed onl y on v eh i c l es wi t h ai r
c ondi t i oni ng . Th i s c ar b u r et o r i s eq u i p p ed wi t h a hot
i d l e c o mp ens at o r v al v e, wh i c h i s a t h er mo s t at i c al l y
o p er at ed ai r b l eed , t o r el i ev e an o v er r i c h c ondi t i on at
i dl e. Th i s c ondi t i on i s t he r es u l t of ex c es s i v e h eat and
r es u l t ant o v er r i c h mi x t u r es . Th es e t h r ee c ar b u r et o r s
ar e al s o eq u i p p ed wi t h a di s t r i but or g r o u nd s wi t c h ,
wh i c h r et ar d s t he di s t r i but or wh en t he c ar b u r et o r i s
at c u r b i dl e, f o r bet t er emi s s i o n c o nt r o l .
Th e B a l l and B a l l d u al t hr oat 1-1/2 i nc h c ar b u r et o r
mo d el s E. C . S. ( Ev ap o r at i o n Co nt r o l Sy s t em) B B D-
4727S and B B D-4728S ar e u s ed on t he 383 c u . i n. en-
g i nes wh en t he v eh i c l es ar e eq u i p p ed wi t h manu al
and aut omat i c t r ans mi s s i o ns r es p ec t i v el y ( Fi g . 2). B o t h
A
BBDFUEL SYSTEM 14-7
of t hes e c ar b u r et o r s ar e eq u i p p ed wi t h a hot i dl e c o m-
pens at or v al v e wh i c h i s a t h er mo s t at i c al l y oper at ed
ai r b l eed t o r el i ev e an o v er r i c h c ondi t i on at i dl e. Th i s
c ondi t i on i s t he r es u l t of ex c es s i v e h eat and r es u l t ant
o v er r i c h mi x t u r es . Th es e t wo c ar b u r et o r s ar e al so
eq u i p p ed wi t h a di s t r i but or g r o u nd s wi t c h , wh i c h r e-
t ar ds t he di s t r i but or wh en t he c ar b u r et o r i s at c u r b
i dl e, f or bet t er emi s s i o n c ont r ol .
Si nc e t he s er v i c e p r o c ed u r es ar e i d ent i c al o n al l
B B D c ar b u r et o r s , t he i l l us t r at i ons s h o wi ng t he v ar i -
ous d i s as s emb l y p r o c ed u r es wi l l not al way s s h o w any
one s pec i f i c c ar b u r et o r .
Th e B a l l and B a l T m ^ d o w n -
dr af t t y pe. Ea c h t hr oat h as i t s o wn t hr ot t l e v al v e, and
mai n met er i ng s y s t ems and ar e s u p p l ement ed b y t he
float, ac c el er at i ng , i d l e and p o wer s y s t ems .
On eac h B B D s er i es c ar b u r et o r , t h e mo d el nu mb er
i s s t amp ed on met al t ag at t ac h ed t o ai r h o r n. Do not
r emo v e or des t r oy t hi s t ag , as i t i s t he onl y means
p r o v i d ed f or c ar b u r et o r mo d el i dent i f i c at i on. B ef o r e
at t empt i ng t o r ep ai r or o v er h au l c ar b u r et o r , r ef er t o
mo d el nu mb er and s ec u r e a r ep ai r k i t f or nu mb er
i nd i c at ed on t ag.
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Figs. 1 or 2.)
(1) Ins er t t hr ee To o l T-109-287S and one To o l T-
109-288S el ev at i ng l egs t h r o u g h c ar b u r et o r t hr ot t l e
body s t u d hol es . ( Thes e t ool s ar e u s ed t o pr ot ec t
t hr ot t l e v al v es f r o m damag e and t o p r o v i d e a s ui t abl e
bas e f or wor k i ng . )
(2) Remo v e h ai r p i n c l i p and d i s eng ag e f as t i dl e
c o nnec t o r r o d f r o m f as t i dl e c am and c h o k e l ev er .
(3) Remo v e h ai r p i n c l i p and di s eng ag e ac c el er at o r
r od f r o m t hr ot t l e l ev er and p u mp r o c k er ar m.
(4) Remo v e v ac u u m hos e b et ween c ar b u r et o r t hr ot -
t l e body f i t t i ng and v a c u u m d i ap h r ag m.
(5) Remo v e c l i p f r o m c h o k e o p er at i ng l i nk and di s-
eng ag e l i nk f r o m d i ap h r ag m p l u ng er and c h o k e l ev er .
( Fi g s . 1 or 2).
(6) Remo v e v ac u u m d i ap h r ag m and b r ac k et as s em-
bl y and pl ac e to one s i d e, t o be c l eaned as a s p ec i al
i t em. A liquid cleaner may d amag e t he d i ap h r ag m
material.
(7) Remo v e s c r ews t hat at t ac h hot i dl e c ompens at or
v al v e c o v er to mai n body. Remo v e c o v er and l i f t out
hot i dl e c o mp ens at o r v al v e and g as k et ( Fi g . 3).
(8) Remo v e ai r h o r n r et ai ni ng s c r ews and l i f t ai r
ACCELERATOR PUMP
ROCKER ARM
ACCELERATOR
BOWL VENT
P U M P
VALVE
AIR
HORN
DISTRIBUTOR GROUND
SWI TCH TERMINAL
CHOKE LEVER
FUEL INLET
NEEDLE, VALVE, '
SEAT f MAIN
AND GASKET f BODY
IDLE LIMITER CAP (2)
(IDLE MIXTURE ADJ USTI NG
SCREWS 2)
FAST IDLE
CONNECTOR ROD
CHOKE OPERATI NG
LINK
DI APHRAGM
STEM
CURB IDLE SPEED
ADJ USTI NG SCREW
CHOKE VALVE
CHOKE VACUUM * *
DIAPHRAGM ^
CHOKE VACUUM '
HOSE
FAST IDLE
CAM
THROTTLE LEVER
UNLOADER TANG
t
CLOSED CRANKCASE
VENT TUBE FITTING
IDLE LIMITER CAP (2)
(IDLE MIXTURE ADJ USTI NG
SCREWS 2)
DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
ACCELERATOR PUMP
ROD PY498
Fi g. f-Carburetor Assembly (BBB-1-1/ 2 inch) C.A.S.
14-8 FUEL SYSTEMBBD
A
CHOKE VALVE
FAST IDLE SPEED
ADJ USTI NG SCREW
BOWL VENT
VALVE COVER
CHOKE OPERATI NG
LINK
BOWL VENT
VALVE VENT
TUBE FITTING
ACCELERATOR PUMP
ROCKER ARM
/
CURB IDLE
SPEED
ADJ USTI NG
SCREW
AIR CLEANER TO
CARBURETOR
VACUUM
TUBE FITTING
CLOSED CRANKCASE
VENT TUBE
FITTING
CHOKE VALVE
BOWL VENT
VALVE COVER
BOWL VENT VALVE
VENT TUBE
AIR HORN
CHOKE LEVER
MAI N BODY
FUEL INLET""*""'*
NEEDLE, VALVE, SEAT
AND GASKET
ACCELERATOR PUMP
ARM
FAST IDLE
CONNECTOR ROD
DISTRIBUTOR
^ j ;
ground
SWITCH
TERMINAL
IDLE LIMITER CAP (2)
(IDLE MIXTURE ADJ USTI NG
SCREWS 2)
DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
CHOKE VACUUM
DI APHRAGM
THROTTLE BODY
FAST IDLE
CAM
THROTTLE LEVER
UNLOADER TANG
ACCELERATOR PUMP
ROD
PY499
Fig. 2Carburetor Asset
h o r n s t r ai g ht u p and away f r o m mai n body . Di s c a r d
g as k et (2 s c r ews r ec es s ed ) .
(9) Di s eng ag e ac c el er at o r p u mp p l u ng er f r o m ac -
c el er at o r p u mp a r m b y p u s h i ng u p on bot t om of
p l u ng er and s l i d i ng p l u ng er s h af t off hook . Sl i d e
p l u ng er out of ai r h o r n and r emo v e c o mp r es s i o n
s p r i ng and s eat . Remo v e b o wl v ent v al v e c ov er .
If ol d p l u ng er c an be u s ed ag ai n o r i f a new p l u ng -
er i s t o be i ns t al l ed , p l ac e p l u ng er i n a j a r of c l ean
PY500
Fig. 3Removing or Installing Hot Idle
Compensator Valve
y (BBD 1-1/ 2 inch) F.C.S.
g as ol i ne o r k er o s ene t o p r ev ent l eat h er f r o m d r y i ng
out .
(10) Remo v e f u el i nl et need l e v al v e, s eat and g as k et
f r o m mai n body.
(11) L i f t out float f u l c r u m p i n r et ai ner , and l i f t out
floats and f u l c r u m p i n.
(12) Remo v e s t ep-up pi s t on and r et ai ni ng s c r ew
and s l i d e s t ep-up pi s t on and r ods out of wel l , ( Fi g . 4).
L i f t out s t ep-up pi s t on s p r i ng . Remo v e s t ep-up pi s t on
g as k et f r o m bot t om of wel l .
(13) Remo v e mai n met er i ng j et s ( Fi g . 5).
(14) Remo v e v ent u r i c l u s t er s c r ews , t h en l i f t v en-
t u r i c l u s t er and g as k et s u p and away f r o m mai n body ,
( Fi g . 6). Di s c ar d g as k et s . Do not remove idle orifice
Fig. 4Removing or Installing Step-Up Piston
A-
- B B DFUEL SYSTEM 14-9
SPECIAL TOO!,
MAIN -~-
METERING J ETS
3r it-tj
VENTURI CLUSTER
SCREWS
-VENTURI CLUSTER
NR380A
F i g . 5Removi ng or installing Main Metering J ets
tubes or mai n vent tubes from cluster. Th e y c an be
c l eaned i n a s ol v ent and d r i ed wi t h c o mp r es s ed ai r .
(15) Inv er t c ar b u r et o r and dr op out ac c el er at o r
p u mp d i s c h ar g e c h ec k b al l and i nt ak e c h ec k b al l .
( The i nt ak e c h ec k b al l i s t he l ar g es t . )
(16) Remo v e s c r ews t hat at t ac h t hr ot t l e body t o
mai n body. Sep ar at e t he bodi es and d i s c ar d g as k et .
(17) Remo v e pl as t i c l i mi t er c ap s f r o m i dl e ai r mi x -
t ur e s c r ews . (B e s u r e and c o u nt nu mb er of t u r ns t o
s eat t he s c r ews , as t he s ame nu mb er of t u r ns (f r om
t he seat ) mu s t be mai nt ai ned at i ns t al l at i on. ) Remo v e
s c r ews and s p r i ng s f r o m t hr ot t l e body .
Th e c ar b u r et o r no w h as b een d i s as s emb l ed i nt o
t hr ee s u b -as s emb l i es , t he ai r h o r n, mai n body and
t hr ot t l e body and t he c o mp o nent s of eac h d i s as s em-
bl ed as f ar as nec es s ar y f or c l eani ng and i ns p ec t i o n.
It i s u s u al l y not adv i s abl e t o r emo v e t he t hr ot t l e
s haf t or v al v es f r o m t he t hr ot t l e body , u nl es s wear or
damag e nec es s i t at es t he i ns t al l at i on of new p ar t s .
Th er e i s about . 005 i nc h c l ear anc e b et ween t he
t hr ot t l e s haf t and t he t hr ot t l e s haf t bor es i n t h e t hr ot -
t l e body. Any c l ear anc e o v er .010 i nc h , a new t hr ot t l e
s haf t a nd /o r t hr ot t l e body s h o u l d be i ns t al l ed .
INSPECTION AND REASSEMB L Y, .
Throttle Body
(1) Ins p ec t t he t hr ot t l e s haf t and t hr ot t l e body f o r
ex c es s i v e wear . If ei t h er or bot h ar e wo r n t o t he poi nt
wh er e t he c ar b u r et o r oper at i on wi l l be af f ec t ed, r e-
pl ac e as r eq u i r ed .
Du r i ng manu f ac t u r e, t he l oc at i on of t he i d l e t r ans -
f er por t and t he s p ar k ad v anc e c o nt r o l por t s t o t he
t hr ot t l e v al v e, i s c ar ef u l l y es t ab l i s h ed f or one p ar t i c u -
l ar as s emb l y , ( Fi g . 7).
If a new s haf t s h o u l d be i ns t al l ed i n an ol d, wo r n
t hr ot t l e body, i t wo u l d be v er y u nl i k el y t hat t he or i gi -
nal r el at i ons hi p of t he por t s t o t he v al v es wo u l d be
obt ai ned. Ch ang i ng t he r el at i o ns h i p of t he v al v es t o
t he por t s wo u l d ad v er s el y af f ec t no r mal c ar oper at i on
b et ween t he s p eed s of 15 and 30 mi l es p er h o u r . If i t
h as b een d et er mi ned , h o wev er , t hat a new s haf t or
VENTURI CtOSTER
CAP
GASKET
ACCELERATOR
PUMP DI SCHARGE
ACCELERATOR
PUMP DI SCHARGE
CHECK BALL
GASKET
NR381
Fi g. 6Removing or Installing Venturi Cluster
v al v es i s t o be i ns t al l ed , ad h er e t o t he f o l l o wi ng i n-
s t r uc t i ons :
(2) Mar k pos i t i on of t hr ot t l e v al v es i n bor es .
(3) Remo v e s c r ews t hat h o l d t hr ot t l e v al v es t o s haf t
and s l i de v al v es out of b o r es . These screws are
staked on the opposite side and care should be used at
removal so as not to break off in the shaft.
Remo v e t he s t ak ed end of t he s c r ews wi t h a file.
(4) Sl i d e t hr ot t l e s haf t and l ev er out of body .
(5) Ins t al l new t hr ot t l e s haf t and l ev er .
(6) Ins t al l t hr ot t l e v al v es i n t h ei r r es p ec t i v e b o r es
(wi t h v al v e nu mb er s t o war d mani f ol d) . Ins t al l new
s c r ews but do not t i g ht en. Ho l d v al v es i n p l ac e (f ul l y
c l o s ed posi t i on) wi t h fingers p r es s i ng on h i g h s i d es
of v al v es . Tap v al v es l i g ht l y wi t h a s c r ewd r i v er t o s eat
i n t hr ot t l e b o r es . Par t i al l y t i g ht en s c r ews . Ho l d u p t o
a s t r o ng l i g ht t o c h ec k f o r a p r o p er pos i t i on i n b o r e.
( Th ey may h av e t o be r ot at ed s l i g ht l y as t h e v al v es ar e
el i pt i c al . ) Wh e n p r o p er l y pos i t i oned t i g ht en s c r ews
s ec u r el y and s t ak e, u s i ng p l i er s .
(7) Ins t al l i d l e mi x t u r e s c r ews and s p r i ng s i n body.
( Th e t ap er ed p o r t i o n mu s t be s t r ai g ht and s moot h. If
t ap er ed por t i on i s g r o o v ed or r i d g ed , a new i dl e mi x -
t ur e s c r ew s h o u l d be i ns t al l ed t o i ns u r e h av i ng c or -
r ec t i dl e mi x t u r e c ont r ol . ) DO NOT USE A SCREW
DRI VER. T u r n s c r ews l i g ht l y ag ai ns t t h ei r s eat s wi t h
IDL E TRANSFER PORTS
r- - / V
SPARK
ADVANCE
PORT
w
\
0
:
!
' THROTTLE VAIVFS NR3B2
F i g . 7Ports in Relation to Throttle Valves
14-10 FUEL SYSTEMBUD*
fingers. B a c k off t he nu mb er of t u r ns c o u nt ed at di s -
as s emb l y . Ins t al l new p l as t i c c ap s wi t h t abs ag ai ns t
st op. Thi s s c r ew has a l ef t h and t hre a d . T ur n c ount er -
c l o c k wi s e ( Ri c h er ) and c l o c k wi s e (Leaner) .
Main Body
(1) Inv er t mai n body and p l ac e a new g as k et i n
pos i t i on and pl ac e t hr ot t l e body on mai n body and
al i g n. Ins t al l s c r ews and t i g ht en s ec u r el y .
(2) Ins t al l ac c el er at o r p u mp d i s c h ar g e c h ec k b al l i n
d i s c h ar g e pas s ag e and c h ec k ac c el er at o r p u mp s y s -
t em; f u el i nl et and d i s c h ar g e c h ec k b al l s as f ol l ows :
(3) Po u r c l ean g as ol i ne i nt o c ar b u r et o r b o wl , ap-
p r o x i mat el y 1/2 i nc h deep. Remo v e p u mp p l u ng er
f r o m j a r of g as ol i ne, flex l eat h er s ev er al t i mes , t h en
s l i d e d o wn i nt o p u mp c y l i nd er . Rai s e p l u ng er and
p r es s l i g ht l y on p l u ng er s haf t t o ex p el al l ai r f r o m
p u mp pas s ag e.
(4) Us i ng a s mal l c l ean b r as s r o d , h o l d d i s c h ar g e
c h ec k b al l d o wn firmly on i t s s eat . Ag ai n r ai s e p l u ng -
er and p r es s d o wnwar d . No f u el s h o u l d be emi t t ed
f r o m ei t h er i nt ak e o r d i s c h ar g e p as s ag e, ( Fi g . 8).
If any f u el does emi t f r o m ei t h er p as s ag e, i t i ndi -
c at es t he p r es enc e of d i r t or a d amag ed c h ec k b al l
s eat . Ch e c k t he p as s ag e ag ai n and r ep eat t est . If l eak -
age i s s t i l l ev i dent , i ns t al l a new c h ec k b al l . Th e f u el
i nl et c h ec k b al l i s l o c at ed at t he bot t om of t he p l u ng er
wel l .
(5) Ins t al l new g as k et s on v ent u r i c l u s t er , and i n-
s t al l i n pos i t i on i n mai n body . Ins t al l c l u s t er s c r ews
and t i g ht en s ec u r el y . Te s t p u mp d i s c h ar g e b y p r es s -
i ng p u mp p l u ng er d o wn. Tw o fine s t r eams of f u el
s h o u l d be f o r c ed f r o m c l u s t er . If ei t h er s t r eam i s
r es t r i c t ed or d i v er t ed , r emo v e c l u s t er and r ec l ean.
Af t er t est , p o u r f u el f r o m t he b o wl and r emo v e p u mp
p l u ng er .
(6) Ins t al l mai n met er i ng j et s . Ti g h t en s ec u r el y .
( Fi g . 5).
Fig. 3Testing Accelerator Pump Intake and
Discharge Check Balls
; , A
(7) B ef o r e i ns t al l i ng s t ep-up pi s t on, be s u r e s t ep-up
r o d s ar e abl e t o mov e f r eel y , eac h s i de of t he v er t i c al
pos i t i on, ( Fi g . 9). ( Th e s t ep-up r o d s mu s t be s t r ai g ht ,
s moot h and f r ee t o mov e f o r war d and b ac k war d f r o m
v er t i c al . )
(8) Sl i d e s t ep-pi s t on g as k et d o wn i nt o pos i t i on i n
pi s t on wel l , t h en i ns t al l t he st ep-up pi s t on s p r i ng ,
s t ep-up pi s t on and r o d s . Car ef u l l y g ui de st ep-up r o d s
i nt o mai n met er i ng j et s ( Fi g . 4). Ins t al l r et ai ni ng
s c r ew and t i g ht en s ec u r el y . Ch ec k pi s t on f or f r ee
oper at i on i n wel l .
A s t ep-up pi s t on s t u c k i n t he Up pos i t i on wi l l c au s e
a r i c h mi x t u r e at p ar t t hr ot t l e, wh er eas a pi s t on s t u c k
i n t he Down pos i t i on wi l l c au s e a l ean mi x t u r e at wi d e
open t hr ot t l e and poor ac c el er at i o n.
Measuring Float Setting
Th e c ar b u r et o r s ar e eq u i p p ed wi t h a r u b b er -t i p p ed
f u el i nl et needl e. Th e r u b b er t i p i s flexible eno u g h t o
mak e a good s eal on t he needl e s eat , and t o g i v e
i nc r eas ed r es i s t anc e t o flooding. Car e s h o u l d be t ak en
t o p er f o r m t hi s oper at i on ac c u r at el y i n o r d er t o s e-
c u r e t he bes t p er f o r manc e and f u el ec onomy .
(1) To c o r r ec t l y s et float hei g ht wh en c ar b u r et o r i s
b ei ng o v er h au l ed , i ns t al l floats wi t h f u l c r u m p i n and
p i n r et ai ner i n mai n body .
(2) Ins t al l r ubber -t i pped need l e, s eat and g as k et i n
body and t i g ht en s ec u r el y .
(3) Inv er t mai n body so t hat wei g h t of float onl y
i s f o r c i ng needl e ag ai ns t s eat . Ho l d finger ag ai ns t r e-
t ai ner t o f u l l y s eat f u l c r u m p i n.
(4) Us i ng To o l T-109-280 o r a " T " s c al e, meas u r e
float, ( Fi g . 10). Th e r e s h o u l d be 5/16 i nc h f r o m s u r f ac e
of f u el b o wl t o c r o wn of eac h float at c ent er .
If an ad j u s t ment i s nec es s ar y , h o l d t he floats on
bot t om of t he b o wl and b end float l i p t o war d o r away
f r o m needl e. Re c h e c k t he 5/16 i nc h s et t i ng ag ai n and
r ep eat t he l i p b end i ng oper at i on as r eq u i r ed .
CAUTI ON: Wh e n bending the float lip, do not allow
the lip to push against the needle as the synethetic
rubber tip can be compressed sufficiently to cause a
false setting which will affect correct level of fuel in
the bowl.
STEP-UP RODS
MUST MOVE
FREELY
NK617
Fig. 9Step-Up Rods Freeplay
A
BBDFUEL SYSTEM 14-11
FULCRUM PIN
RETAINER IN
POSITION
R OAT GAUGF ONLY WEIGHT OF FLOATS
NR384 AGAI NST INLET NEEDLE
Fig. I0Checking Float Setting
Af t er bei ng c o mp r es s ed , t he t i p i s v er y s l ow t o r e-
c o v er i t s or i g i nal s h ap e.
CAUTI ON: It is very important that the float lip be
perpendicular to the needle or slanted not more than
ten degrees away from the needle when the float
height is correct.
Air Horn
(1) Tes t f r eenes s of c h o k e mec h ani s m i n ai r h o r n.
Th e c hok e s haf t mu s t fl oat f r ee t o oper at e c o r r ec t l y .
If c hok e s haf t s t i c k s i n b ear i ng ar eas , or ap p ear s
t o be g u mmed f r o m depos i t s i n ai r h o r n, a t hor oug h
c l eani ng wi l l be r eq u i r ed .
(2) Remo v e ac c el er at o r p u mp p l u ng er f r o m gaso-
l i ne, s l i de c o mp r es s i o n s p r i ng and s p r i ng s eat ov er
s haf t . Ins t al l as s emb l y i n ai r h o r n and engage wi t h
ac c el er at o r p u mp ar m.
(3) Pl ac e a new g as k et on mai n body , and i ns t al l ai r
h o r n. Ins t al l at t ac h i ng s c r ews and t i g ht en s ec u r el y .
( Wh en i ns t al l i ng ai r h o r n, be s u r e l eat h er on pl ung -
er does not wr i nk l e or f ol d bac k . )
(4) Eng ag e ac c el er at o r p u mp r o d wi t h p u mp r o c k er
ar m and i ns t al l l oos e end i n out er hol e of t hr ot t l e
l ev er . Ins t al l h ai r p i n c l i p t o s ec u r e ( Fi g . 1).
(5) Eng ag e f as t i dl e c o nnec t o r r o d (l oop at t op) i n
f ast i dl e c am and i n s l ot t ed c h o k e l ev er . Ins t al l r et ai n-
i ng c l i p s t o s ec u r e.
(6) Ins t al l hot i dl e c o mp ens at o r v al v e g as k et i n pos i -
t i on i n r ec es s i n mai n body , f ol l owed by v al v e. (B e s u r e
v al v e i s pos i t i oned wi t h l eg s t o war d out s i de of mai n
body.) ( Fi g . 3). Pl ac e c o v er ov er openi ng and i ns t al l
at t ac hi ng s c r ews . Ti g h t en s ec u r el y . (If so equi pped) .
Choke Vacuum Diaphragm
Ins p ec t t he d i ap h r ag m v ac u u m fitting t o be s u r e
t hat t he pas s ag e i s not p l u g g ed wi t h f o r ei g n mat er i al .
L e a k c h ec k t he d i ap h r ag m t o d et er mi ne i f i t h as i n-
t er nal l eak s . To do t hi s , first d ep r es s t he d i ap h r ag m
s t em, t hen pl ac e a finger o v er t he fitting t o s eal t he
openi ng . Rel eas e t he s t em. If t he s t em mo v es mo r e
t h an 1/16 i nc h i n t en (10) s ec o nd s , t he l eak ag e i s
ex c es s i v e and t he as s emb l y mu s t be r ep l ac ed .
Ins t al l t he d i ap h r ag m as s emb l y on t he ^ h o f n ~a s
f ol l ows :
(1) As s emb l e d i ap h r ag m t o ai r h o r n and t i g ht en
at t ac h i ng s c r ews s ec u r el y .
(2) I ns t al l c h o k e oper at i ng l i nk i n pos i t i on b et ween
d i ap h r ag m p l u ng er (st em) and c h o k e l ev er . Ins t al l
c l i p t o s ec u r e.
(3) Ins p ec t r u b b er hos e f o r c r ac k s bef or e p l ac i ng i t
on c o r r ec t c ar b u r et o r fitting. ( Fi g . 1). Do not c o nnec t
v ac u u m hos e t o d i ap h r ag m fitting u nt i l af t er v ac u u m
k i c k ad j u s t ment h as b een mad e. (See Car b u r et o r Ad -
j u s t ment s . )
CARBURETOR ADJ USTMENTS
It i s v er y i mp o r t ant t hat t he f ol l owi ng ad j u s t ment s
ar e mad e on a r ec o nd i t i o ned c ar b u r et o r and i n t he
s eq u enc e l i s t ed :
Accel erator Pump
(1) B a c k off i dl e s peed ad j u s t i ng s c r ew. Op en
c h o k e v al v e so t hat f as t i dl e c a m al l ows t hr ot t l e v al v es
t o be c o mp l et el y s eat ed i n bor es . B e s u r e t hat p u mp
c o nnec t o r r o d i s i ns t al l ed i n out er hol e of t hr ot t l e
l ev er .
(2) Cl o s e t hr ot t l e v al v es t i ght l y . Meas u r e t he di s-
t anc e b et ween t op of ai r h o r n and end of p l u ng er
s haf t , ( Fi g . 11). Th i s meas u r ement s h o u l d be 1 i nc h .
(3) To ad j u s t p u mp t r av el , b end p u mp oper at i ng
r o d u s i ng To o l T-109-213, at l o wer ang l e of r o d ,
u nt i l c o r r ec t s et t i ng h as b een obt ai ned.
Fast Idle Speed and Cam Position Adjustment
T h e f as t i dl e eng i ne s p eed ad j u s t ment s h o u l d be
mad e on t he v eh i c l e, as d es c r i b ed i n t he F a s t Id l e
Sp eed Ad j u s t ment (On t he Veh i c l e) Par ag r ap h . How-
fig. 11Checki ng Accelerator Pump Setting
14-12 FUEL SYSTEMBBD
A
ev er , t he F a s t Id l e Ca m Po s i t i o n Ad j u s t ment c an be
mad e on t he bench. Th i s ad j u s t ment i s i mp o r t ant t o
as s u r e t ha t t he speeds of eac h s t ep of t he c am occur
at t he prope r t i me d ur i n g eng i ne war m- up.
(1) W i t h f ast i dl e speed a d j us t i ng screw cont act i ng
second hi ghest speed step on f ast i d l e cam, mo v e
choke val ve t owa rd cl osed pos i t i on w i t h l i ght pressure
on choke shaf t l ev er .
(2) I ns e rt speci f i ed d r i l l (see speci f i cati ons) be-
t ween c h o k e val ve a nd wal l of ai r horn . An ad j u s t -
ment wi l l be nec es s ar y i f a s l i g ht d r ag i s n ot obt ai ned
as d r i l l i s b ei ng r emo v ed .
(3) If an ad j u s t ment i s nec es s ar y , b end f ast i dl e c on-
nec t o r r o d at l o wer ang l e, u s i ng To o l T109-213, u nt i l
c o r r ec t v al v e openi ng h as b een obt ai ned ( Fi g . 12).
Va c u u m K i c k Ad j u s t me nt Th i s t es t c an be mad e
ON or O F F v eh i c l e.
Th e c h o k e d i ap h r ag m ad j u s t ment c ont r ol s t he f u el
d el i v er y wh i l e t he eng i ne i s r u nni ng . It pos i t i ons t he
c h o k e v al v e wi t h i n t he ai r h o r n b y ac t i on of t he l i nk -
age b et ween t he c h o k e s haf t and t he d i ap h r ag m. Th e
d i ap h r ag m mu s t be ener g i zed t o meas u r e t he v ac u u m
k i c k ad j u s t ment . Us e ei t her a d i s t r i b u t o r t est mac h i ne
wi t h a v ac u u m s o u r c e, or v ac u u m s u p p l i ed b y t he
v eh i c l e.
(1) If ad j u s t ment i s t o be mad e wi t h eng i ne r u n-
ni ng , d i s c o nnec t f as t i dl e l i nk ag e t o al l ow c h o k e t o
c l os e t o t he k i c k pos i t i on wi t h eng i ne at c u r b i d l e. If
an au x i l i ar y v ac u u m s o u r c e i s t o b e u s ed , open t hr ot -
t l e v al v es (engi ne not r u nni ng ) and mo v e c h o k e t o
c l o s ed pos i t i on. Rel eas e t hr ot t l e first, t h en r el eas e
c h o k e.
(2) Wh e n u s i ng an au x i l i ar y v ac u u m s o u r c e, di s-
c o nnec t v ac u u m hos e f r o m c ar b u r et o r and c o nnec t i t
t o hos e f r o m v ac u u m s u p p l y wi t h a s mal l l eng t h of
t ube t o ac t as a fitting. Remo v al of hos e f r o m di a-
p h r ag m may r eq u i r e f o r c es wh i c h damag e t he s y s -
- DRILL OR GAUGE
>CHOKE VALVE
BEND FAST IDLE
CONNECTOR ROD
AT ANGLE
LIGHT CLOSING PRESSURE
AGAINST CHOKE LEVER
FAST IDLE SPEED
<*
y
S ADJUSTING SCREW
ON SECOND STEP
AND AGAINST FACE
OF NEXT STEP OF
FAST IDLE CAM
PY502
t er n. Ap p l y a v ac u u m of 10 or mo r e i nc h es of mer -
c u r y .
(3) Ins er t s pec i f i ed d r i l l ( r ef er t o Spec i f i c at i ons ) be-
t ween c h o k e v al v e and wal l of ai r h o r n ( Fi g . 13).
Ap p l y suf f i c i ent c l o s i ng p r es s u r e on l ev er t o wh i c h
c h o k e r o d at t ac hes t o pr ov i de a mi ni mu m c h o k e
v al v e openi ng wi t hout di s t or t i on of d i ap h r ag m l i nk .
Not e t hat t he c y l i nd r i c al s t em of d i ap h r ag m wi l l
ex t end as i nt er nal s p r i ng i s c o mp r es s ed . Th i s s p r i ng
mu s t be f u l l y c o mp r es s ed f o r p r o p er meas u r ement of
v ac u u m k i c k ad j u s t ment .
(4) An ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag
i s not obt ai ned as d r i l l i s b ei ng r emo v ed . Sh o r t en or
l eng t h en d i ap h r ag m l i nk t o obt ai n c o r r ec t c h o k e open-
i ng . L eng t h c h ang es s h o u l d be mad e c ar ef u l l y by
b end i ng (open o r c l os i ng ) t he b end p r o v i d ed i n di a-
p h r ag m l i nk . C AUT I ON : DO NOT A P P L Y T WI ST -
I NG OR BENDI NG FORCE TO DI APHR AGM.
(5) Rei ns t al l v ac u u m hos e on c o r r ec t c ar b u r et o r fit-
t i ng . Ret u r n f as t i dl e l i nk ag e t o i t s o r i g i nal c ondi t i on
i f d i s t u r b ed as s ug g es t ed i n St ep No. 1.
(6) Mak e f ol l owi ng c h ec k . Wi t h no v ac u u m appl i ed
t o d i ap h r ag m, t he C HO K E V A L V E S HOUL D MOV E
F R E E L Y b et ween open and c l o s ed pos i t i ons . If mov e-
ment i s not f r ee, ex ami ne l i nk ag e f or mi s al i g nment
or i nt er f er enc es c au s ed by b end i ng oper at i on. Rep eat
ad j u s t ment i f nec es s ar y t o pr ov i de p r o p er l i nk oper a-
t i on.
C h o k e Unlmader (Wide Open Kick)
Th e c h o k e u nl o ad er i s a mec h ani c al d ev i c e t o par -
t i al l y open t he c h o k e v al v e at wi d e open t hr ot t l e. It
i s u s ed t o el i mi nat e c h o k e enr i c h ment d u r i ng c r ank -
i ng of an eng i ne. Eng i nes wh i c h h av e b een flooded or
s t al l ed b y ex c es s i v e c h o k e enr i c h ment c an be c l ear ed
LIGHT CLOSING
PRESSURE AGAINST
CHOKE LEVER
DRILL OR GAUGE
CHOKE VALVE
-CHOK E OPERATING
LINK
TO
VACUUM
SOURCE
DIAPHRAGM STEM
RETRACTED
APPLY 10 OR MORE
INCHES OF VACUUM
ON DIAPHRAGM
PY503
Fig. 12Fast Idle Cam Position Adjustment
Fig. 13Checking Choke Vacuum Kick Setting
(Wide Open Kick)
- BBDFUEL SYSTEM 14-13
b y u s e of t he u nl o ad er . Ad j u s t t he c h o k e u nl o ad er as
f ol l ows :
(1) Ho l d t hr ot t l e v al v es i n wi d e open pos i t i on. In-
s er t s pec i f i ed d r i l l (see Spec i f i c at i ons ) b et ween u p p er
edge of c h o k e v al v e and i nner wal l of ai r h o r n. ( Fi g .
14).
(2) Wi t h a finger l i g h t l y p r es s i ng ag ai ns t s haf t l ev -
er , a s l i g ht d r ag s h o u l d b e f el t as d r i l l i s b ei ng wi t h-
d r awn. If an ad j u s t ment i s nec es s ar y , b end u nl o ad er
t ang on t hr ot t l e l ev er u nt i l c o r r ec t o p eni ng has b een
obt ai ned ( Fi g . 15). Us e To o l T109-214.
Bowl Vent Adjustment (EXS.)
(1) Op en c h o k e v al v e so t hat f as t i dl e c am al l ows
v al v es t o c l o s e, ( c ur b i dl e).
(2) B e s u r e t hat p u mp oper at i ng r o d i s i n l ong
s t r ok e hol e i n t hr ot t l e l ev er . Remo v e b o wl v ent v al v e
c ov er i f not p r ev i o u s l y done.
(3) Cl os e t hr ot t l e v al v es t i ght l y . Us i ng a nar r o w
r u l er , meas u r e t he d i s t anc e f r o m t op of b o wl v ent
v al v e r u b b er t i p, t o t op of ai r h o r n c as t i ng ( Fi g . 16).
Th i s meas u r ement s h o u l d be 5/32 i nc h .
(4) If an ad j u s t ment i s nec es s ar y , b end bowl v ent
l i f t ar m, u s i ng a s ui t abl e t ool , u nt i l c o r r ec t openi ng
h as been obt ai ned. ( WARNI NG: DO NOT B END B OWL
V ENT V A L V E L EA F S P RI NG DURI NG B ENDI NG
OP ER AT I ON OR I MP ROP ER V ENT V A L V E OP ER-
AT I ON WI L L R ES UL T . ) Ins t al l bowl v ent v al v e c o v er
and s ec u r e wi t h at t ac h i ng s c r ews .
(5) On C.A.S. carburetors, wi t h t he t hr ot t l e v al v es
c l o s ed , (c ur b i dl e), t h er e s h o u l d be 1/16 i nc h c l ear -
anc e bet ween b o wl v ent v al v e and s eat on ai r h o r n
( Fi g . 16). ( Wh en meas u r ed at out er mos t or l ar g es t
d i mens i o n wi t h a d r i l l s h ank ) .
(6) If an ad j u s t ment i s nec es s ar y , b end v ent v al v e
l i f t er ar m u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
Idle Speed Adjustment (Curb Idle)
Ref er t o Gener al Inf o r mat i o n at F r o nt of Sec t i o n.
CHOKE LEVER
LIGHT CLOSING
PRESSURE AGAINST
CHOKE LEVER V
/
BEND UNLOADER TANG
ON THROTTLE LEVER
(FIGS. 1 OR 2)
DRILL OR GAUGE
CHOKE VALVE
^t ^*- ^ 'J ? PY504
Fig. 14Checking Choke Unloader Setting
UNLOADER
TANG ON
THROTTLE LEVER
V x SPECIAL TOOL
Fig. 15Bending Choke Unloader Tang
PY517
Measuring Float Setting (On Vehicle)
(1) Remo v e h ai r p i n c l i p and di s eng ag e ac c el er at o r
p u mp r o d f r o m t hr ot t l e l ev er and p u mp r o c k er ar m.
Di s c o nnec t aut omat i c c h o k e r o d b y u ns nap p i ng c l i p .
(2) Remo v e ai r h o r n at t ac hi ng s c r ews and l i f t
ai r h o r n s t r ai g h t u p and away f r o m mai n body . Re -
mo v e g as k et .
(3) Set float f u l c r u m p i n b y p r es s i ng a finger ag ai ns t
f u l c r u m p i n r et ai ner .
Th e r e s h o u l d be eno u g h f u el i n t he b o wl t o r ai s e
floats so t hat t he l i p b ear s firmly ag ai ns t need l e. Ad -
di t i onal f u el may be admi t t ed by s l i g ht l y d ep r es s i ng
BOWL VENT VA.VE LIFT ARM
1
SCALE OR RULE- ^3g
TOP EDGE OFv J *
AIRHORN X | H
CASTING
BOWL VENT T I T v # * m
VALVE mJ ^^mzz, ^J ^J *J S%>
r
VENT VALVE LEAF SPRING^ '
;
W " * /
S E A T - *f3- ~~M.'
BOWL VENT
.DRILL OR GAUGE j
BEND SHi FT^W^/ . ^N
ARM FOR ^f * ^ f c / k
BOWL VENT*^
ADJUSTMENT
(CA.S.)
CARBURETORS
'THROTTLE-:
HELDCLOSED
CURB IDL~
v~
V
PY518
Fig. 16Measuring Bowl Vent Valve Opening
(CJ LS^tXA)
14-14 FUEL SYSTEMHOLLEY 2200
float. I f f uel ., pressure i n t he l i n e i s i nsuf f i ci ent t o
f orce a d d i t i ona l f ue l i n t o bowl , a d d n ec essa r y f u e l
f r om a cl ean cont ai ne r.
WARNI NG: Since t he ma ni f ol d may be hot , i f i s d an-
gerous f s pi l l fuel o n t o these su r f a c es. Take t he nec-
essary p r e c a u t i o n s t o a v o i d sp i l l a g e.
(4) Wi t h onl y pressure f r o m buoya nt float h o l d i ng
l i p agai nst i n l e t needl e, check float s et t i ng , us i ng To o l
T-109-280, or a " T " sc al e. The re s houl d be 5/16 i n ch
f r om surf ace o f bow l (gasket r e m o v e d ) t o crown of
floats at cent er.
I f an a dj us t me nt i s nec es s ar y , hol d t he floats on t he
bot t om of t he bowl , t he n be nd t he float l i p t owa rd or
a w a y f r om t he needl e. Rec h ec k t he 5/16 i n ch s et t i ng
agai n, t he n repeat t he l i p bendi ng, ope ra t i on as re -
q ui re d . Whe n be ndi ng t he float l i p, do not al l ow t he
l i p t o push agai nst t he needl e as t he r u b b er t i p can be
compressed su f f i c i en tl y tcause a f a l se se t t i n g whi ch
w i l l a f f ec t c o r r e c t l evel of f ue l i n t he b o w l , Af t e r
be i ng compressed, t he rubber tip is very slow to re-
cover its original shape. It is very important that the
float lip be perpendicular to the needle or slanted not
more than 10 d eg r ees sway from the needle when the
float is set correctly.
(5) Af t er float h as b een c o r r ec t l y s et , r eas s emb l e
t he ai r h o r n.
Fast Idle Speed Adjustment (On Vehicle)
F a s t i d l e eng i ne s p eed i s u s ed t o o v er c o me c o l d
eng i ne f r i c t i o n, s t al l s af t er c o l d s t ar t s and s t al l s be-
c au s e of c ar b u r et o r i c i ng . Set t hi s ad j u s t ment af t er
t h e v eh i c l e odomet er i nd i c at es o v er 500 mi l es t o i n-
s u r e a no r mal eng i ne f r i c t i o n l ev el . Pr ep ar e eng i ne
b y d r i v i ng at l eas t 5 mi l es . Co nnec t a t ac h o met er and
B
p CHOKE VALVE
V/lOS OPEN
/
FAST IDLE SPEED
ADJUSTING SCREW
ON SECOND HIGHEST
STEP OF CAM
PY505
Fig. 17-Fast Idle Speed Adjustment (On Vehicle)
s et t he c u r b i dl e s p eed and mi x t u r e, t h en p r o c eed as
f ol l ows :
(1) Wi t h eng i ne off and t r ans mi s s i o n i n P A R K or
NEUT R A L pos i t i on, open t hr ot t l e s l i g ht l y .
(2) Cl o s e c h o k e v al v e u nt i l f as t i d l e s c r ew c an be
pos i t i oned on s ec o nd hi g hes t -s peed s t ep of f as t i dl e
c am ( Fi g . 17).
(3) St ar t eng i ne and d et er mi ne s t abi l i zed s p eed .
T u r n f as t i dl e s p eed s c r ew i n or out t o s ec u r e s p ec i -
fied s p eed . (See Spec i f i c at i ons . )
(4) St oppi ng eng i ne b et ween ad j u s t ment s i s not
nec es s ar y . Ho wev er , r epos i t i on f as t i dl e s p eed s c r ew
on c am af t er eac h s p eed ad j u s t ment t o p r o v i d e c o r r ec t
t hr ot t l e c l o s i ng t or que.
To s et t he i d l e s p eed on v eh i c l es , r ef er t o F u e l
Sy s t em Gener al Inf o r mat i o n Par ag r ap h .
HOLLEY 2200 SERIES CARBURETOR
Pag e
Car bur et or Ad j u s t ment s 24
Ac c el er at o r Pu mp 25
B owl Vent 25
Ch o k e Unl o ad er (Wi de Open K i c k ) . . . . . . . 25
Fas t Idl e Sp eed and Cam Posi t i on . . . . . . . . 24
Fas t Idl e Sp eed (On Veh i c l e) . . . . . . . . . . . . . . . . 26
Idl e Sp eed . . 26
GENERAL INFORMATION
Page
Vac u u m K i c k 24
Car bur et or Sy s t ems 14
Cl eani ng Car bur et or Par t s 21
Di s as s emb l i ng Car bur et or . . . . . . . . 18
Gener al Inf or mat i on . . . . . . . . . . . . . 14
Ins pec t i on and Reas s emb l y 21
Sp ec i f i c at i o ns 66
Th e Ho l l ey d u al t hr oat , 2200 s er i es c ar b u r et o r mo d -
el C. A. S. (Cl eaner Ai r System) R-4371A, ( Fi g . 1) i s
u s ed on t he 383 c u . i n. eng i ne wh en t he v eh i c l es ar e
eq u i p p ed wi t h an aut omat i c t r ans mi s s i o n and wi t hout
ai r c ondi t i oni ng onl y . Th i s c ar b u r et o r i s eq u i p p ed wi t h
a di s t r i but or g r o u nd s wi t c h , wh i c h r et ar d s t h e di s -
t r i but or wh en t he c ar b u r et o r i s at c u r b i dl e, r es u l t i ng
i n bet t er emi s s i o n c ont r ol .
Ea c h t hr oat of t he c ar b u r et o r h as i t s o wn t hr ot t l e
v al v e and mai n met er i ng s y s t ems and ar e s uppl e-
ment ed by t he float, ac c el er at i ng , i dl e and p o wer s y s -
t ems .
CARBURETOR SYSTEMS
Th e c ar b u r et o r ut i l i zes f o u r bas i c f u el met er i ng
A
HOL L EY 2200FUEL SYSTEM 14-15
ACCELERATOR PUMP ROCKER ARM
ACCELERATOR PUMP ROD
BOWL VENT VALVE OPERATI NG LEVER
FAST IDLE CAM
FAST IDLE CONNECTOR ROD
CHOKE:
;
VALVE
J
1
'
CRANKCASE YEN!
TUBE FITTING
CHOKE VACUUM
DIAPHRAGM*
CHOKE OPERATI NG
LINK
CHOKE LEVER
DISTRIBUTOR
VACUUM A DVA N CE- ^.
TUBE FITTING
CRANKCASE VENT
TUBE FITTING
CHOKE OPERATI NG LEVER
FAST IDLE CONNECTOR ROD /
FAST IDLE SPEED ADJ USTI NG SCREW
CURS IDLE SPEED ADJ USTI NG SCREWS !
_ \
CARBURETOR AIR
CLEANER VENT TUBE
FITTING
DISTRIBUTOR
GROUND SWI TCH
CONTACT
CARBURETOR AIR
CLEANER VENT
TUBE FITTING
1
ELEVATOR LEGS (4)
THROTTLE LEV'JR
CURB IDLE
SPEED ADJ USTI NG
SCREW
- Ch O, <
LONG AIR
HORN SCREW
BOWL VENT
VALVE
DISTRIBUTOR GROUND SWITCH CONNECTOR
ACCELERATOR PUMP SHAFT
ACCELERATOR PUMP PLUNGER STEM
BOWL VENT VALVE ADJ USTI NG TANG
ACCELERATOR PUMP ROCKER ARM
PY834
F i g . ICarburetor Asse
s y s t ems . Th e Idl e Sy s t em pr ov i des a r i c h mi x t u r e f or
s moot h i dl e and l ow s peed p er f o r manc e; t he Ac c el er -
at or Pu mp Sy s t em, pr ov i des addi t i onal f u el d u r i ng
ac c el er at i o n; t he Mai n Met er i ng Sy s t em, p r o v i d es an
ec o no mi c al mi x t u r e f or no r mal c r u i s i ng c ondi t i ons ;
and t he Po wer Enr i c h ment Sy s t em, p r o v i d es a r i c h er
mi x t u r e wh en h i g h p o wer out put i s d es i r ed .
I n addi t i on t o t hes e f o u r bas i c s y s t ems , t h er e i s a
f u el i nl et s y s t em t hat c ons t ant l y s u p p l i es t he f u el t o
t he bas i c met er i ng s y s t ems , and a c h o k e s y s t em wh i c h
t emp o r ar i l y enr i c h es t he mi x t u r e t o ai d i n s t ar t i ng
and r u nni ng a c ol d eng i ne.
Fuel Inlet System (Fig. 2)
Al l f u el ent er s t he f u el bowl t h r o u g h t he f u el i nl et
fitting i n t he bowl c ov er .
Th e " Vi t o n" t i pped f u el i nl et need l e s eat s d i r ec t l y
i n t he f u el i nl et s eat . Th e f u el i nl et need l e i s c on-
t r ol l ed by a ni t r o p h y l float (a c el l u l ar b u o y ant mat e-
r i al wh i c h c annot c ol l aps e or l eak ) and s t ai nl es s s t eel
float l ev er wh i c h i s h i ng ed by a " De l r i n" float f ul -
c r u m p i n.
Th e f u el i nl et s y s t em mu s t c ons t ant l y mai nt ai n
t he s pec i f i ed l ev el of f u el as t he bas i c f u el met er i ng
s y s t ems ar e c al i b r at ed t o del i v er t he p r o p er mi x t u r e
onl y wh en t he f u el i s at t hi s l ev el . Wh e n t he f u el
ty (Holley 2210 Series)
l ev el i n t he bowl dr ops t h e float al s o d r o p s p er mi t t i ng
addi t i onal f u el t o flow p as t t he f u el i nl et need l e i nt o
t he bowl . A baffl e ov er t h e need l e as s i s t s i n s epar at -
i ng t he ai r bubbl es f r o m t h e f u el t o p r o v i d e a mo r e
s ol i d f u el s u p p l y i n t he b o wl .
Th e float c h amb er i s v ent ed i nt er nal l y i nt o t he ai r
h o r n. An ex t er nal v ent ac t u at ed b y t he p u mp l ev er
i s opened at c u r b i d l e or wh e n t he eng i ne i s not r u n-
ni ng t o r el eas e f u el v ap o r s f r o m t he bowl .
FUEL INLET
FITTING
FLOAT
FLOAT
ADJ USTI NG TAB PY863
F i g . 2fuel Inlet System
14-16 FUEL SYSTEMHOLLEY 2200
A
idle System (Fig. 3)
F u e l u s ed d u r i ng c u r b i dl e and l ow s p eed oper -
at i on flows t h r o u g h t he mai n met er i ng j et i nt o t he
mai n wel l .
A hor i zont al c o nnec t i ng pas s ag e p er mi t s t he f u el t o
flow f r o m t he mai n wel l i nt o t he i dl e wel l . F u e l c on-
t i nues up t he i dl e wel l and t h r o u g h an i dl e f eed
r es t r i c t i on i nt o an i dl e c h annel wh er e t he f u el i s
mi x ed wi t h ai r wh i c h ent er s t h r o u g h i dl e ai r bl eeds
l oc at ed i n t he ai r h o r n.
At c u r b i dl e t he f u el and ai r mi x t u r e flows d o wn
t he i dl e c h annel and i s f u r t h er mi x ed or b r o k en u p
by ai r ent er i ng t he i dl e c h annel t h r o u g h t he t r ans f er
sl ot wh i c h i s abov e t he t hr ot t l e v al v e at c u r b i dl e.
Du r i ng l ow s p eed oper at i on t he t hr ot t l e v al v e
mov es ex p o s i ng t he t r ans f er sl ot and f u el beg i ns t o
flow t h r o u g h t he t r ans f er sl ot as wel l as t he i dl e
por t . As t he t hr ot t l e v al v es ar e opened f u r t h er and
eng i ne s p eed i nc r eas es t he ai r flow t h r o u g h t he c ar -
bur et or al s o i nc r eas es . Th i s i nc r eas ed ai r flow c r eat es
a v ac u u m or d ep r es s i o n i n t he v ent u r i and t he mai n
met er i ng s y s t em beg i ns t o d i s c h ar g e f u el .
Main Metering System (Fig. 4)
As t he eng i ne ap p r o ac h es c r u i s i ng s p eed t he i n-
c r eas ed ai r flow t h r o u g h t he v ent u r i c r eat es v ac u u m
(l ow p r es s u r e ar ea) i n t he v ent u r i of t he c ar b u r et o r .
Near at mo s p h er i c p r es s u r e p r es ent i n t he b o wl i n t he
ar ea abov e t he f u el c au s es t he f u el t o flow t o t he
l o wer p r es s u r e ar ea c r eat ed by t he v ent u r i and mag -
ni f i ed by t he boos t er v ent u r i .
F u e l flows t h r o u g h t he mai n j et i nt o t he mai n wel l ;
ai r ent er s t h r o u g h t he mai n wel l ai r bl eeds and i nt o
t he mai n wel l t h r o u g h hol es i n t he mai n wel l t ube.
Th e mi x t u r e of f u el and ai r b ei ng l i g ht er t h an r aw
f u el r es p o nd s f as t er t o c h ang es i n v ent u r i v ac u u m
and i s al s o mo r e r ead i l y v apor i zed wh en d i s c h ar g ed
i nt o t he v ent u r i .
I D L E F E E D I D L E A I R B L E E D
T R A N S F E R
S L O T
A D J U S T I N G N E E D L E
P Y 8 6 4
Fig. 3Idle System
M A I N
M A I N W E L L V E N T U R I P Y G 6 5
Fig. 4Main Metering System
Th e mai n d i s c h ar g e nozzl e pas s ag e i s a p ar t of t he
boost er v ent u r i wh i c h i s an i nt eg r al p ar t of t he mai n
body c as t i ng . Di s t r i b u t i o n t abs i n t he mai n v ent u r i
p r o v i d e f u r t h er v apor i zat i on of t he f u el and ai r mi x -
t ur e.
Th e mai n met er i ng s y s t em i s c al i b r at ed t o d el i v er a
l ean mi x t u r e f or bes t o v er al l ec onomy . Wh e n addi -
t i onal p o wer i s r eq u i r ed a v ac u u m oper at ed p o wer
s y s t em enr i c h es t he f uel -ai r mi x t u r e.
P ower Enrichment System (Fig. 5)
Th e p o wer enr i c h ment s y s t em c ons i s t s of a p o wer
v al v e i ns t al l ed i n t he c ent er of t he c ar b u r et o r body
b et ween t he mai n j et s and a v ac u u m pi s t on i ns t al l ed
i n t he b o wl c ov er . A v ac u u m pas s ag e l ead s f r o m t he
t op of t he pi s t on d o wn t o t he mani f o l d flange.
Wh e n mani f o l d v ac u u m i s h i g h t he v ac u u m pi s t on
i s r ai s ed t o t he t op of i t s c y l i nd er and t he s p r i ng on
t he pi s t on s t em i s c o mp r es s ed .
V A C U U M P A S S A G E P O W E R V A L V E P I S T O N
P O W E R V A L V E P Y 8 6 6
Fig. 5Power Enrichment System
A HOLLEY 2200FUEL SYSTEM 14-17
Wh e n mani f oIJ L TVac uu^ t o a p r ed et er mi ned
l ev el t he s p r i ng o v er c o mes t he v a c u u m and p u s h es
t he pi s t on s t em d o wn.
Th e pi s t on s t em i n t u r n p u s h es t he p o wer v al v e
s t em d o wn openi ng t he p o wer v al v e and p er mi t t i ng
f u el t o flow t h r o u g h t he p o wer v al v e t h r o u g h p o wer
v al v e c h annel r es t r i c t i ons and i nt o t he mai n wel l on
ei t her s i de of t he p o wer v al v e.
Accelerating Pump System (Fig. 6)
Wh e n t he t hr ot t l e v al v es ar e o p ened s u d d enl y t he
ai r flow t hr oug h t he c ar b u r et o r r es p o nd s al mos t i m-
medi at el y . Ho wev er , t h er e i s a b r i ef t i me i nt er v al or
l ag bef or e t he f u el c an o v er c o me i t s i ner t i a and
mai nt ai n t he d es i r ed f uel -ai r r at i o.
Th e pi s t on t ype ac c el er at i ng p u mp s y s t em mec h an-
i c al l y s uppl i es t he f u el nec es s ar y t o o v er c o me t hi s
def i c i enc y f or a s hor t per i od of t i me.
F u e l ent er s t he p u mp c y l i nd er f r o m t he f u el b o wl
t h r o u g h a sl ot i n t he p u mp wel l abov e t he no r mal
pos i t i on of t he p u mp pi s t on. Wh e n t he eng i ne i s
t u r ned off, f u el v ap o r s i n t he p u mp c y l i nd er ar e
v ent ed t h r o u g h t he ar ea b et ween t he p u mp r o d and
p u mp pl ung er .
As t he t hr ot t l e l ev er i s mo v ed t he p u mp l i nk op-
er at i ng t h r o u g h a s y s t em of l ev er s and a p u mp ov er -
r i d e s p r i ng p u s h es t he p u mp pi s t on down. F u e l i s
f o r c ed t h r o u g h a pas s ag e ar o u nd t he p u mp d i s c h ar g e
need l e v al v e and out t he p u mp d i s c h ar g e j et s wh i c h
ar e d r i l l ed i n t he mai n body.
Automatic Choke System (Fig. 7)
T h e aut omat i c c h o k e p r o v i d es t h e r i c h er f uel -ai r
mi x t u r e r eq u i r ed f o r s t ar t i ng and oper at i ng a c o l d
eng i ne. A bi -met al s p r i ng i ns i d e t he c h o k e h o u s i ng ,
wh i c h i s i ns t al l ed i n a wel l i n t h e i nt ak e mani f o l d ,
hol ds t he c hok e v al v e i n t he c l o s ed posi t i on.
Wh e n t he eng i ne s t ar t s , mani f o l d v ac u u m i s ap-
pl i ed t o t he c h o k e d i ap h m a r ubbr ~l i Dse~
f r o m t he t hr ot t l e body t o t he c h o k e d i ap h r ag m as -
s emb l y . Th e ad j u s t ment of t he c h o k e v al v e openi ng ,
wh en t he eng i ne s t ar t s and v ac u u m i s appl i ed t o t he
c hok e d i ap h r ag m, i s c al l ed v ac u u m k i c k .
Mani f ol d v a c u u m al one i s not s t r ong eno u g h t o
pr ov i de t he p r o p er deg r ee of c h o k e openi ng d u r i ng
t he ent i r e c h o k i ng p er i o d . T h e i mp ac t of i n r u s h i ng
ai r pas t t he offset c h o k e v al v e p r o v i d es t he addi -
t i onal o p eni ng f o r c e.
As t he eng i ne war ms u p mani f o l d heat t r ans mi t -
t ed t o t he c h o k e h o u s i ng r el ax es t he bi -met al s p r i ng
u nt i l i t ev ent u al l y p er mi t s t he c h o k e t o open f ul l y .
Distributor Vacuum Advance
As eng i ne s p eed i nc r eas es , t he s p ar k t i mi ng mu s t
be ad v anc ed so t hat t he b u r ni ng i n t he c y l i nd er may
be c o mp l et ed at t he p r o p er t i me t o ac hi ev e max i mu m
p r es s u r e and ef f i c i enc y.
A v ac u u m s p ar k por t l oc at ed i n t he t hr ot t l e bor e,
j u s t abov e t he c l o s ed t hr ot t l e v al v e, i s c o nnec t ed t o
t he di s t r i but or v a c u u m c h amb er by a s er i es of pas -
s ag es t o a fitting i n t he c ar b u r et o r body and a flexible
hos e.
As t he t hr ot t l e i s opened, t hi s por t i s ex p o s ed t o
mani f o l d v ac u u m wh i c h v ar i es wi t h c h ang es i n eng i ne
s p eed and l oad.
Th i s c h ang i ng v ac u u m i s ap p l i ed t o t he di s t r i but or
v ac u u m d i ap h r ag m.
Th e d i ap h r ag m, i n t u r n r ot at es t he di s t r i but or
b r eak er pl at e t h r o u g h a c o nnec t i ng r o d c h ang i ng t he
s p ar k t i mi ng t o meet eng i ne d emand s .
At c u r b i dl e, t he c u r b i dl e s c r ew c ont ac t s t he di s -
t r i but or r et ar d i ng s ol enoi d. Th i s i n t u r n r et ar d s t he
di s t r i but or t o ma x i mu m r et ar d f o r i mp r o v ed emi s s i o n
c ont r ol at i dl e.
PUMP OPERATI NG LINK
PUMP ASSEMBLY
PUMP
OVERRI DE
SPRI NG
PUMP DI SCHARGE
RESTRICTION
PUMP
CUP
DI SCHARGE
CHECK NEEDLE
PY867
F i g . 6Accelerating Pump System
PY868
F i g . 7Automatic Choke System
14-18 FUEL SYSTEMHOLLEY 2200
A
SERVICE PROCEDURES
DI SASSEMBLI NG CARBURETOR
(1) I ns e rt t hre e Tool T-109-287S and one T ool T109-
288S e l e vat i ng l egs t hr ough ca rbure t or t hrot t l e body
moun t i n g s t ud hol es. (These t ool s are used t o prot e ct
t hr ot t l e v al v es f r o m d amag e and t o p r o v i d e a s ui t abl e
bas e f o r wor k i ng . ) ( Fi g . 1).
(2) Remo v e nu t and was h er at t ac h i ng ac c el er at o r
p u mp r o c k er ar m t o ac c el er at o r p u mp s haf t . Remo v e
ar m f r o m flats on p u mp s haf t , t h en di s eng ag e ac c el er -
at or p u mp r o d f r o m c ent er sl ot i n a r m and f r o m hol e
i n t hr ot t l e l ev er . ( Fi g . 2).
(3) Remo v e nu t and was h er t hat at t ac hes c h o k e
l ev er t o c h o k e s haf t . Di s eng ag e f as t i dl e c o nnec t o r
r o d f r o m l ev er and f as t i dl e c am. ( Fi g . 3).
(4) Remo v e c h o k e v ac u u m d i ap h r ag m hos e f r o m
t hr ot t l e body t ube fitting. Remo v e s c r ews t hat at t ac h
c h o k e d i ap h r ag m and mo u nt i ng b r ac k et t o ai r h o r n.
(5) Remo v e c h o k e d i ap h r ag m and at t he s ame t i me,
di s eng ag e c h o k e o p er at i ng l i nk f r o m sl ot i n c h o k e
oper at i ng l ev er . ( Fi g . 4). Pl ac e c h o k e u ni t t o one s i d e
t o be c l eaned as a s p ec i al i t em. A liquid cleaner may
damage diaphragm material.
(6) Remo v e " E " c l i p t hat r et ai ns b o wl v ent v al v e
o p er at i ng l ev er on s t u b s haf t of ai r h o r n. Sl i d e l ev er
off s haf t , b ei ng c ar ef u l not t o l ose l ev er s p r i ng . (Not e
pos i t i on of s pr i ng ) . ( Fi g . 5).
(7) Remo v e ei ght ai r h o r n at ac h i ng s c r ews , t h en l i f t
ai r h o r n s t r ai g ht u p and away f r o m mai n body (l ong
s c r ew i n c ent er . ) USE EXTREME CARE WHEN
HANDL I NG AI R HORN SO AS NOT TO B END OR
DAMAG E WE L L TUBES. ( Fi g . 6).
(8) Di s eng ag e ac c el er at o r p u mp p l u ng er f r o m p u mp
s haf t b y p u s h i ng up on bot t om of p l u ng er , t h en t i l t i ng
s l i g ht l y t o war d c ent er , t h en s l i de off p u mp s haf t . Sl i d e
p l u ng er s t em out of ai r h o r n and r emo v e c o mp r es s i o n
s p r i ng ( Fi g . 7).
(9) Sl i d e ac c el er at o r p u mp s haf t out of ai r h o r n.
( Fi g . 8).
(10) Remo v e f u el i nl et fitting and g as k et f r o m ai r
h o r n.
(11) Wi t h ai r h o r n i nv er t ed , r emo v e s c r ew t hat at -
t ac h es f u el baffle t o ai r h o r n ( Fi g . 9).
(12) Sl i d e ny l o n float f u l c r u m p i n out of ai r h o r n,
t h en r emo v e float. I nv er t ai r h o r n and dr op out f u el
i nl et need l e. Us i ng a wi d e bl ade s c r ew d r i v er , r emo v e
f u el i nl et need l e v al v e s eat and g as k et ( Fi g . 10).
(13) Remo v e ai r h o r n g as k et . (Note: This gasket is
a self sealing type and will stick to air horn mounting
s u r f ac e. Care s h o u l d be used at removal s o as not to
FAST I D L E S P E E D A D J U S T I N G S C R E W
C H O K E V A C U U M D I A P H R A G M
T W D H T T I F \/A J V C C I
C U R B IDLE S P E E D
ADJ USTING S C R E W
F A S T IDLEC A M
C U R B I D L E S P E E D
A D J U S T I N G SCREW
BOWL VENT V A L V E
C R A N K C A S E V E N T T U B E F I T T I N G
F A S T I D L E S P E E D
A D J U S T I N G S C R E W
T H R O T T L E
L E V E R
C H O K E O P E R A T I N G
L E V E R
L I M I T E R C A P
IDLE M I X T U R E
A D J U S T I N G
S C R E W )
D I S T R I B U T O R V A C U U M
A D V A N C E T U B E F I T T I N G
C H O K E V A C U U M
D I A P H R A G M
A C C E L E R A T O R
P U M P R O D
C R A N K C A S E V E N T
TUBE F I T T I NG
C A R B U R E T O R A I R C L E A N E R
VENT T U B E F I T T I N G
C H O K E V A C U U M
D I A P H R A G M H O S E
L I M I T E R C A P ( I D L E M I X T U R E
SCREWS)
D I S T R I B U T O R G R O U N D ' ^ % ~ ' ~ R O T T L E B O D Y
S W I T C H C O N N E C T O R A T T A C H I N G S C R E W S
F U E L INLET F I T T I N G
D I S T R I B U T O R V A C U U M A D V A N C E T U B E F I T T I N G
P Y 8 3 5
F i g . I Carburetor Assembly
-HOLLEY 2200FUEL SYSTEM 14-19
ACCELERATOR PUMP
ROCKER ARM
V.
A C C E L E R A T O R
PUMP K OD
/
THROTTLE LEV?;-
LOCKWASHER-
CENTER SIO'
Or A,tV\
Nur
' .ATS ON SHAFT
CHOKE LEVER
SLOT I N LEVER
CHOKE
ERATING LINK
PY836
- CHOKE DIAPHRAGM
JTACHING SCREWS
Fig. 2Removing or installing Accelerator
Pump Rocker Arm
mar or scratch mating surface of air horn.
(14) Remo v e v ac u u m p o wer pi s t on f r o m ai r h o r n,
u s i ng t ool C-4141 ( Fi g . 11). ( Thi s as s emb l y i s s t ak ed
i n posi t i on and c ar e mu s t be u s ed at r emov al . ) Remo v e
s t ak i ng u s i ng a s ui t abl e s h ar p t ool .
(15) WARNI NG: DO NOT AT T EMP T T O R EMOV E
MAI N W EL L T UB ES F ROM AI R HORN. Th es e t ubes
ar e a p r es fi t i n ai r h o r n, and wi l l be d amag ed i f r e-
mo v ed . Th e y c an be c l eaned i n a s ol v ent and b l o wn
d r y wi t h c o mp r es s ed ai r . If c ar b u r et o r par t s ar e
c l eaned i n a bas k et , be s u r e ot her c ar b u r et o r p ar t s
ar e not s t r i k i ng t hes e t ubes .
(16) Us i ng To o l TMC-36A, r emo v e mai n met er i ng
j et s ( Fi g . 12). ( Nu mb er 65 l oc at ed on t hr ot t l e l ev er
s i de of bowl ; nu mb er 63 on opposi t e si de. )
(17) Us i ng To o l T109-73S, r emo v e p o wer v al v e as -
s emb l y ( Fi g . 13).
(18) Inv er t mai n body and dr op out ac c el er at o r
p u mp d i s c h ar g e c h ec k need l e f r o m d i s c h ar g e pas -
: HOKc VALVE
WI DE OPEN
CHOKER-
LEVER
FAST IDLE
CAM
LOCKWASKZR
\
FLATS O N
SHAFT
FAS'*" IDLE
CONNECTOR ROD
PY838
Fig. 4Removing or Installing Choke Diaphragm
sage (Fi g. 15).
(19) Remo v e f as t i dl e c am r et ai ni ng " E " c l i p , t h en
s l i de f as t i dl e c am off s t ub s haf t ( Fi g . 14).
(20) Inv er t mai n body and r emo v e t hr ot t l e body t o
mai n body at t ac hi ng s c r ews . Sep ar at e bodi es and di s -
c ar d g as k et .
(21) T u r n i dl e l i mi t er c aps t o st op. (Top of t hr ot t l e
l ev er s i d e and bot t om of st op on ot her . ) Remo v e i dl e
l i mi t er c ap s by p r y i ng off wi t h s ui t abl e t ool . (B e c ar e-
f u l not t o b end s c r ews . ) B e s u r e and c ount nu mb er of
t u r ns t o s eat t he s c r ews , as t he s ame nu mb er of t u r ns
(f r om t he seat ) mu s t be mai nt ai ned at i ns t al l at i on. Re -
mov e s c r ews and s p r i ng s f r o m t hr ot t l e body.
Th e c ar b u r et o r now has been d i s as s emb l ed i nt o
t h r ee s u b -as s emb l i es , t he ai r h o r n, mai n body, t hr ot t l e
body and t he c o mp o nent s of eac h d i s as s emb l ed as f ar
as nec es s ar y f or c l eani ng and i ns pec t i on.
Caution: In normal routine cleaning and overhaul
of the carburetor, do not remove throttle valves unless
STUB
SHAFT
Z C VJNT VALVE
. C?=:Ur i NG LEVER
A-
tNDS OF
SPRING
BOWL VENT *
VALVE
SPRING
*NUT
PY837
, L
E" CUP
Fig. 3Removing or Installing Fast Idle
Connector Rod
Fig. 5Removing or Installing Bowl Vent Valve
Operating lever
14-20 FUEL SYSTEMHOLLEY 2200
A
AIR HORN
GASKET
ACCELERATOR PUMP
PLUNGER
MAIN WELL TUBES.^
VACUUM POWER
PISTON STEM
SLOTS
DO NOT BEND
MAIN BODY
PY840
Fig. 6Removing or installing Mir Horn
ACCELERATOR- ^
PUMP *
SHAFT
ACCELERATOR PUMP
PLUNGER STEM
PY841
Fig. 7Removing or installing Accelerator
Pump Plunger
ACCELERATOR PUMP SHAFT
FUEL INLET
TUBE FITTING
PUMP \
PLUNGER *~6
SMALL END
OF SPRING
PY842
Fig. 8Removing or Installing Accelerator
Pump Shaft
FUEL
BAFFLE
LUGS
FULCRUM PIN
CENTERED
ATTACHING SCREW-
PY843
Fig. 9Removing or Installing Fuel Bahle
they^ are nicked or damaged, i f necessary to remove,
p r o c eed as follows:
(1) Remo v e s c r ews t hat h o l d t hr ot t l e v al v es i n
t hr ot t l e s haf t . These screws are staked to prevent
loosening and care is necessary to avoid breaking off
in shaft. Remo v e staking with a file.
(2) Sl i d e d amag ed v al v es out of bor es . It s h o u l d be
not ed at t hi s t i me, t hat t he nu mb er ed s i de i s on t he
bot t om (or c ar b u r et o r mo u nt i ng flange s i de) and op-
pos i t e t he i dl e mi x t u r e s c r ew por t s .
FLOAT
ADJ USTING TAB
(FLOAT DROP)
SCREWDRIVER
j> SEAT ANDGASKET
FUEL INLET NEEDLE *f*
Fig. 10Removing or Installing Float and
Needle Seat
PY844
A ,HOLLEY 2200FUEL SYSTEM 14-21
MAI N WELL TUBES
DO NOT REMOVE.
SERVICED I N AIR
HORN CASTING ONLY
4 ~;
SPECIAL
TOOL
VACUUM
* POWER
PISTON
F i g . 11Removi ng Vacuum Power Piston
PY845
SP ECI AL
TOOL
MAI N METERING
JET (#63)
PUMP DI SCHARGE
CHECK NEEDLE
POWER VALVE
MAI N METERING
JET (#65)
PY846
F i g . 12Removi ng or Installing Main Metering J ets
CLEANI NG CARBURETOR PARTS
Eef er t o General I n f orma t i on Sect i on at f ron t of Fue l
System, f or cl eani ng I ns t ruct i ons .
. SPECIAL TOOL
POWER V A L V E
PY847
Fig. 13-Removing or Installing Power Valve
H E
S T UB S H A F T
FAST I DL E C A M
/
STOP LUG
\
m
x
THROTTLE WIDE OPEN
" E" C L I P
PY848
F i g . 14Removing or Installing Fast Idle Cam
I NSPECTI ON AND REASSEMBLY
DO NOT c l ean any r u b b er or pl as t i c p ar t s i nc l u d i ng
d i ap h r ag ms and el ec t r i c al p ar t s (t hat may be at t ac hed
t o c ar b u r et o r ) i n c l eani ng s ol v ent b ec au s e of pos s i bl e
d amag e.
Ch e c k f or c r ac k s , war p ag e, s t r i p p ed s c r ew t h r ead s ,
d amag ed or mar r ed mat i ng s u r f ac es , on al l maj o r
c as t i ng s . Th e pas s ag es i n t he c as t i ng s s h o u l d be f r ee
of r es t r i c t i o ns . Ins t al l new c as t i ng s as r eq u i r ed . Ch ec k
fl oat as s emb l y f or damag e or any c ondi t i on t hat wo u l d
i mp ai r t hi s i t em f r o m f u r t h er s er v i c e. Th e c h o k e and
t hr ot t l e v al v es s h o u l d be r ep l ac ed i f t he edg es hav e
b een ni c k ed or i f t he pr ot ec t i v e pl at i ng h as b een r e-
mo v ed . B e s u r e t hat t he c hok e and t hr ot t l e s h af t s ar e
not bent or s c o r ed . Rep l ac e any b r o k en or di s t or t ed
s p r i ng s . Rep l ac e al l t h r ead s and l o c k was h er s t hat s how
s i g ns of s t r i p p ed t h r ead s or di s t or t i on.
Throttle Body
If t he t hr ot t l e v al v es wer e r emo v ed b ec au s e of dam-
l
CHECK NEEDLE
DI SCHARGE PASSAGE
PY849
F i g . 15Installing Accelerator Pump Discharge
Check Needle
14-22 FUEL SYSTEMHOLLEY 2200
age, i n s t a l l new val ves as f ol l ows :
(1) Sl i de new val ves i n t o pos i t i on i n t hrot t l e shaf t ,
w i t h t he val ve n umbe r on t he bot t om, (or moun t i n g
flange side,) and away f r om i d l e a i r mi x t ur e a d j us t i ng
screw port s .
(2) I n s t a l l new val ve screws but do n ot t i ght e n .
(3) Hol d val ves i n pl ace w i t h fingers. (Fi ngers press-
i n g on hi gh si de of valves.)
(4) Tap val ve l i ght l y w i t h a screw d ri ve r t o cent er
I n bores. Now, t i ght e n val ve a t t a chi ng screws securel y.
Operat e t he t hrot t l e shaf t . Fr om cl osed t o open posi -
t i on , t he y mus t operat e s moot hl y w i t hout d ra g or
s t i ck i ng. Hol d t hrot t l e body up t o a s t rong l i ght . The
l i ght whi ch Is vi s i bl e a round t he out e r di a me t e r of
val ves i n bore s houl d be un i f or m. Stake screws, us i ng
a pa i r of pl i e rs .
(5) I n s t a l l i d l e mi x t ur e screws and s pri ngs i n body.
(The t ape re d port i on mus t be s t ra i ght and smoot h. I f
t he t a pe re d port i on i s grooved or ri d ge d , a new i dl e
mi x t ur e screw s houl d be i ns t a l l e d t o I ns ure ha vi ng
corre ct i d l e mi x t ur e cont rol .) DO NOT US E A S C R EW
DR I V ER . T ur n screws l i ght l y agai nst t he i r seats w i t h
fingers. Back off t he n umbe r of t urn s ( f rom t he seat)
count e d at di sassembl y. I n s t a l l new pl ast i c caps w i t h
t a b agai nst st op.
Main Body
(1) I n ve rt ma i n body and pl ace a ne w gasket i n
pos i t i on. Pl ace t hrot t l e body on ma i n body and a l i gn.
I n s t a l l a t t a chi ng screws and t i ght e n securel y.
(2) I n s t a l l accel erat or pump di scharge check needl e
i n di scharge passage (Fi g. 15). Cheek accel erat or
pump, f ue l i n l e t and di scharge systems as f ol l ows :
(3) Pour cl ean gasol i ne i n t o f ue l bowl , approx i mat e -
l y 1 I nch deep. Sl i de accel erat or pump pl un ge r I nt o
cyl i nde r. Raise pl unge r and press d own l i ght l y on
pl un ge r st em t o e x pe l l a l l a i r f r om pump passage.
(4) Us i ng a s ma l l cl ean brass rod , hol d di scharge
check needl e d own on i t s seat. Aga i n rai se pl un ge r
and press d own wa rd . No f ue l s houl d be e mi t t e d f r om
pump di scharge passage (Fi g. 16).
I f any f ue l does e mi t f r om di scharge passage, i t i n -
di cat es t he presence of d i r t or a damaged or w or n
check needl e, or seat. Cl ean t he passage agai n and re-
t est as above. I f l eakage i s s t i l l e vi de nt , a t t e mpt t o
f or m a ne w seat as f ol l ows :
(5) W i t h di scharge check needl e i ns t a l l e d, i ns e rt a
pi ece of d r i l l r od d own on needl e. L i ght l y t ap d r i l l r od
w i t h a ha mme r t o f or m a new seat. Remove and di s-
ca rd ol d needl e and i n s t a l l a new one. Retest as de-
scri bed pre vi ous l y. I f servi ce fix does n ot corre ct t he
cond i t i on, a ne w ma i n body s houl d be i ns t a l l e d. Re-
move accel erat or pump pl unge r, di scharge check
needl e a nd f ue l f r om ma i n body.
(6) I n s t a l l powe r val ve, us i ng T ool T109-73S, (Fi g.
13). T i ght e n securel y.
r ^gf ?^T' "> BRASS ROD
U ACCELERATOR
PUMP
\
NO FUEL SHOULD BE
EMITTED FROM PASSAGE
OR PARTS
PY850
F i g . 16Testing Accelerator Pump Discharge
Check Needle
(7) I n s t a l l ma i n me t e ri n g j e t s , us i ng T ool TMC-36A.
(Fi g. 12). T i ght e n securel y. ( Numbe r 65 on t hrot t l e
l ever si de and numbe r 63 an ot he r si de of bowl .)
(8) I n s t a l l accel erat or pump di scharge check needl e
i n pump di scharge passage (Fi g. 15).
Air Horn
(1) Test freeness of choke mechani sm i n ai r horn .
The choke shaf t mus t float f ree t o operat e corre ct l y.
I f choke st i cks i n be a ri ng bores, or appears t o be
gumme d f r om deposi ts i n a i r horn , a t horough cl ean-
i n g w i l l be re q ui re d .
(2) I n s t a l l va cuum powe r pi s t on i n i t s cyl i nd e r (Fi g.
17). Lock i n pos i t i on by pr i ck pun chi n g r i m of cyl i n -
de r (at l east t hre e places.) Do not over-stake. Compress
pi s t on t o be sure no bi n d i n g exi st s. I f pi s t on st i cks or
bi nds enough t o hi n d e r smoot h ope rat i on, a ne w pi s-
t on s houl d be i ns t al l e d.
(3) Sl i de accel erat or pump pl unge r compressi on
s pri n g over pl un ge r st em, w i t h s ma l l di ame t e r t owa rd
SPECI AL TOOL TO SEAT
PISTON RETAI NI NG WASHER
PY851
F i g . 17Installing Vacuum Power Piston
-HOLLEY 2200FUEL SYSTEM 14-23
p l u ng ei HB Ei s t ^ h P
1
? s haf t l i t a i r hor n ( Fi g . 8).
(4) As p l u ng er i s bei ng Ins t al l ed In a i r h o r n, s l i g ht -
l y t i l t p l u ng er t o eng ag e w i t h p l u ng er s haf t .
(5) Ins t al l f u el Inl et need l e v al v e s eat and g as k et
i n ai r h o r n. Ti g h t en s ec u r el y , u s i ng a wi d e b l ad e
s c r ewd r i v er . Ins t al l f u el i nl et need l e i n s eat ( Fi g . 10).
(6) Ins t al l float i n pos i t i on, t h en s l i de ny l o n f u l c r u m
pi n t h r o u g h float hi ng e to r et ai n float. Cent er f u l c r u m
pi n ( Fi g . 9).
(7) Ins t al l f u el baffl e on bos s es wi t h sl ot s eng ag ed
l u g s . Ins t al l at t ac h i ng s c r ew and t i g ht en s ec u r el y ( Fi g .
9).
F L O A T S rLOAT RAISED
pi
FLOAT ADJ USTING LIP
Measuring Float Setting
Th e c ar b u r et o r s ar e eq u i p p ed wi t h a v i t on t i p p ed
f u el i nl et need l e. Th e t i p i s flexible eno u g h t o mak e a
good s eal on t he needl e s eat , and t o gi v e i nc r eas ed
r es i s t anc e t o flooding. Care should be taken to perform
this operation accurately in order to secure best per-
formance and fuel economy.
(1) To c o r r ec t l y set float hei g ht wh en c ar b u r et o r i s
b ei ng o v er h au l ed , p r o c eed as f ol l ows :
(2) Inv er t ai r h o r n so t hat wei g ht of float only i s
f o r c i ng need l e ag ai ns t seat .
(3) Meas u r e t he c l ear anc e b et ween t op of float and
float st op ( Fi g . 18). T h e c l ear anc e s h o u l d be .200 i nc h
d= 1/64 ( #7 dr i l l ) . B e s u r e d r i l l or gauge i s p er f ec t l y
l ev el wh en meas u r i ng .
If an ad j u s t ment i s nec es s ar y , bent float l i p t o war d
or away f r o m need l e, u s i ng a nar r o w bl ade s c r ew-
d r i v er ( Fi g . 19), u nt i l c o r r ec t c l ear anc e or s et t i ng h as
b een obt ai ned.
(4) Ch ec k float dr op, by h o l d i ng ai r h o r n i n an u p -
r i g ht pos i t i on. Th e bot t om edge of float s h o u l d be
p ar al l el t o u nd er s i d e s u r f ac e of ai r h o r n ( Fi g . 20). If
an ad j u s t ment i s nec es s ar y , b end t ang on float ar m
u nt i l p ar al l el s u r f ac es h av e b een obt ai ned.
Installing Air Horn
(1) Pl ac e a new g as k et on ai r h o r n, t h en c h ec k t o
be s u r e mai n wel l t ubes ar e s t r ai g ht . L o w e r ai r h o r n
s t r ai g ht down on mai n body; g u i d i ng ac c el er at o r
PY853
FLOAT STOP
AIR HORN INVERTED
- FLOAT
Fig. 19Bending Float Adjusting Lip
p u mp p l u ng er i nt o i t s c y l i nd er . Caution: Do not cut lip
of plunger on sharp edge of cylinder. Ins t al l at t ac h i ng
s c r ews (l ong s c r ew i n c ent er ) and t i g ht en s ec u r el y
( Fi g . 6).
(2) Ins t al l f u el i nl et t ube fitting and g as k et i n ai r
h o r n and t i g ht en s ec u r el y .
(3) Eng ag e h o o k ed end of ac c el er at o r p u mp r o d i n
t hr ot t l e l ev er (hook end t o war d out s i de). Eng ag e ot her
end of r o d i n c ent er sl ot of p u mp r o c k er a r m ( Fi g . 2).
(4) Ins t al l r o c k er a r m on ac c el er at o r p u mp s haf t
wi t h flats i n al i g nment ( Fi g . 2). Ins t al l at t ac hi ng l oc k -
was h er and nut . Ti g h t en s ec u r el y .
(5) Ins t al l b o wl v ent v al v e l ev er on ai r h o r n, b y first
i ns er t i ng s p r i ng i nt o pos i t i on i n ar m, wi t h end s of
s p r i ng poi nt i ng t o war d f u el i nl et fitting ( Fi g . 5). Sl i d e
as s emb l y ov er s t ub s haf t on ai r h o r n. Al i g n s p r i ng and
ar m wi t h s t ub s haf t and end of s p r i ng ov er r ai s ed por -
t i on of f u el i nl et fitting. Ins t al l " E " c l i p t o s ec u r e. Vent
v al v e s h o u l d be i n c l o s ed pos i t i on.
(6) Ins t al l f as t i dl e c am on ai r h o r n s t ub s haf t , wi t h
s t eps t o war d f as t i dl e ad j u s t i ng s c r ew. Ins t al l " E "
c l i p t o s ec u r e ( Fi g . 14).
(7) To i ns t al l f as t i dl e c o nnec t o r r o d , eng ag e p l ai n
end i n sl ot of f as t i dl e c am (f r om i ns i de) . Eng ag e ot her
end of r o d i n c h o k e l ev er . Wi t h c h o k e v al v e wi d e open,
AIR HORN
UNDERSIDE
m \ SURFACE OF
yj AIR HORN
FLOAT -
DRILL OR GAUGE
PY852
BOTTOM EDGE
OF FLOAT
FLOAT SHOULD BE PARALLED
PY854
Fig. IB-Checking Float Setting Fig. 20Checking Float Drop
14-24 FUEL SYSTEMHOLLEY 2200-
s l i de l ev er o v er c h o k e s h af t s ; ( al i g ni ng flats) and poi nt -
i ng d i r ec t l y t o f as t i dl e c am s t ub s haf t ( Fi g . 3). Ins t al l
at t ac hi ng l o c k was h er and nut . Ti g h t en s ec u r el y .
Choke Vacuum Diaphragm
Ins p ec t t he d i ap h r ag m v ac u u m fitting t o be s u r e
t hat t he pas s ag e i s not p l u g g ed wi t h f o r ei g n mat er i al .
L e a k c h ec k t he d i ap h r ag m t o d et er mi ne i f i t h as i n-
t er nal l eak s . To do t hi s , first d ep r es s t he d i ap h r ag m
s t em, t h en p l ac e a finger ov er t he fitting t o s eal t he
openi ng . Rel eas e t he s t em. If t he s t em mo v es mo r e
t h an 1/16 i nc h i n 10 (t en) s ec o nd s , t he l eak ag e i s ex-
c es s i v e and t he as s emb l y mu s t be r ep l ac ed .
Ins t al l c h o k e d i ap h r ag m as s emb l y on t he ai r h o r n
as f ol l ows :
(1) Eng ag e f r ee end of c h o k e oper at i ng l i nk i n sl ot
of c h o k e l ev er .
(2) Ins t al l c h o k e d i ap h r ag m and mo u nt i ng b r ac k et
on ai r h o r n. Ins t al l at t ac h i ng s c r ews and t i g ht en s e-
c u r el y .
(3) Ins p ec t r u b b er hos e f o r c r ac k s bef or e p l ac i ng i t
on c o r r ec t c ar b u r et o r fitting, ( Fi g . 1) af t er v ac u u m
k i c k ad j u s t ment h as b een mad e.
CARBURETOR ADJ USTMENTS
It i s v er y i mp o r t ant t hat t he f ol l owi ng ad j u s t ment s
ar e mad e on a r ec o nd i t i o ned c ar b u r et o r and i n t he
s eq u enc e l i s t ed :
Fast Idle Speed and Cam Position Adjustment
Th e f as t i dl e eng i ne s p eed ad j u s t ment s h o u l d be
mad e on t he v eh i c l e, as d es c r i b ed i n t he F a s t Id l e
Sp eed Ad j u s t ment ( On Veh i c l e) p ar ag r ap h . Ho wev er ,
t he F a s t Id l e Ca m Po s i t i o n Ad j u s t ment c an be mad e
on t he b enc h . Th i s ad j u s t ment i s i mp o r t ant t o as s u r e
t hat t h e s p eed s of eac h s t ep of t he c am o c c u r at t he
p r o p er t i me d u r i ng eng i ne war m-u p .
(1) Wi t h f as t i dl e s p eed ad j u s t i ng s c r ew c o nt ac t i ng
s ec o nd h i g h es t s p eed s t ep on t he f as t i dl e c am, mo v e ,
c h o k e v al v e t o war d c l o s ed pos i t i on wi t h l i g ht p r es s u r e
on c h o k e s h af t l ev er .
(2) I ns er t s pec i f i ed d r i l l (see Spec i f i c at i ons ) b et ween
t op of c h o k e v al v e and wal l of ai r h o r n ( Fi g . 21). An
ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag i s not
obt ai ned as d r i l l s h ank i s b ei ng r emo v ed .
(3) If an ad j u s t ment i s nec es s ar y , b end f as t i dl e
c o nnec t o r r o d at ang l e, u s i ng To o l T109-213, u nt i l
c o r r ec t v al v e o p eni ng h as b een obt ai ned.
V acu u m Kick Adjustment(This test can be
made On or Off vehicle.)
Th e c h o k e d i ap h r ag m ad j u s t ment c ont r ol s t h e f u el
d el i v er y wh i l e t he eng i ne i s r u nni ng . It pos i t i ons t he
c h o k e v al v e wi t h i n t he ai r h o r n by ac t i on of t he l i nk -
age b et ween t he c h o k e s haf t and t he d i ap h r ag m. T h e
d i ap h r ag m mu s t be ener g i zed t o meas u r e t he v ac u u m
LIGHT CLOSING A
PRESSURE ON *
CHOKE LEVER ~
DRILL OR GAUGE
FAST IDLE SPEED
ADJUSTING SCREW
ON SECOND HIGHEST
STEP OF CAM
(ADJUST SCREW TO
OBTAIN FAST IDLE
S P E E
- CAM
I
/
BEND ROD
AT ANGLE FOR
ADJUSTMENT
SCREW PY855
F i g . 21Fast Idle Speed and Cam Position
Adjustment
k i c k ad j u s t ment . Us e ei t h er a di s t r i but or t est mac h i ne
wi t h a v ac u u m s o u r c e, or v ac u u m s u p p l i ed by ano t h er
v eh i c l e.
(1) If ad j u s t ment i s t o be mad e wi t h eng i ne r u nni ng ,
d i s c o nnec t f as t i dl e l i nk ag e t o al l ow c h o k e t o c l os e t o
t he k i c k pos i t i on wi t h eng i ne at c u r b i dl e. If an au x i l -
i ar y v ac u u m s o u r c e i s t o be u s ed , open t hr ot t l e v al v es
(engi ne not r u nni ng ) and mo v e c h o k e t o c l o s ed pos i -
t i on. Rel eas e t hr ot t l e first, t h en r el eas e c h o k e.
(2) Wh e n u s i ng an au x i l i ar y v ac u u m s o u r c e, di s -
c o nnec t v ac u u m hos e f r o m c ar b u r et o r and c o nnec t i t
t o hos e f r o m v ac u u m s u p p l y , wi t h a s mal l l eng t h of
t ube t o ac t as a fitting. Remo v al of h o s e f r o m di a-
p h r ag m may r eq u i r e f o r c es wh i c h c an d amag e t he s y s -
t em. Ap p l y a v ac u u m of 10 or mo r e i nc h es of mer c u r y .
(3) Ins er t s pec i f i ed d r i l l ( r ef er t o Spec i f i c at i ons ) be-
DRiLL OR GAUGE
MINIMUM OF
10 INCHES
OF VACUUM
OR DIAPHRAGM
(REQUIRED)
4
TO
VACUUM
SOURCE
LIGHT
^CLOSING PRESSURE
ON CHOKE LEVER
BEND LINK
FOR ADJUSTMENT
PY856
F i g . 22Vacuum Kick Adjustment
A
t ween t op of c h o k e v al v e and wal l of ai r h o r n ( Fi g . 22).
Ap p l y suf f i c i ent c l o s i ng p r es s u r e on l ev er t o wh i c h
c h o k e r o d at t ac hes t o pr ov i de a mi ni mu m c h o k e v al v e
openi ng , wi t hout di s t or t i on of d i ap h r ag m l i nk . Not e
t hat t he c y l i nd r i c al s t em of d i ap h r ag m wi l l ex t end as
i nt er nal s p r i ng i s c o mp r es s ed . Th i s s p r i ng mu s t be
f u l l y c o mp r es s ed f o r p r o p er meas u r ement of v ac u u m
k i c k ad j u s t ment .
(4) An ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag
i s not obt ai ned as d r i l l i s b ei ng r emo v ed . Sh o r t en or
l eng t h en d i ap h r ag m l i nk to obt ai n c o r r ec t c h o k e open-
i ng . L eng t h c h ang es s houl d be made c ar ef u l l y b y b end -
i ng (open or c l os i ng) t he b end p r o v i d ed i n d i ap h r ag m
l i nk . CAUTI ON: DO NOT APPLY TWI STI NG OR
B ENDI NG F O R C E T O DI AP HRAGM.
(5) Rei ns t al l v ac u u m hos e on c o r r ec t c ar b u r et o r
fitting. Ret u r n f as t i dl e l i nk ag e to i t s o r i g i nal c ondi -
t i on i f d i s t u r b ed as s ug g es t ed i n St ep No . 1.
(6) Mak e f ol l owi ng c h ec k . Wi t h no v a c u u m appl i ed
to d i ap h r ag m, t he choke valve should move freely
b et ween open and c l os ed pos i t i ons . If mo v ement i s
not f r ee, ex ami ne l i nk ag e f o r mi s al i g nment o r i nt er -
f er enc es c au s ed by bendi ng oper at i on. Rep eat adj us t -
ment i f nec es s ar y to pr ov i de p r o p er l i nk oper at i on.
Choke Unloader (Wide Open Kick)
Th e c h o k e u nl o ad er i s a mec h ani c al d ev i c e t o par -
t i al l y open t he c h o k e v al v e at wi d e open t hr ot t l e. It i s
u s ed to el i mi nat e c hok e enr i c h ment d u r i ng c r ank i ng
of an eng i ne. Eng i nes wh i c h h av e flooded or s t al l ed
b y ex c es s i v e c h o k e enr i c h ment c an be c l ear ed by u s e
of t he u nl o ad er . Ad j u s t t he c h o k e u nl o ad er as f ol l ows :
(1) Ho l d t hr ot t l e v al v es i n wi de open pos i t i on. In-
s er t s pec i f i ed d r i l l (see Spec i f i c at i ons ) b et ween u p p er
edg e of c h o k e v al v e and i nner wal l of ai r h o r n ( Fi g .
23).
(2) Wi t h a finger l i g ht l y p r es s i ng ag ai ns t s haf t
Fig. 23Choke Unloader Adjustment
(Wide Open Kick)
HOLLEY 2200FUEL SYSTEM 14-2S
Fig. 24Accelerator Pump Adjustment
l ev er , a s l i g ht d r ag s h o u l d be f el t as d r i l l i s b ei ng
wi t h d r awn. If an ad j u s t ment i s nec es s ar y , b end u n-
l o ad er t ang on t hr ot t l e l ev er u nt i l c o r r ec t openi ng h as
b een obt ai ned ( Fi g . 23). Us e To o l T109-213.
Accel erator Pump
(1) B a c k off c u r b i dl e s p eed ad j u s t i ng s c r ew. Op en
c h o k e v al v e so t hat f as t i dl e c a m al l ows t hr ot t l e v al v es
t o be c ompl et el y s eat ed i n b o r es . B e s u r e t hat p u mp
c o nnec t o r r o d i s i ns t al l ed i n c ent er sl ot of ac c el er at o r
p u mp r o c k er ar m.
(2) Cl o s e t hr ot t l e v al v es t i ght l y . Meas u r e t he di s-
t anc e bet ween t op of ai r h o r n and end of p l u ng er
s haf t ( Fi g . 24). Th i s meas u r ement s h o u l d be 9/16 i nc h .
(3) To ad j u s t p u mp t r av el , b end p u mp oper at i ng
r o d , u s i ng To o l T109-213, at l oop of r o d , u nt i l c o r r ec t
s et t i ng h as b een obt ai ned.
Bowf Vent
(1) Wi t h c u r b i dl e s p eed ad j u s t i ng s c r ew at c u r b
W PY859
Fig. 25Bowl Vent Adjustment
14-28 FUEL SYSTEMAVS
A
i dl e, t h er e s h o u l d be 5/ 64 i nc h c l ear anc e b et ween
b o wl v ent v al v e and s eat on ai r h o r n wh en t hr ot t l e
v al v es ar e c l o s ed ( Fi g . 25).
(2) If an ad j u s t ment i s nec es s ar y , b end t ang on ac -
c el er at o r p u mp r o c k er ar m, u s i ng To o l T109-41, u nt i l
c o r r ec t v ent v al v e o p eni ng h as b een obt ai ned.
Idle Speed Adjustment (Curb Idle)
( Ref er t o Gener al Inf o r mat i o n at F r o nt of Sec t i on. )
F as t Idle Speed Adjustment (On Vehicle)
F a s t i dl e eng i ne s p eed i s u s ed t o o v er c o me c ol d
eng i ne f r i c t i o n s t al l s , af t er c o l d s t ar t s and s t al l s be-
c au s e of c ar b u r et o r i c i ng . Set t hi s ad j u s t ment af t er
t he v eh i c l e odomet er i nd i c at es o v er 500 mi l es t o i n-
s u r e a no r mal eng i ne f r i c t i o n l ev el . Pr ep ar e eng i ne by
d r i v i ng at l eas t five mi l es . Co nnec t a t ac h o met er and
s et t he c u r b i dl e s p eed and mi x t u r e, t h en p r o c eed as
f ol l ows :
(1) Wi t h eng i ne off and t r ans mi s s i o n i n P AR K or
NEUT R A L pos i t i on, open t hr ot t l e s l i g ht l y .
(2) Cl o s e c h o k e v al v e u nt i l f as t i dl e s c r ew c an be
pos i t i oned on s ec o nd h i g h es t s t ep of f as t i d l e c am
( Fi g . 26).
(3) St ar t eng i ne and d et er mi ne s t abi l i zed s p eed .
T u r n f as t i dl e s p eed s c r ew i n or out t o s ec u r e s pec i f i ed
FAST IDLE
CAM
CHOKE VALVE
^"WI DE OPEN
J *.:r FAST IDLE
WSPEED
A\ ADJUSTING
1
*' I SCREW ON
.'SECOND
HIGHEST
STEP OF
CAM
(ADJ UST
SCREW TO
OBTAIN
FAST IDLE
SPEED)
SCREW
P Y 8 6 0
Fig. 26-Fast Bdle Spedl Adjustment (On Vehicle)
s p eed . (See Spec i f i c at i ons . )
(4) St o p p i ng eng i ne b et ween ad j u s t ment s i s not
nec es s ar y . Ho wev er , r epos i t i on f as t i dl e s p eed s c r ew
on c a m af t er eac h s p eed ad j u s t ment t o p r o v i d e c or -
r ec t t hr ot t l e c l o s i ng t or que.
To s et i dl e s p eed on v eh i c l es , r ef er t o F u e l Sy s t em
Ge ne r a l Inf o r mat i o n Par ag r ap h .
AVS SERIES CARBURETOR
I NDEX
Pag e
Aut omat i c Ch o k e (wel l t ype) 1
Car bur et or Ad j u s t ment s 33
Ac c el er at o r Pu mp and B owl Vent . . . . . . . . 34-35
Ai r Val v e Sec o nd ar y 35
B owl Vent Val v e 35
Ch o k e Vac u u m K i c k 33
Ch o k e Unl o ad er (Wi de Op en K i c k ) 34
Fas t Idl e Cam Pos i t i on 33
Fas t Idl e Sp eed (On Veh i c l e) 35
GENERAL I NFORMATI ON
Pag e
Idl e Sp eed 35
Sec o nd ar y Thr ot t l e L ev er 34
Sec o nd ar y Thr ot t l e L o c k o u t . . 35
Cl eani ng Car bur et or Par t s 1
Cl o s ed Cr ank c as e Vent Sy s t em . . . ( Eng i ne Gr oup)
Di s as s emb l i ng Car bur et or 28
Gener al Inf or mat i on 26
Ins pec t i on and Reas s emb l y 30
Sp ec i f i c at i o ns . . 66
383 Cubi c Inch Engine
T h e Car t er f o u r b ar r el c ar b u r et o r mo d el s C. A. S.
( Cl eaner Ai r Sy s t em) AVS- 4736S and AVS- 4732S ar e
u s ed on t he 383 c u . i n. eng i nes wh en t he v eh i c l es ar e
eq u i p p ed wi t h au t o mat i c t r ans mi s s i o ns . AVS- 4732S
i s u s ed on v eh i c l es wi t h ai r c o nd i t i o ni ng onl y , and i s
eq u i p p ed wi t h a hot i dl e c o mp ens at o r v al v e. Th i s v al v e
i s a t h er mo s t at i c al l y o p er at ed ai r b l eed , t o r el i ev e
an o v er r i c h c ondi t i on at i dl e. Th i s c ondi t i on i s t he
r es u l t of ex c es s i v e heat and r es u l t ant o v er r i c h mi x -
t u r es ( Fi g . 1).
Th e Car t er f o u r b ar r el c ar b u r et o r mo d el E. C . S.
( Ev ap o r at i o n Co nt r o l Sy s t em) AVS-4734S i s u s ed wh e n
t h e v eh i c l e i s eq u i p p ed wi t h an aut omat i c t r ans mi s -
s i o n. Th i s c ar b u r et o r i s al s o eq u i p p ed wi t h a hot i dl e
c o mp ens at o r v al v e, as AVS-4732S abov e. ( Fi g . 1).
Al l of t hes e c ar b u r et o r s ar e eq u i p p ed wi t h a di s t r i b-
u t o r g r o u nd s wi t c h , wh i c h r et ar d s t he d i s t r i b u t o r
wh en t he c ar b u r et o r i s at c u r b i dl e, f or bet t er emi s -
s i o n c o nt r o l .
440 Cubi c Inch Engine
T h e Car t er f o u r b ar r el c ar b u r et o r mo d el s C. A. S.
( Cl eaner Ai r Sy s t em) AVS-4737S, AVS-4738S and
AVS- 4741S ar e u s ed on t he 440 c u . i n. eng i nes w h e n
t he v eh i c l es ar e eq u i p p ed wi t h a s t and ar d or aut o-
mat i c t r ans mi s s i o n r es p ec t i v el y . AVS-4741S i s u s ed
wi t h ai r c ondi t i oni ng onl y and h as a hot i dl e c o m-
-AVSFUEL SYSTEM 14-27
CHOKE VALVE
CHOKE VALVE
ACCELERATOR PUMP
ROCKER ARM
CHOKE VACUUM
DIAPHRAGM
STEP-UP PISTON COVER
PLATE (2)
BOWL VENT
VALVE ARM
DISTRIBUTO!
VACUUM
ADVANCE
TUBE FITTING
STEP-UP PISTON
COVER PLATE (2)
FUEL INLET
TUBE ' FITTING
CLOSED
CRANKCASE
VENT
TUBE FITTING
IDLE MIXTURE ADJUSTING
SCREW LIMITER CAPS
ACCELERATOR
PUMP ROD
CURB IDLE SPEED
ADJUSTING SCREW
BOWL VENT VALVE
' CHOKE CONTROL
. FAST IDLE
L E V E R
' ^CONNECTOR C H Q K E
'
R O D
DIAPHRAGM
\A FAST IDLE LINK
!p*CAM
UNLOADER
TANG
THROTTLE LEVER ^ R S X
CONNECTOR LINK
THROTTLE
4 BODY
FAST IDLE SPEED / DIAPHRAGM
ADJUSTING SCREW / VACUUM HOSE
ACCELERATOR PUMP
PLUNGER STEM
CHOKE
VACUUM
DIAPHRAGM
ACCELERATOR PUMP
PLUNGER STEM
ACCELERATOR
PUMP ROCKER
ARM
THROTTLE
LEVER
ACCELE-
RATOR
^-.PUMP
ROD
(CENTER
HOLE)
CURB IDLE
SPEED
ADJUSTING
SCREW
ACCELERATOR
PUMP ROD
IDLE MIXTURE ADJUSTING
SCREW LIMITER CAPS
CARBURETOR ASSEMBLY AVS C.A.S.
DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
ACCELERATOR PUMP
PLUNGER STEM
ACCELERATOR
PUMP
ROCKER ARM
CHOKE
LEVER
ACCELERATOR
PUMP ROD
THROTTLE
LEVER
CURB IDLE
SPEED
ADJUSTING
SCREW
FAST IDLE
SPEED
ADJUSTING
SCREW
CHOKE VALVE
AIR VALVE
STEP-UP PISTON CHOKE
COVER PLATE (2) VALVE ACCELERATOR
BOWL VENT VALVE
TUBE FITTING
BOWL VENT VALVE
(CHECKING OPENING)
PLUG
; FUEL INLET
J
>
:>
'^TUBE FITTING
FUEL INLET
TUBE FITTINC
\
CHOKE CONTROL
LEVER " ,h Vj
BOWL VENT VALVE ^
TUBE FITTING
CHOKE
DIAPHRAGM LINK ^
AIR CLEANER TO
CARBURETOR
VENT TUBE BOWL VENT VALVE
OPERATING LEVE
PUMP
ROCKER ARM
THROTTLE
LEVER
/ CURB IDLE
S&*J
S P E E D
. ADJUSTING
FAST IDLE
CONNECTOR ROD
CHOKE UNLOADER TANG
(BEND TO ADJUST

DISTRIBUTOR
GROUND
SWITCH
TERMINAL
CLOSED
CRANKCASE
DISTRIBUTOR \ \ VENT TUBE
VACUUM \ \ FITTING
ADVANCE \\
TUBE FITTING \
ADJUSTING SCREW
LIMITER CAPS
/ VACUUM IDLE MIXTURE
j DIAPHRAGM
BOWL VENT VALVE
OPERATING LEVER
(BEND TO ADJUST)
CARBURETOR ASSEMBLY AVS E.C.S.
PY726
Fig. ICarburetor Assembly
14-28 FUEL SYSTEMAVS
A
pens at or val ve, as descri bed pre vi ous l y. (Fi g. 1).
The Cart e r f our ba rre l ca rbure t or model s E.C.S.
(Evaporat i on Con t rol System) AVS- 4739S and AV S -
4740S are used on t he 440 cu. i n . engi nes whe n t he
vehi cl es are e qui ppe d w i t h s t andard or aut omat i c
t ransmi ssi ons respect i vel y. These t wo ca rbure t ors are
also e qui ppe d w i t h a hot I dl e compensat or val ve as Is
AVS-4741S above. (Fi g. I ) .
These five AVS carbure t ors are e qui ppe d w i t h a
d i s t ri but or groun d s wi t ch, whi ch re t a rds t he d i s t ri b-
ut or whe n t he ca rbure t or Is at i dl e , f or be t t e r emi s-
si on cont rol . The i d l e speed sol enoi d whi ch i s moun t e d
on t hes e carbure t ors , (Fi g. 21) i s used t o ma i n t a i n a
hi ghe r I dl e speed whe n t he vehi cl e i s r un n i n g a nd
al l ows t he t hrot t l e t o close t o a l ow I dl e speed t hr ot t l e
pos i t i on whe n t he I gn i t i on ke y i s t ur n e d off, t o pre ve nt
" a f t e r r un n i n g . "
Since t he servi ce procedures, are i d e n t i ca l on a l l
Cart e r AVS carbure t ors , t he I l l us t ra t i ons s howi ng t he
vari ous di sassembl y procedures w i l l not al ways show
any one specific ca rbure t or.
The t hrot t l e val ves of t he secondary ha l f of t he
ca rbure t or are me chani cal l y connect ed t o t he pr i ma r y
val ves and open w i t h t he pr i ma r y af t e r an a pprox i -
mat e 60 l ag; and cont i nue t o open un t i l bot h pr i ma r y
and secondary t hrot t l e val ves re ach t he wi d e open
pos i t i on s i mul t ane ous l y. As engi ne speed Increases,
t he f orces e xe rt e d by t he ve l oci t y of i n t a k e a i r d own
t hrough t he Vent uri s of t he ca rbure t or Increases a nd
t ends to o v er c o me t he ai r v al v e s p r i ng at t ac hed t o
t he ai r v al v e, p er mi t t i ng t he ai r v al v e to pos i t i on i t s
s el f ac c o r d i ng t o eng i ne r eq u i r ement s .
Th e AV S (ai r v al v e s ec o nd ar y ) c ar b u r et o r c on-
t ai ns many f eat u r es , s ome of wh i c h ar e t he l oc at i ons
f or t he st ep-up r ods and pi s t ons . Th e st ep-up r o d s ,
pi s t ons and s p r i ng s ar e ac c es s i b l e f o r s er v i c e wi t hout
r emo v i ng t he ai r h o r n or t he c ar b u r et o r f r o m t h e
eng i ne. Th e p r i mar y v ent u r i as s emb l i es ar e r ep l ac e-
abl e and c ont ai n many of t he c al i br at i on poi nt s f o r
bot h t he h i g h and l ow s p eed s y s t em. One f u el b o wl
f eeds bot h t he p r i mar y and s ec o nd ar y nozzl es on t he
r i g h t s i de wh i l e t he ot her f u el b o wl t ak es c ar e of t h e
p r i mar y and s ec o nd ar y nozzl es on t he l ef t s i de. Th i s
p r o v i d es i mp r o v ed p er f o r manc e i n c o r ner i ng , q u i c k
s t ops and ac c el er at i o n.
Al l t he maj o r c as t i ng s of t he c ar b u r et o r ar e al u mi -
nu m, wi t h t he t hr ot t l e body c as t i nt eg r al wi t h t he
mai n body. Th i s al l ows an o v er al l h ei g h t r ed u c t i o n i n
t he c ar b u r et o r . Th e s ec t i on c o nt ai ni ng t he ac c el er at o r
p u mp i s t er med t he p r i mar y s i de of t he c ar b u r et o r .
Th e r ear s ec t i on i s t he s ec o nd ar y . Th e five c o nv en-
t i onal s y s t ems u s ed i n p r ev i o u s f o u r b ar r el c ar b u r et -
o r s ar e al s o u s ed i n t hi s uni t . Th e five c o nv ent i o nal
s y s t ems ar e, t wo float s y s t ems , t wo l o w s p eed s y s t ems ,
( p r i mar y s i de onl y ) t wo h i g h s p eed s y s t ems , one
ac c el er at o r p u mp s y s t em and one aut omat i c c h o k e
c o nt r o l s y s t em.
SERVICE PROCEDURES
DI SASSEMBLI NG CARBURETOR (Fig 1)
(1) Pl ac e c ar b u r et o r as s emb l y on r ep ai r s t and To o l
C-3400 or T-109-287S el ev at i ng l eg s . Th e s e t ool s ar e
u s ed to pr ot ec t t hr ot t l e v al v es f r o m d amag e and t o
pr ov i de a s ui t abl e bas e f o r wo r k i ng .
(2) Remo v e h ai r p i n c l i p t hat at t ac hes f as t i dl e c o n-
nec t o r r o d t o f as t i d l e c am. Di s eng ag e r o d f r o m c am
t h en s wi ng r o d at an ar c u nt i l i t c an be d i s eng ag ed
f r o m c h o k e oper at i ng l ev er .
(3) Remo v e h ai r p i n c l i p t hat hol ds t hr ot t l e c o n-
nec t o r r o d i n c ent er hol e of ac c el er at o r p u mp ar m.
Di s eng ag e r o d f r o m ar m and t hr ot t l e l ev er , t h en r e-
mo v e f r o m c ar b u r et o r .
(4) Remo v e s c r ews at t ac h i ng s t ep-up pi s t on and r o d
c o v er pl at es . Ho l d c o v er d o wn wi t h a finger t o p r ev ent
pi s t on and r o d s f r o m f l y i ng out . L i f t off pl at es and
s l i de s t ep-up pi s t ons and r o d s out of ai r h o r n, ( Fi g .
2). Remo v e s t ep-up pi s t on s p r i ng s .
(5) Remo v e v a c u u m h o s e b et ween c ar b u r et o r t hr ot -
t l e body and v a c u u m d i ap h r ag m.
(6) Remo v e c l i p f r o m c h o k e o p er at i ng l i nk and di s -
eng ag e l i nk f r o m d i ap h r ag m p l u ng er (st em) and
c h o k e l ev er . ( Fi g . 1).
(7) Remo v e v ac u u m d i ap h r ag m and b r ac k et as s em-
bl y and pl ac e t o one s i de t o be c l eaned as a s p ec i al
i t em. A l i q u i d c l eaner may d amag e d i ap h r ag m ma-
t er i al .
(8) Remo v e s c r ews t hat at t ac h i dl e s ol enoi d b r ac k et
and s ol enoi d t o ai r h o r n and mai n body. Remo v e sol e-
S T EP UP
PISTON AND
METERING ROD
STEP UP
PISTON
SPRING
SCREW
COVER PLATE 3 S T A G E M ET ERI N G ROD NR513A
Fig. 2Removing or installing Step-Up
Pistons and Rods
A
AVSFUEL SYSTEM 14-29
noi d as s emb l y f r o m c ar b u r et o r . (If so equi pped. )
(9) Remo v e ei ght s c r ews t hat at t ac h ai r h o r n to
mai n body. L i f t ai r h o r n s t r ai g ht u p and away f r o m
mai n body. Wh e n r emo v i ng ai r h o r n, u s e c ar e so as
not to b end or d amag e floats. Remo v e ac c el er at o r
p u mp , p l u ng er l o wer s p r i ng f r o m p u mp c y l i nd er .
(10) Remo v e hot i dl e c o mp ens at o r and g as k et (i f
so equi pped).
Disassembling Air Horn
Pl ac e ai r h o r n i n an i nv er t ed pos i t i on on b enc h (to
pr ot ec t t he floats) t h en p r o c eed t o d i s as s emb l e as f ol -
l ows :
(1) Us i ng a s ui t abl e t ool , r emo v e float f u l c r u m p i ns ,
(l eft and r i ght ) t h en l i f t float up and out of bos s es on
ai r h o r n. It i s s ug g es t ed t hat t he float on t he p u mp
s i de be mar k ed so t hat floats c an be r ei ns t al l ed i n
t hei r r es p ec t i v e pos i t i ons .
(2) Remo v e t wo need l e v al v es f r o m t h ei r r es p ec t i v e
s eat s , af t er mar k i ng one on p u mp s i de f o r i dent i f i c a-
t i on. Us i ng a wi d e bl ade s c r ew d r i v er , r emo v e need l e
v al v e s eat s . B e s u r e eac h need l e v al v e i s r et u r ned t o
i t s o r i g i nal seat at r eas s emb l y .
(3) Remo v e s h o u l d er s c r ew and s p r i ng h o l d i ng ac -
c el er at or p u mp r o c k er ar m and b o wl v ent ar m t o ai r
h o r n ( C. A. S. ) . Remo v e ar ms and di s eng ag e p u mp l i nk
f r o m p u mp s t em. Sl i d e ac c el er at o r p u mp p l u ng er and
s p r i ng out of ai r h o r n. Remo v e g as k et .
(4) Pl ac e ac c el er at o r p u mp p l u ng er i n a j a r of
c l ean gas ol i ne o r k er o s ene, t o p r ev ent l eat h er f r o m
d r y i ng out .
(5) Remo v e f u el i nl et fitting and filter s c r een f r o m
ai r h o r n.
(6) Tes t f r eenes s of c h o k e mec h ani s m i n ai r h o r n.
Th e c h o k e s haf t mu s t float f r ee t o oper at e c o r r ec t l y .
If c hok e s haf t s t i c k s i n b ear i ng ar ea, or ap p ear s t o b e
g u mmed f r o m depos i t s i n ai r h o r n, a t hor oug h c l ean-
i ng wi l l be r eq u i r ed .
Main Body Disassembly
(1) Remo v e s c r ews t hat at t ac h ac c el er at o r p u mp j et
h o u s i ng t o mai n body . L i f t out j et h o u s i ng and g as k et
( Fi g . 3). Di s c ar d g as k et . Now, i nv er t mai n body and
dr op out d i s c h ar g e c h ec k need l e f r o m d i s c h ar g e pas -
s age.
(2) Us i ng To o l T-109-58, r emo v e mai n met er i ng j et s
( pr i mar y s i de), ( Fi g . 4). The primary and secondary
main metering jets are not interchangeable. It is
very important that these jets be installed in their
respective locations in the mai n body at reassembly.
(3) Ag ai n u s i ng To o l T-109-58, r emo v e mai n met er -
i ng j et s ( s ec ondar y s i de) , ( Fi g . 4). Remo v e i nt ak e
c h ec k .
(4) Remo v e s c r ews t hat at t ac h p r i mar y v ent u r i
(c hoke and p u mp s i de) t o mai n body . L i f t v ent u r i
s t r ai g ht u p and away f r o m mai n body , ( Fi g . 5). Di s -
c ar d g as k et s . The venturi assemblies are not inter-
PRIMA3Y
G A 5 ; <
"
VEK"."UR;
CLUSTH
(PUMP SIDE* h >,f r
; '
/
ACCEL ERA
T
OR PUMP
-**\ / JET HOUSING
/
- " J T
^ DI SCHARGE P ASSAGE
' ' . PRIMARY
L ; ^ " , VENTURI
f ] N CLUSTER
I CHOKE SIDE)
1
\
INTAKE CHECK BALL
ASSEMBLY
NR514
F i g . 3Removing or installing Accelerator
Pump J et Housing
changeable, side for side and must be reinstalled in
their original locations at reassembly.
(5) Us i ng To o l T-109-59, s c r ew d r i v er bi t , r emo v e
ac c el er at o r p u mp i nt ak e c h ec k v al v e l oc at ed i ns i d e
f u el b o wl , ad j ac ent t o ac c el er at or p u mp c y l i nd er .
(6) Remo v e pl as t i c l i mi t er c ap s f r o m i dl e ai r mi x -
t u r e s c r ews . (B e s u r e and c ount nu mb er of t u r ns t o
s eat t he s c r ews (f r om st op), as t he s ame nu mb er of
t u r ns (f r om seat ) mu s t be mai nt ai ned at i ns t al l at i on. )
Remo v e s c r ews and s p r i ng s f r o m t hr ot t l e body.
Th e c ar b u r et o r no w h as b een d i s as s emb l ed i nt o t wo
u ni t s , namel y ai r h o r n and t he mai n and t hr ot t l e body
c as t i ng . Th e c o mp o nent par t s of eac h h av e b een di s-
as s emb l ed as f ar as nec es s ar y f or c l eani ng and i n-
s p ec t i o n.
It i s u s u al l y not adv i s abl e t o r emo v e t he t hr ot t l e
s haf t s or v al v es u nl es s wear or d amag e nec es s i t at es
t he i ns t al l at i on of new par t s . Du r i ng t he manu f ac t u r e
of t h e c ar b u r et o r , t he l oc at i on of t he i dl e t r ans f er
por t s and t he i dl e d i s c h ar g e por t s t o t he v al v e i s c ar e-
f u l l y es t ab l i s h ed f o r one p ar t i c u l ar as s emb l y , ( Fi g . 6).
Yl
:CIAL TOOL
CHEGC ASSEMBLY
ACCE--:RA~OR "
PU.v.P WrLL
MAIN METERING'
J ET PRIMARY (2)
f $6
1
I NTAKE CH5CK ASSlWVy '>
MAIN
iMETERING
JET
SECONDARY
(2)
NR515
F i g . 4Removing or Installing Main Metering J ets
14-30 FUEL SYSTEMAVS
GASKET
PRIMARY VENTURI
CLUSTER
J (
D
UMP SIDE)
- PRIMARY VENTURI
CLUSTER
* (CHOKE SIDE)
ATTACHI NG
A
SCREWS
NR516
Fig. 5Removing or Installing Primary
Venturi Cluster
T h e v al v es ar e mi l l ed t o gi v e p r b p er p o r t r el at i o n.
I f new t hr ot t l e s haf t s s h o u l d bei ns t al l ed i n an ol d
wo r n body , i t wo u l d be v er y u nl i k el y t hat t he o r i g i nal
r el at i o ns h i p of t h es e por t s t o t he v al v es wo u l d be ob-
t ai ned . A v er y s l i g ht c h ang e i n t he por t r el at i o ns h i p
t o t he v al v es wo u l d ad v er s el y af f ec t no r mal c ar b u -
r et o r oper at i on, b et ween t he s p eed s of 15 and 30
mi l es p er h o u r .
It i s r ec o mmend ed t hat i f t he t hr ot t l e s h af t s ar e
ex c es s i v el y wo r n, t hat a new c ar b u r et o r be i ns t al l ed .
Ho wev er , i f t he t hr ot t l e v al v es h av e b ec o me ni c k ed ,
b u r r ed o r d amag ed , new v al v es may be i ns t al l ed , pr o-
v i d i ng t he f o l l o wi ng i ns t r u c t i o ns ar e c ar ef u l l y f ol -
l o wed . The screws that attach the throttle valves are
staked on the opposite side and care should be used in
removal so as not to break the screws in the t hr ot t l e
shaft. Remove the staked portion of the screws with a
f i l e.
Remo v e t he s c r ews t hat at t ac h t he p r i mar y t hr ot t l e
v al v es t o t he t hr ot t l e s haf t and s l i de v al v e (or v al v es )
out of b o r es .
Remo v e t he s c r ews t hat at t ac h t he s ec o nd ar y t hr ot -
t l e v al v es t o t he t hr ot t l e s haf t and s l i de v al v e (or
v al v es ) out of b o r es .
SPARKAD VANG PORT IDU; DISCH A R O POR IS
PRIMARY
THRO ni l
VALVf S r
SECONDARY , .^4-
THRorm *
VALVES
Th e p r i mar y v al v es and s ec o nd ar y v al v es ar e not
i nt er c h ang eab l e and s h o u l d be k ep t s ep ar at e i n o r d er
t hat eac h may be r et u r ned t o i t s r es p ec t i v e b o r e
( Fi g . 7).
INSPECTION AND REASSEMBLY
(1) Sl i d e p r i mar y t hr ot t l e v al v e (or v al v es ) i nt o
t h ei r r es p ec t i v e bor es , i ns t al l new s c r ews , but do not
t i g ht en. B e s u r e i dl e s peed ad j u s t i ng s c r ew i s b ac k ed
out . Ho l d v al v es i n pl ac e wi t h f i ng er s . ( Fi ng er s p r es s -
i ng on h i g h s i de of v al v es . )
(2) Tap v al v es l i g ht l y i n t hi s pos i t i on, t i g ht en
s c r ews s ec u r el y . St ak e s c r ews b y s q u eezi ng wi t h
p l i er s .
(3) Ins t al l i dl e mi x t u r e s c r ews and s p r i ng s i n t hr ot -
t l e body. ( The t ap er ed por t i on mu s t be s t r ai g ht and
s moot h. If t aper ed por t i on i s g r oov ed or r i d g ed , a
new i dl e mi x t u r e s c r ew s h o u l d be i ns t al l ed t o i ns u r e
h av i ng c o r r ec t i dl e mi x t u r e c ont r ol . ) DO NOT USE A
SCREW DRI VER. T u r n s c r ews l i g ht l y ag ai ns t t h ei r
s eat s wi t h f i nger s . B a c k off t he nu mb er of t u r ns
c o u nt ed at d i s as s emb l y . Ins t al l new pl as t i c c ap s wi t h
t ab ag ai ns t st ops. Th i s s c r ew h as a l ef t h and t h r ead .
T u r n c o u nt er c l o c k wi s e ( Ri c h er ) and c l o c k wi s e ( L ean-
er ) .
(4) Be sure all the metering holes and vent tubes
are clean, in the primary venturi. Pl ac e new p r i mar y
v ent u r i g as k et s i n pos i t i on, t h en i ns t al l t he p r i mar y
v ent u r i (pump and c h o k e s i de) b y l o wer i ng s t r ai g ht
d o wn on g as k et s ( Fi g . 5). Ins t al l at t ac h i ng s c r ews and
t i g ht en s ec u r el y .
(5) Ins t al l p r i mar y and s ec o nd ar y mai n met er i ng
j et s , u s i ng To o l T-109-58. ( Fi g . 4.) Ti g h t en j et s s e-
c u r el y . Ins t al l i nt ak e c h ec k .
(6) Ins t al l ac c el er at o r p u mp i nt ak e c h ec k b al l u s i ng
To o l T-109-59.
(7) Ins t al l hot i dl e c o mp ens at o r and g as k et (i f so
equi pped). Ti g h t en s c r ews s ec u r el y .
Accelerator Pump Test
(1) Po u r c l ean g as ol i ne i nt o c ar b u r et o r b o wl (ap-
' /- SECONDARY
VALVE
PRIMARY
VALVE
l Ml . H'Ai "H R :*o!;:, HM17 KF946C
Fig. 6Ports in Relation to Throttle Valves Fig. 7Throttle Valve Identification
A
p r o x i mat el y 1/2 i nc h deep). Remo v e ac c el er at o r p u mp
p l u ng er f r o m j a r of g as ol i ne. F l e x l eat h er s ev er al
t i mes , t h en s l i de i nt o p u mp c y l i nd er .
(2) Ins t al l ac c el er at o r p u mp d i s c h ar g e c h ec k need l e
i n d i s c h ar g e pas s ag e. Rai s e p u mp p l u ng er and p r es s
l i g h t l y on p l u ng er s haf t t o ex p el ai r f r o m p u mp pas -
s ag es . Us i ng a s mal l c l ean b r as s r o d , hol d d i s c h ar g e
c h ec k need l e f i r ml y on i t s s eat . Ag ai n r ai s e p l u ng er
and p r es s d o wnwar d . No f u el s h o u l d be emi t t ed f r o m
ei t h er t he i nt ak e or d i s c h ar g e pas s ag e.
(3) If f u el does emi t f r o m i nt ak e pas s ag e, r emo v e
i nt ak e c h ec k b al l and r ec l ean t he pas s ag e. F u e l l eak -
age at d i s c h ar g e c h ec k need l e i ndi c at es p r es enc e of
di r t or a d amag ed c h ec k need l e. Cl ean ag ai n and
t h en i ns t al l a new c h ec k need l e. Ret es t f or l eak ag e.
(4) If ei t h er i nt ak e c h ec k as s emb l y or d i s c h ar g e
c h ec k need l e l eak s af t er abov e t es t and s er v i c e fix,
at t empt t o r es eat as f ol l ows :
Intake Check Ball
Remo v e t he i nt ak e c h ec k as s emb l y f r o m t h e t hr ot -
t l e body . Ins t al l a new c h ec k as s emb l y , t h en r et es t as
d es c r i b ed p r ev i o u s l y ( Fi g . 4).
Discharge Check Needle
(1) Wi t h d i s c h ar g e c h ec k need l e i ns t al l ed , i ns er t
a p i ec e of d r i l l r o d d o wn on needl e. L i g h t l y t ap d r i l l
r o d wi t h a h a mme r t o f o r m a new seat . Remo v e and
d i s c ar d ol d need l e and i ns t al l a new one. Ret es t as
d es c r i b ed p r ev i o u s l y . If s er v i c e fix does not c o r r ec t
t he c ondi t i on, a new c ar b u r et o r wi l l h av e t o be i n-
s t al l ed .
(2) Ins t al l ac c el er at o r p u mp d i s c h ar g e c h ec k
need l e, j et h o u s i ng and g as k et . Ins t al l h o u s i ng and
at t ac hi ng s c r ews . Ti g h t en s c r ews s ec u r el y .
(3) Pr es s d o wn on ac c el er at o r p u mp p l u ng er s haf t ,
and as p l u ng er i s b ei ng d ep r es s ed , a c l ear s t r ai g ht
s t r eam s h o u l d emi t f r o m eac h j et . If s t r eams ar e not
i d ent i c al , (i f ei t h er one i s d i v er t ed or r es t r i c t ed ) a
new ac c el er at o r p u mp j et h o u s i ng s h o u l d be i ns t al l ed .
Af t er t est , p o u r g as ol i ne f r o m c ar b u r et o r b o wl and
r emo v e p u mp p l u ng er .
Assembling Air Horn
(1) Sl i d e f u el i nl et s c r een i nt o f u el l i ne fitting, t h en
i ns t al l i n ai r h o r n. Ti g h t en s ec u r el y .
(2) Ch ec k t o s ee i f l eat h er o n ac c el er at o r p u mp
p l u ng er i s h ar d , c r ac k ed or wo r n. If any s i g n of wear
o r det er i or at i on i s ev i dent , i ns t al l a new p l u ng er as -
s emb l y . I ns t al l p u mp l i nk .
(3) Pl ac e p u mp a r m i n pos i t i on ov er bos s of ai r
h o r n and eng ag e p u mp l i nk . Ins t al l b o wl v ent a r m
i n pos i t i on o v er p u mp ar m. Sl i d e s p r i ng o v er pi v ot
s c r ew and i ns t al l t h r o u g h ar ms and bos s . B e s u r e
s h o u l d er of s c r ew ent er s ar ms . Ti g h t en s ec u r el y . En -
g ag e ends of s p r i ng wi t h t ang on v ent ar m and p i n
on ai r h o r n. Ch e c k f o r p r o p er oper at i on.
AVSF UEL SYSTEM 14-31
Th e c ar b u r et o r s ar e eq u i p p ed wi t h s y nt h et i c r u b -
b er t i pped f u el i nl et need l es . T h e need l e t i p i s a r u b -
b er mat er i al wh i c h i s not af f ec t ed b y g as ol i ne and i s
s t abl e o v er a wi d e r ang e of t emp er at u r es . T h e t i p i s
flexible eno u g h t o mak e a good s eal on t he need l e
s eat , and t o gi ve i nc r eas ed r es i s t anc e t o flooding.
Th e u s e of new i nl et need l es r eq u i r e t hat c ar e be
u s ed wh en mak i ng float ad j u s t ment s . Av o i d ap p l y i ng
any p r es s u r e on t he floats wh i c h mi g h t c o mp r es s t he
t i p of t he f u el i nl et need l es . The tip can be com-
pressed sufficiently to cause a f al s e s et t i ng which will
af f ec t correct level of fuel in the bowl.
(4) Pl ac e a new ai r h o r n t o mai n body g as k et i n
pos i t i on on ai r h o r n, t h en i ns t al l float need l e v al v e
s eat s . (B e s u r e eac h need l e s eat and need l e i s r ei n-
s t al l ed i n i t s o r i g i nal posi t i on. )
(5) Sl i d e r i g ht and l ef t floats i nt o pos i t i on i n ai r
h o r n, t hen i ns t al l float f u l c r u m p i ns . (Be sure marked
float is installed on pump side of the air horn.) See
disassembly procedures.
(6) Af t er floats h av e b een i ns t al l ed , c h ec k float
al i g nment , l ev el and dr op s et t i ng s as f ol l ows :
Float Alignment Setting
(1) Si g ht d o wn s i de of eac h float s h el l t o d et er mi ne
i f s i de of t he float i s p ar al l el t o o u t er c ag e of ai r h o r n
c as t i ng , ( Fi g . 8).
(2) If s i d es of float ar e not i n al i g nment wi t h edg e
of c as t i ng , b end float l ev er b y ap p l y i ng p r es s u r e t o
end of float s h el l wi t h t h u mb . To avoid damage to
the float, apply only enough pressure to bend the
float lever.
(3) Af t er al i g ni ng floats, r emo v e as mu c h c l ear anc e
as pos s i bl e bet ween ar ms of float l ev er and l u g s of ai r
h o r n. To do t hi s , b end float l ev er . Th e ar ms of float
l ev er s h o u l d be as p ar al l el as pos s i bl e t o i nner s u r -
f ac es of l ug s of c as t i ng .
F f o c i f Level Setting
(1) Wi t h ai r h o r n i nv er t ed , ai r h o r n g as k et i n p l ac e
THESE SURFACES
MUST BE PARALLEL
WITH EDGE OF CASTING
VALVE SPRING PY727
F i g . 8Checki ng F loat Alignment
14-32 FUEL SYSTEMAVS
and float need l e s eat ed , s l i de float g aug e ( r ef er t o
s pec i f i c at i ons f o r c ar b u r et o r b ei ng wo r k ed on) be-
t ween t op of t he float (at o u t er end) and ai r h o r n gas -
k et , ( Fi g . 9). F l o at s h o u l d j u s t t o u c h g aug e (T-109-
107).
(2) Ch ec k ot her float i n s ame manner . If an ad-
j u s t ment i s nec es s ar y , b end float a r m u s i ng To o l
T-109-22, u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
Af t er b end i ng ar m, r ec h ec k t he float al i g nment .
Float Drop Setting
Fl o at dr op i s t he d i s t anc e t he floats mo v e f r o m t he
i nv er t ed ai r h o r n (fl oat l ev el s et t i ng posi t i on) t o t he
ai r h o r n i n u p r i g h t pos i t i on.
(1) Wi t h ai r h o r n i nv er t ed (ups i de down) p l ac e ai r
h o r n i n u p r i g h t pos i t i on and meas u r e t h e d i s t anc e
floats mo v e f r o m i nv er t ed t o u p r i g h t pos i t i on. Th i s
meas u r ement s h o u l d be 1/2 i nc h ( Fi g . 10). Ai r h o r n
g as k et i ns t al l ed . If an ad j u s t ment i s nec es s ar y , b end
st op t abs on float l ev er s u nt i l c o r r ec t dr op s et t i ng
h as b een obt ai ned. B e nd t ab t o war d need l e s eat t o
l es s en dr op, o r away f r o m s eat t o i nc r eas e dr op.
(2) Af t er floats h av e b een c h ec k ed and ad j u s t ed ,
c o nt i nu e t o as s emb l e c ar b u r et o r as f ol l ows :
(3) Pl ac e ac c el er at o r p u mp p l u ng er l o wer s p r i ng i n
p u mp c y l i nd er , t h en l o wer ai r h o r n c ar ef u l l y d o wn on
mai n body. Ca r e mu s t be t ak en t o c ent er s mal l b r as s
mai n b l eed t u b es so t hat t hey wi l l p as s t h r o u g h hol es
i n ai r h o r n wi t hout b ei ng d amag ed . Be sure the fuel
baffles on the air horn, slide down in front, (bowl side)
of the float chamber baffles, or the air horn will not
index correctly with the main body and can cause the
floats to hang up. Be sure the leather on the plunger
does not curl or wrinkle. Accelerator pump operation
will be affected if this precaution is not observed.
Pl ac e c u r b i dl e s o l eno i d i n pos i t i on on c ar b u r et o r .
Ins t al l at t ac h i ng s c r ews and t i g ht en s ec u r el y . (If so
equi pped. )
(4) Ins t al l ai r h o r n at t ac h i ng s c r ews and t i g ht en
s ec u r el y .
Th e c h ang e f r o m l o w s p eed , bes t f u el ec o no my ,
r o ad l oad mi x t u r es t o r i c h er wi d e open t hr ot t l e f u l l
p o wer mi x t u r es i s no w ac c o mp l i s h ed i n t wo s t ep s .
Th i s h as mad e i t pos s i bl e t o s ec u r e bes t l ow s p eed
f u el ec o no my wi t h o u t s ac r i f i c i ng p er f o r manc e i n t he
FLOAT
I i OAi o AUOi
/
ND Of MOAT
Fig. 10Checking Float Drop
i nt er med i at e s p eed r ang e. To do t hi s , t h er e i s a s t ep-
u p pi s t on, new met er i ng r ods wi t h t h r ee d i amet er s ,
and p r i mar y met er i ng j et s , ( Fi g . 11).
(5) Sl i d e s t ep-up pi s t on s p r i ng i nt o pi s t on c y l i nd er s ,
f o l l o wed b y s t ep-up pi s t ons and st ep-up r ods . I ns t al l
c o v er pl at es and at t ac h i ng s c r ews wh i l e h o l d i ng s t ep-
u p pi s t ons d o wn i n pos i t i on. Ti g h t en s c r ews s ec u r el y .
(6) Ch ec k fit of c h o k e v al v e i n ai r h o r n. T h e v al v e
s h o u l d be ev enl y s p ac ed on al l s i d es . L o o s en s c r ews
and r epos i t i on i f nec es s ar y .
(7) Eng ag e t hr ot t l e c o nnec t o r r o d wi t h hol e i n
t hr ot t l e l ev er . Ins t al l ot her end i n ac c el er at o r p u mp
r o c k er ar m, (c ent er hol e) and i ns t al l h ai r p i n c l i p t o
s ec u r e.
(8) Eng ag e u p p er end of f as t i dl e c o nnec t o r r o d i n
sl ot of c h o k e oper at i ng l ev er . Swi ng r o d i n an ar c and
eng ag e wi t h f as t i dl e c am. Sec u r e wi t h h ai r p i n c l i p .
installing Vacuum Diaphragm
Ins p ec t t he d i ap h r ag m v ac u u m fitting t o be s u r e
t hat t he p as s ag e i s not pl ug g ed wi t h f o r ei g n mat er i al .
L e a k c h ec k t he d i ap h r ag m t o d et er mi ne i f i t h as i n-
t er nal l eak s . To do t hi s , first d ep r es s t he d i ap h r ag m
s t em, t h en p l ac e a finger ov er t he v ac u u m fitting t o
s eal t he openi ng . Rel eas e t h e d i ap h r ag m s t em. If t h e
s t em mo v es mo r e t h an 1/16 i nc h i n t en (10) s ec o nd s ,
t he l eak ag e i s ex c es s i v e and t he as s emb l y mu s t be
r ep l ac ed . Ins t al l t he d i ap h r ag m as s emb l y o n t he c ar -
b u r et o r as f ol l ows :
(1) As s emb l e t o c ar b u r et o r and t i g ht en at t ac h i ng
s c r ews s ec u r el y .
(2) Ins t al l c h o k e oper at i ng l i nk i n pos i t i on b et ween
d i ap h r ag m p l u ng er (st em) and c h o k e l ev er . Ins t al l
2 STEPS
COVER
Nh\j!9
2 STAGE
STEP-UP PI STON STEP-UP
SPRI NG PISTON
J ET-NEW TYPE -
SCREW
NB171A
Fig. 9-Checking Float Height Fig. 11Step-Up Piston Rod and J et
A-
-AVSFUEL SYSTEM 14-33
c l i p to s ec u r e. Sec u r e c h o k e l ev er end wi t h s p r i ng
" E " c l i p.
(3) Ins p ec t r u b b er h o s e f o r c r ac k s , bef or e p l ac i ng It
on c o r r ec t c ar b u r et o r fitting. ( Fi g . 1). Do not c onnec t
t he v ac u u m hose t o the d i ap h r ag m f i t t i ng unt i l af t er
t he v ac u u m k i c k ad j u s t ment h as been mad e. (See Car -
bur et or Ad j u s t ment s . )
CARBURETOR ADJ USTMENTS
Th e f ol l owi ng ad j u s t ment s s h o u l d be mad e wi t h t he
c ar b u r et o r on t he b enc h f or eas e of wo r k i ng , and ,
s houl d be made i n t he f o l l o wi ng or der :
Fast Idle Speed Cam Position Adjustment
Th e f as t i dl e eng i ne s p eed ad j u s t ment s h o u l d be
made on t he v eh i c l e, as d es c r i b ed i n t he F a s t Idl e
Sp eed Ad j u s t ment (On Veh i c l e Par ag r ap h . ) Ho wev er ,
t he F as t Idl e Ca m Po s i t i o n Ad j u s t ment c an be mad e
on t he b enc h .
Th i s ad j u s t ment i s i mp o r t ant t o as s u r e t hat t he
s peeds of eac h c am s t ep o c c u r at t he p r o p er t i me
d u r i ng eng i ne war m-u p . Ad j u s t as f ol l ows :
(1) Wi t h f ast i dl e s p eed ad j u s t i ng s c r ew c ont ac t i ng
s ec o nd hi g hes t s p eed s t ep on f as t i d l e c am, mo v e
c h o k e v al v e t o war d c l o s ed pos i t i on wi t h l i g ht p r es s u r e
on c h o k e s haf t l ev er .
(2) Ins er t s pec i f i ed d r i l l ( r ef er t o Spec i f i c at i ons ), be-
t ween c h o k e v al v e and wal l of ai r h o r n ( Fi g . 12). An
ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag i s not
obt ai ned as t he d r i l l i s b ei ng r emo v ed .
(3) To adj us t , b end f as t i dl e c o nnec t o r r o d at ang l e,
u s i ng To o l T-109-213 u nt i l c o r r ec t v al v e openi ng h as
been obt ai ned ( Fi g . 12).
Vacuum Kick Adjustment(This test can be
made ON or OFF vehicle.)
Th e c h o k e d i ap h r ag m ad j u s t ment c ont r ol s t he f u el
DRILL OR GAUGE
LIGHT CLOSING
PRESSURE ON
CHOKE LEVER
FAST IDLE
' CAM
BEND FAST IDLE
CONNECTOR
ROD AT THIS
ANGLE
NR521A
FAST IDLE SPEED
ADJUSTING SCREW
FAST IDLE SPEED
SCREW ON 2ND
HIGHEST STEP OF
CAM AND RIDING
AGAINST FACE
OF HIGHEST STEP
d el i v er y wh i l e t he eng i ne i s r u nni ng . It pos i t i ons t h e
c h o k e v al v e wi t h i n t he ai r h o r n b y u s e of t he l i nk ag e
b et ween t he c h o k e s haf t and t he d i ap h r ag m. Th e d i a-
p h r ag m mu s t be ener g i zed t o meas u r e t he v a c u u m
k i c k ad j u s t ment . Us e ei t h er a di s t r i but or t es t mac h i ne
wi t h a v ac u u m s o u r c e, or v ac u u m s u p p l i ed b y t h e
v eh i c l e.
(1) If ad j u s t ment i s t o be mad e wi t h eng i ne r u nni ng ,
d i s c o nnec t f as t i dl e l i nk ag e t o al l ow c hok e t o c l os e t o
k i c k pos i t i on wi t h eng i ne at c u r b i dl e. If an au x i l i ar y
v ac u u m s o u r c e i s to be u s ed , open t hr ot t l e v al v es
(engi ne not r u nni ng ) and mov e c h o k e v al v e t o c l o s ed
pos i t i on. Rel eas e t hr ot t l e first, t h en r el eas e c h o k e.
(2) Wh e n u s i ng an au x i l i ar y v ac u u m s o u r c e, di s -
c o nnec t v a c u u m hos e f r o m c ar b u r et o r and c o nnec t i t
t o hos e f r o m v a c u u m s u p p l y wi t h a s mal l l eng t h of
t ube t o ac t as a fitting. Remo v al of hos e f r o m d i a-
p h r ag m may r eq u i r e f o r c es wh i c h damag e t he s y s t em.
Ap p l y a v ac u u m of 10 or mo r e i nc h es .
(3) I ns er t s pec i f i ed d r i l l ( r ef er t o Spec i f i c at i ons )
b et ween c h o k e v al v e and wal l of ai r h o r n ( Fi g . 13).
Ap p l y suf f i c i ent c l o s i ng p r es s u r e on lever t o w h i c h
c h o k e r o d at t ac h es t o pr ov i de a mi ni mu m c h o k e v al v e
o p eni ng wi t h o u t di s t or t i on of d i ap h r ag m l i nk . No t e
t hat on mos t u ni t s , a c y l i nd er i c al s t em ex t ends as
an i nt er nal s p r i ng i s c o mp r es s ed . Th i s s p r i ng mu s t be
f u l l y c o mp r es s ed f o r p r o p er meas u r ement of v a c u u m
k i c k ad j u s t ment .
(4) An ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag
i s not obt ai ned as d r i l l i s bei ng r emo v ed . Sh o r t en or
l eng t h en d i ap h r ag m l i nk t o obt ai n c o r r ec t c h o k e
openi ng . L e ng t h c h ang es s h o u l d be mad e by c ar ef u l l y
o p eni ng o r c l o s i ng t he b end p r o v i d ed i n d i ap h r ag m
l i nk . C AUT I ON : DO NOT A P P L Y T WI ST I NG OR
BENDI NG FORCE TO DI APHR AGM.
(5) Rei ns t al l v ac u u m hos e on c o r r ec t c ar b u r et o r
CHOKE VALVE
"CHOKE
LEVER
SLOT
CHOKE
LEVER
j
' DRILL OR GAUGE
MINIMUM OF
;
10 INCHES
OF VACUUM
ON DIAPHRAGM
REQUIRED
TO
VACUUM
SOURCE
J
Fig. 12-Fast Idle Cam Position Adjustment
/ 4 ,
LIGHT CLOSING
PRESSURE ON CHOKE
LEVER DIAPHRAGM STEM RETRACTED PY728
Fig. 13Checking Choke Vacuum Kick Setting
- X
^ VACUUM CHOKE
TUBE FITTING
1
14-34 FUEL SYSTEMAVS-
f i t t i ng. Re t u r n f as t i dl e l i nk ag e t o i t s o r i g i nal c ondi t i on
i f d i s t u r b ed as s ug g es t ed i n s t ep no. 1.
(6) Mak e f o l l o wi ng c h ec k . Wi t h no v ac u u m ap p l i ed
t o d i ap h r ag m. CHOKE VALVE SHOULD MOVE
FREELY b et ween open and c l os ed pos i t i ons . If mov e-
ment i s not f r ee, ex ami ne l i nk ag e f o r mi s al i g nment
or i nt er f er enc es c au s ed by b end i ng oper at i on. Rep eat
ad j u s t ment i f nec es s ar y t o p r o v i d e p r o p er l i nk oper a-
t i on.
Choke Unloader Adjustment
T h e c h o k e u nl o ad er i s a mec h ani c al d ev i c e t o par -
t i al l y o p en t he c h o k e at wi d e o p en t hr ot t l e. It i s u s ed
t o el i mi nat e c h o k e enr i c h ment d u r i ng c r ank i ng of
an eng i ne. Eng i nes wh i c h h av e b een flooded or s t al l ed
b y ex c es s i v e c h o k e enr i c h ment c an b e c l ear ed b y
u s e of t he u nl o ad er . Ad j u s t t he s y s t em as f ol l ows :
(1) Ho l d t hr ot t l e v al v es i n wi d e open pos i t i on. In-
s er t s pec i f i ed d r i l l (r ef er t o Spec i f i c at i ons ) , b et ween
u p p er edg e of c h o k e v al v e and i nner wal l of ai r
h o r n ( Fi g . 14).
(2) Wi t h a finger l i g ht l y p r es s i ng ag ai ns t c h o k e l ev -
er , a s l i g ht d r ag s h o u l d b e f el t as d r i l l i s b ei ng wi t h -
d r awn. If an ad j u s t ment i s nec es s ar y , b end u nl o ad er
t ang on f as t i d l e c am, u s i ng To o l T-109-22, u nt i l c or -
r ec t o p eni ng h as b een obt ai ned ( Fi g . 14).
Accel erator Pump Adjustment
Mov e t he c h o k e v al v e t o wi d e open pos i t i on, t o r e-
l eas e t he f as t i dl e c am. B a c k off t he i dl e s p eed adj us t -
i ng s c r ew ( c ur b i dl e) u nt i l t he t hr ot t l e v al v es ar e
s eat ed i n t he b o r es .
Meas u r e t he d i s t anc e f r o m t he t op of t he ai r h o r n
t o t h e t op of t h e p l u ng er s haf t , u s i ng a " T " s c al e,
( Fi g . 15). Th i s d i s t anc e s h o u l d b e 7/16 i nc h .
If an ad j u s t ment i s nec es s ar y , b end t he t hr ot t l e
c o nnec t o r r o d at t he l o wer ang l e, u s i ng To o l T-109-
f - DRI LL C;< GAUGE
/
LI GHT CLOSING
PRESSURE UP
* . ON CHOKE
LEVER
BEND UNLOADER
TANG FOR
CORRECT OPENING
THROTTLE IN WIDE -
OPEN POSITION
mm
TOP OF PLUNGER
TO TOP OF
AIR HORN
BEND ACCELERATOR
PUMP ROD-*-
AT ANGLE
. 4 f*
? r r
V? X
CURB IDLE SPEED ADJUSTING " ^
c c r N
SCREW BACKED OFF TO ALLOW THROTTLE CLOSED
VALVES TO FULLY SEAT
P Y 7 2 9
Fig. ISCheeking Accelerator Pump Adjustment
213, u nt i l c o r r ec t t r av el h as b een obt ai ned.
Secondary Throttle Lever Adjustment
To c h ec k t he s ec o nd ar y t hr ot t l e l ev er ad j u s t ment ,
bl oc k t he c h o k e v al v e i n t he wi d e open pos i t i on and
i nv er t t he c ar b u r et o r . Sl o wl y open t he p r i mar y t hr ot -
t l e v al v es u nt i l i t i s pos s i bl e t o meas u r e b et ween t he
l o wer edge of t he p r i mar y v al v e and t he b o r e (op-
pos i t e i d l e por t ) ( Fi g . 16). ( Ref er t o Spec i f i c at i ons ).
T h e s ec o nd ar y v al v es s h o u l d j u s t s t ar t to open. If an
ad j u s t ment i s nec es s ar y , b end t he s ec o nd ar y t hr ot t l e
oper at i ng r o d at t he ang l e, u s i ng To o l T-109-213, u nt i l
c o r r ec t ad j u s t ment has b een obt ai ned.
Wi t h p r i mar y and s ec o nd ar y t hr ot t l e v al v es i n
t i g ht l y c l os ed pos i t i on, i t s h o u l d be pos s i bl e t o i ns er t
To o l T-109-29 (.020" ) wi r e g aug e, b et ween pos i t i v e
c l o s i ng s hoes on t he s ec o nd ar y t hr ot t l e l ev er s , ( Fi g .
17).
If an ad j u s t ment i s nec es s ar y , b end t he s h o e on t he
s ec o nd ar y t hr ot t l e l ev er , u s i ng To o l T-109-22, u nt i l
c o r r ec t c l ear anc e h as b een obt ai ned.
BEND ROD A T
THIS ANGLE
, PRIMARY
THROTTLE
VALVES
SCALE
S EC O NDA R Y
y
. -
THROTTLE
VALVES 1
SHOULD JUST \ f
START TO
OPEN
" SLOWLY OPEN
, ' P .THROTTLE
V J k - ^ VALVES
NR523A
NOTCH OF
LOCKOUT DOG
TANG ON SECONDARY LEVER '
.CHOK E VALVE WIDE OPEN
NR525A
Fig. 14Checking Choke Unloader (wide open kick) Fig. 16Checking Secondary Throttle Adjustment
Fig. I J Checking Clearance Between Closing Shoes
Second ary Throttle Lock Out Adjustment
Cr a c k t he t hr ot t l e v al v es , t h en manu al l y o p en and
c l os e t he c h o k e v al v e. Th e t ang on t he s ec o nd ar y
t hr ot t l e l ev er s h o u l d f r eel y eng ag e i n t he no t c h of t he
l oc k out dog ( Fi g . 16).
If an ad j u s t ment i s nec es s ar y , b end t he t ang on t he
s ec o nd ar y t hr ot t l e l ev er , u nt i l eng ag ement h as b een
made. Us e To o l T-109-22 f or t hi s oper at i on.
Af t er ad j u s t ment s h av e b een mad e, r ei ns t al l c ar b u -
r et or on eng i ne, u s i ng a new g as k et .
It i s s ug g es t ed t hat t he c ar b u r et o r be filled wi t h
c l ean gas ol i ne. Th i s wi l l h el p p r ev ent di r t t hat i s
t r apped i n t he f u el s y s t em, f r o m b ei ng di s l odg ed by
t he f r ee flow of f u el , as t he c ar b u r et o r i s p r i med .
S ow! Vent Valve Adjustment (C.A.S.)
To c h ec k t he b o wl v ent v al v e ad j u s t ment , p r o c eed
as f ol l ows :
(1) Wi t h t hr ot t l e v al v es t i ght l y c l o s ed , i ns er t a
1/8 i nc h d r i l l b et ween ai r h o r n and v al v e at s mal l es t
openi ng ( Fi g . 18).
(2) If an ad j u s t ment i s nec es s ar y , b end ad j u s t i ng
t ang (on pi vot end of l ev er ) u nt i l c o r r ec t o p eni ng h as
b een obt ai ned.
Bowl Vent Valve Adjustment (E.CS*)
To c h ec k t he bowl v ent v al v e ad j u s t ment , p r o c eed
as f ol l ows :
(1) Us i ng To o l T109-43, r emo v e bowl v ent v al v e
c h ec k i ng hol e p l u g i n ai r h o r n.
(2) Wi t h t hr ot t l e v al v es at c l os ed c u r b i dl e pos i t i on,
i ns er t a nar r o w r u l er d o wn t h r o u g h hol e. Al l o w r u l er
t o r es t l i g ht l y on t op of v al v e. Th e r ead i ng s h o u l d be
3/4 i nc h f r o m t op of v al v e t o t op of ai r h o r n c as t i ng
at openi ng . ( Fi g . 18).
(3) If an ad j u s t ment i s nec es s ar y , b end bowl v ent
AVSFUEL SYSTEM 14-35
FOR ADJ USTMENT ~ PY731
OHM i \ j r %
AIR HORN NR528A
Fig. I S-Bowf Vent Valve Adjustment (C.A.S.) (E.C.S.)
v al v e oper at i ng l ev er , u nt i l c o r r ec t v al v e o p eni ng h as
b een obt ai ned.
(4) Ins t al l new p l u g and r ap l i g ht l y t o s eat , u s i ng a
h ammer .
S econd ary Air Valve Adjustment
(1) L o o s en l o c k s c r ew ( Fi g . 19) and al l ow ai r v al v e
to pos i t i on i t s el f at wi d e open pos i t i on.
(2) F r o m wi d e open pos i t i on, ( s pr i ng b ar el y mo v i ng
v al v e) , t u r n sl ot t ed s l eev e t wo f ul l t u r ns c o u nt er c l oc k -
wi s e, ( Fi g . 19).
(3) Ho l d i n t hi s pos i t i on wi t h finger, t h en t i g ht en
l o c k s c r ew s ec u r el y . Ch ec k v al v e f o r f r eed o m of
mo v ement .
Idle Speed Adjustment(Curb Idle)
Ref er t o Gener al Inf o r mat i o n at F r o nt of Gr o u p .
Fast Idle Speed Adjustment (On Vehicle)
F a s t i d l e eng i ne s p eed i s u s ed t o o v er c o me c o l d
eng i ne f r i c t i o n, s t al l s af t er c ol d s t ar t s and s t al l s be-
c au s e of c ar b u r et o r i c i ng . Set t hi s ad j u s t ment af t er
1446 FUEL SYSTEMAVS-
-A
S E C O ND A R Y AI R V A L V E WI DE O P E N
LOCK SCREW
4nr . . . 4&<
N
ADJ USTING SLEEVE
SECONDARY AIR VALVE JUST CLOSED
LOCK SCREW-
X .
TURN 2 FULL TURNS
FROM WIDE OPEN POSITION
PY732
Fig. 19Secondary Ai r Valve Adf ps f me nf
v eh i c l e odomet er i nd i c at es o v er 500 mi l es t o i ns u r e a
no r mal eng i ne f r i c t i o n l ev el . Pr ep ar e eng i ne b y d r i v -
i ng at l eas t 5 mi l es . Co nnec t a t ac h o met er and s et
c u r b i d l e s p eed and mi x t u r e, t h en p r o c eed as f ol l ows :
(1) Wi t h eng i ne off and t r ans mi s s i o n i n P AR K o r
NEUT R A L pos i t i on open t hr ot t l e s l i g ht l y .
(2) Cl o s e c h o k e v al v e u nt i l f as t i dl e s c r ew c an be
pos i t i oned on t he s ec o nd hi g hes t s p eed s t ep of f as t
i dl e c am ( Fi g . 20).
(3) St ar t eng i ne and d et er mi ne s t abi l i zed s p eed .
T u r n f as t i dl e s p eed s c r ew in or out t o s ec u r e s pec i f i ed
s p eed . ( Ref er t o Spec i f i c at i ons ) .
(4) St o p p i ng eng i ne b et ween ad j u s t ment s i s not
nec es s ar y . Ho wev er , r ep o s i t i o n f as t i d l e s p eed s c r ew
o n c am af t er eac h s p eed ad j u s t ment t o p r o v i d e c or -
r ec t t hr ot t l e c l o s i ng t or que.
B ef o r e ad j u s t i ng i d l e a nd / o r f as t i d l e s p eed s and
mi x t u r es , mak e s u r e t hat t he bas i c t i mi ng i s c o r r ec t l y
ad j u s t ed as out l i ned u nd er Idl e Sp eed Ad j u s t ment
( Cu r b I dl e) .
'"HOKE YA.-.V'Z WIDL, OPEN
-".ST it;: i: oPEED
, / OJUSh.vG SCREW
ON SECOND
HIGHEST STEP OF
CAM
* rAST IDLE SPEED ,
^ ADJUSTING SCREW
/ ". - AST IDLE CAM
N R 5 2 9 A
Fig. 2@- t ef Idle Speed Adjustment (On Vehicle)
FAST
CURB IDLE
SOLENOI D
TERMINAL
FAST CURB IDLE
THROTTLE LEVER
SOLENOI D
PLUNGER
FAST CURB IDLE
ADJ USTI NG SCREW
DISTRIBUTOR
GROUND
SWITCH
LEAD ^ - V L M pY734
Fig. 21 - I dl e Speed Solenoid Adjustment
Idle Speed Solenoid Adjustment (If so
equipped)
To set i dl e s p eed s ol enoi d f or c o r r ec t eng i ne r . p. m. ,
p r o c eed as f ol l ows :
(1) Wa r m u p eng i ne t o no r mal oper at i ng t emp er a-
t u r e, t h en at t ac h a t ac homet er .
(2) Wi t h eng i ne r u nni ng , t u r n i dl e s p eed s ol enoi d
ad j u s t i ng s c r ew in o r out t o obt ai n 900 r . p. m. f o r
manu al t r ans mi s s i o n eq u i p p ed v eh i c l es and 800 r . p. m.
f o r aut omat i c t r ans mi s s i o n eq u i p p ed v eh i c l es ( Fi g . 21).
(3) Af t er s pec i f i ed r . p. m. h as b een obt ai ned and
wi t h eng i ne s t i l l r u nni ng (to ener g i ze s ol enoi d), ad j u s t
c u r b i d l e s p eed s c r ew u nt i l end of s c r ew just touches
s t op on c ar b u r et o r t hr ot t l e body. No w, b ac k off 1
f u l l t u r n t o obt ai n s l o w c u r b i dl e s p eed s et t i ng . (Ap-
p r o x i mat el y 650 t o 700 r .p.m.)
To s et t he i d l e s p eed on v eh i c l es , r ef er t o t h e F u e l
Sy s t em Gener al Inf o r mat i o n Par ag r ap h .
A- HOLLEY-4160FUEL SYSTEM 14-37
HOLLEY 4160 SERIES CARBURETOR
INDEX
Pag e
Aut omat i c Chok e-Wel l Ty pe . . . . . . . . . . . . . . . . 1
Car bur et or Ad j u s t ment s
Ad j u s t i ng t he Fl oat s 49
Ch ec k i ng B owl Vent Val v e Cl ear anc e 51
Ch ec k i ng Pu mp L ev er Cl ear anc e 52
Ch ec k i ng Wet Fu el L ev el 54
Ch o k e Unl oader (Wi de Open K i c k ) 53
Fas t Idl e Ca m Posi t i on 53
F as t Idl e Sp eed (On or Off Veh i c l e) 53
Idl e Mi xt ur e 53
Page
Idle Speed ( Cur b Idle) . . . . . . . . . . . . . . . . . . . . . . . 54
Sec o nd ar y Thr ot t l e 54
Vac u u m K i c k (On or Off Veh i c l e) . . . 53
Di s as s emb l i ng t he Car bur et or 45
Cl eani ng Car bur et or Par t s . . 48
Gener al Inf or mat i on . . . 37
Ins pec t i on and Reas s emb l y 48
Ser v i c i ng Car bur et or . . . . . . . . . . 45
Sp ec i f i c at i o ns 64
GENERAL INFORMATION
3 8 3 Cubic Inch Engine
Th e Ho l l ey f o u r b ar r el c ar b u r et o r mo d el s C. A. S.
( Cl eaner Ai r Sy s t em) R-4367A, R-4368A and R-4369A
ar e u s ed on t he 383 c u . i n. eng i nes wh en t he v eh i c l es
ar e equi pped wi t h manu al or aut omat i c t r ans mi s s i o ns
r es p ec t i v el y . Model R-4369A i s u s ed wi t h v eh i c l es
eq u i p p ed wi t h ai r c ondi t i oni ng onl y and h as a hot i d l e
c o mp ens at o r v al v e. Th i s v al v e i s a t h er mo s t at i c al l y
oper at ed ai r b l eed , t o r el i ev e an o v er r i c h c ondi t i on
at i dl e. Th i s c ondi t i on i s t he r es u l t of ex c es s i v e heat
and r es u l t ant o v er r i c h mi x t u r es . ( Fi g . 1).
Th e Ho l l ey f o u r b ar r el c ar b u r et o r mo d el s E. C . S.
( Ev ap o r at i o n Co nt r o l Sy s t em) R-4217A and R-4218A
ar e al s o u s ed on t he 383 c u . i n. eng i nes wh e n t he v e-
h i c l es ar e eq u i p p ed wi t h a manu al or aut omat i c
t r ans mi s s i o n r es p ec t i v el y . Th es e t wo c ar b u r et o r s ar e
al s o eq u i p p ed wi t h a hot i dl e c o mp ens at o r v al v e as i s
R-4369A abov e. ( Fi g . 2).
Al l of t hes e c ar b u r et o r s ar e eq u i p p ed wi t h a di s-
t r i but or g r o u nd s wi t c h , wh i c h r et ar d s t he d i s t r i b u t o r
wh en t he c ar b u r et o r i s at c u r b i dl e, f o r bet t er emi s -
s i o n c ont r ol .
440 Cubi c I n c h Engine
Th e Ho l l ey f o u r b ar r el c ar b u r et o r mo d el C. A. S.
( Cl eaner Ai r Sy s t em) R-4366A i s u s ed on t he 440 c u . i n.
eng i ne wh en t he v eh i c l e i s eq u i p p ed wi t h an aut omat i c
t r ans mi s s i o n. ( Fi g . 1).
Th e Ho l l ey f o u r b ar r el c ar b u r et o r mo d el E. C . S.
( Ev ap o r at i o n Co nt r o l Sy s t em) R-4360A i s al s o u s ed on
t he 440 c u . i n. eng i ne wh en t he v eh i c l e i s eq u i p p ed
wi t h an aut omat i c t r ans mi s s i o n. ( Fi g . 2).
B o t h of t hes e c ar b u r et o r s ar e eq u i p p ed wi t h a hot
i dl e c o mp ens at o r v al v e. Th i s v al v e i s a t her mos t at i c al -
l y oper at ed ai r b l eed , t o r el i ev e an o v er r i c h c ondi t i on
at i dl e. Th i s c ondi t i on i s t he r es u l t of ex c es s i v e heat
and r es u l t ant o v er r i c h mi x t u r es . Th e di s t r i but or
g r o u nd s wi t c h r et ar d s t he di s t r i but or wh en t he c ar -
b u r et o r i s at c u r b i dl e, f o r bet t er emi s s i o n c o nt r o l .
Si nc e t he s er v i c e p r o c ed u r es ar e i d ent i c al on al l
Ho l l ey f o u r b ar r el c ar b u r et o r s , t he i l l us t r at i ons s how-
i ng t he v ar i o u s d i s as s emb l y p r o c ed u r es wi l l not al way s
s how any one s pec i f i c c ar b u r et o r .
T h e Ho l l ey 4160 Ser i es Car b u r et o r ( Fi g s . 1, 2 and 3)
c an be c o ns i d er ed as t wo d u al downdr af t c ar b u r et o r s
mo u nt ed s i de by s i d e, eac h h av i ng i t s o wn f u el bowl
and float s y s t em. T h e t wo f u el bowl s i ns u r e a c ons t ant
s u p p l y of f u el f or al l t he f u el met er i ng s y s t ems . F u e l
f r o m t he bowl s flow i nt o t h e p r i mar y and t he s ec ond-
ar y met er i ng bodi es wh er e t he f u el i s mi x ed wi t h
ai r f or al l p h as es of eng i ne oper at i on. Th i s t y pe of
met er i ng p r o v i d es f o r adequat e di ag nos i s and eas i er
s er v i c i ng .
T h e t wo p r i mar y bor es h av e one c h o k e v al v e, c on-
nec t ed t o a wel l t y p e aut omat i c c h o k e. Ea c h b o r e h as
i t s o wn v ent u r i , boos t er v ent u r i , mai n f u el d i s c h ar g e
nozzl e and t hr ot t l e v al v e.
Ad d i t i o nal f u el f o r ac c el er at i o n i s s u p p l i ed b y a
d i ap h r ag m t y pe, mec h ani c al l y oper at ed p u mp wh i c h
i s l oc at ed on t h e p r i mar y f u el b o wl . T h e p u mp i s
ac t uat ed f r o m a c am on t he p r i mar y t hr ot t l e. An ov er -
r i d e s p r i ng on t he p u mp o p er at i ng l ev er p r o l o ng s t he
d i s c h ar g e of f u el f o r s mo o t h er ac c el er at i o n.
A p o wer v al v e, mo u nt ed on t he p r i mar y met er i ng
body , wh i c h i s ac t u at ed b y mani f o l d v ac u u m, d el i v er s
t he addi t i onal f u el nec es s ar y f o r f u l l p o wer and h i g h
s p eed oper at i on.
T h e l ar g er v o l u me of f u el , i n t wo s ep ar at e bowl s
ex p o s ed t o t h e c o o l i ng ai r s t r eam, i s an ef f ec t i v e
means of r ed u c i ng p er c o l at i o n and h ar d s t ar t i ng
wh en t he eng i ne i s hot . An ex t er nal v ent on t h e
p r i mar y b o wl , v ent s t h e p r i mar y f u el b o wl wh en t he
t hr ot t l e i s c l o s ed .
T h e p r i mar y a nd / o r s ec o nd ar y bowl s c an b e q u i c k l y
r emo v ed t o ad j u s t t h e f u el l ev el o r c h ang e t h e f u el
i nl et v al v e wi t hout r emo v i ng t h e c ar b u r et o r f r o m t h e
eng i ne.
Primary Fuel Inlet System
Al l f u el first ent er s t he p r i mar y f u el b o wl wh i c h
s u p p l i es t he f o u r b as i c met er i ng s y s t ems wi t h t h e r e-
q u i r ed amo u nt of f u el ( Fi g . 4).
14-38 FUEL SYSTEMHOLLEY 4160
S E C O N D A R Y F U E L B O W L C H O K E L I N K - C H O K E VALVE
SECONDARY VACUUM
DIAPHRAGM
H
C H O K E D I A P H R A G M L I N K ~ _ '
r^f- . y
?
'
II'
- IDLE MIXTURE SCREW
(LEFT HAND THREAD)
- B O W L V E N T V A L V E
M E T E R I N G B L O C K
C A M P O S I T I O N
ADJUSTING TANG
S E C O N D A R Y STOP
LEVER'
P I
W i l l
" P R I M A R Y F U E L B O W L

R ^ - *
X
D I S T R I B U T O R V A C U U M C O N N E C T I O N
C L O S E D C R A N K C A S E
VENT TUBE FITTING
C H O K E C O N T R O L L E V E R
FAST IDLE CAM
CHOKE UNLOADER LEVER CAS C A R B U R E T O R
CHOKE VALVE GUARD
BOWL VENT VALVE
CHOKE
VACUUM
D I A P H R A G M
CHOKE VALVE
* V A C U U M D I A P H R A G M H O S E
N R 4 4 9 B
F U E L T R A N S F E R T U B E
I D L E M I X T U R E
A D J U S T I N G S C R E W
L I MI T E R C A P
A C C E L E R A T O R P U M P
A D J U S T I N G N U T
A C C E L E R A T O R P U M P L E V E R
S E C O N D A R Y
V A C U U M
D I A P H R A G M
F U E L B O W L
C A R B U R E T O R T O
A I R C L E A N E R V E N T
T U B E F I T T I N G
C U R B I D L E S P E E D
A D J U S T I N G S C R E W
H O T I D L E
C O M P E N S A T O R
V A L V E COVER
T H R O T T L E B O D Y
S E C O N D A R Y T H R O T T L E S H A F T
T H R O T T L E L E V E R
S E C O N D A R Y T H R O T T L E
C O N N E C T I N G L I N K P Y 8 7 1
Fig. 1Carburetor Assembly (C.A.S.)
A- -HOLLEY 4180FUEL SYSTEM 14-39
H O T IDLE
C O M P E NS A T O R
V A L V E C O V E R
F UEL
TRANSFER T UB E
C H O K E V A L V E I
BOWL VENT
VALVE
BOWL \
VENT VALVE
X
^
O P E R A T I NG R O D .
V
I DL E MI X T UR E
A D J U S T I N G ^ .
S C R EW
!
ACCELERATOR
PUMP
A D J US T I NG
NUT
A C C E L E R A T O R
P UM P L EV ER
S E C O ND A R Y
V A C U U M
D I A P H R A G M
/ F UEL
> B O WL
C H O K E V A L V E
C H O K E
V A C U U M
DI APHRAGM
\ CHOKE
S E C O ND A R Y \ ~
L L
^
! S <
VACUUM \ \
DI APHRAGM. \ ^
B O WL V E NT . V A L V E'
OPERATING ROD
I
IDLE MIXTURE
ADJUSTING
SCREW
BOWL VENT
j VALVE
PLUNGER
DISTRIBUTOR
GROUND
SWITCH
CONNECTOR
mm
P I /
X
CAR3 JRETOR
~G A,?: C L EA NER
V. :>7 T UB E
F I T T I NG
S E C O N D A R Y
T HR O T T L E
S H A F T
S E C O ND A R Y /
S T O P L EV ER /
CHOKE
CONTROL
LEVER
M S
\
C UR B !C1= S?2EL
ADJUS'>:G
SCRr*/
S E C O ND A R Y IDLE A!;? 3L i zDS =
S E C O ND A R Y V A C U U M DI APHRAGM
S E C O ND A R Y
T HR O T T L E
CONNECTOR
L I NK
BOWL VENT
VALVE VENT
TUBE
CHOKE
DI AP HRAGM
LINK
FAST IDLE VACUUM HOSE
CAM
DISTRIBUTOR VACUUM
ADVANCE TUBE
CONNECTI ON
C H O K E
UNLOADER L EV ER P Y 8 7 2
Fag. 2Carburetor As s e mbl y (E.C.S.)
...^' SECONDARY FUEL BOWL
^SECONDARY HI GH SPEED BLEEDS
S E C O ND A R Y I DL E AI R BLEEDS
... . BOOSTER VENTURIS
29-
/
PRIMARY IDLE AI R BLEEDS
P R I M A R Y IDLE AI R BLEEDS
C H O K E DIAPHRAGM
-CURB IDLE AIR BLEEDS
BOWL VENT ROD
CURB IDLE AIR BLEEDS-""
P R I M A R Y H I G H S P EED BLEEDS"
P R I M A R Y F UEL B O W L
>- BOWL VENT VALVE
NR451B
^Carburetor Assembly (Top View)
14-40 F UEL SYSTEMHOL L EY 4160
Fig. 4PrimaryFuei Inlet System
Th e f u el ent er s t he f u el b o wl t h r o u g h a f u el i nl et
f i t t i ng and i nt o t he f u el i nl et v al v e. T h e amo u nt of
f u el ent er i ng t he f u el b o wl i s d et er mi ned b y t he s p ac e
b et ween t he t op of t he mo v ab l e need l e and i t s s eat
and al so b y t he p r es s u r e f r o m t he f u el p u mp .
Th e f u el i nl et s y s t em mu s t c ons t ant l y mai nt ai n t he
s pec i f i ed l ev el of f u el as t he b as i c f u el met er i ng s y s -
t ems ar e c al i b r at ed t o d el i v er t he p r o p er mi x t u r e
onl y wh en t he f u el i s at t hi s l ev el .
A float s p r i ng i s i nc o r p o r at ed u nd er t he float t o
k eep t he float i n a s t ab l e pos i t i on.
Th e float c h amb er i s v ent ed i nt er nal l y b y t he v ent
t ube at al l t i mes . At c u r b i dl e or wh en t he eng i ne i s
s t opped, t he c h amb er i s al s o v ent ed b y t h e ex t er nal
v ent on t op of t he p r i mar y f u el b o wl . Th i s ex t er nal
v ent p r o v i d es a r el eas e of ex c es s f u el v ap o r s f r o m t h e
b o wl .
Idle System (Fig, 5)
At i dl e and l ow s p eed s , t he ai r flow t h r o u g h t he
c ar b u r et o r i s not suf f i c i ent l y s t r o ng eno u g h t o d r aw
f u el t h r o u g h t he p r i mar y b ar r el v ent u r i f o r t he mai n
met er i ng s y s t em. Int ak e mani f o l d v ac u u m i s h i g h be-
c au s e of t he g r eat er r es t r i c t i o n to t he ai r flow b y t h e
near l y c l o s ed t hr ot t l e v al v es . Th i s h i g h mani f o l d v ac -
u u m i s u s ed t o p r o v i d e t he p r es s u r e di f f er ent i al wh i c h
oper at es t he i dl e s y s t em.
T h e c ar b u r et o r ut i l i zes t wo i d l e s y s t ems , one f o r
eac h p r i mar y b ar r el . Si nc e t he t wo p as s ag es f u nc t i o n
i d ent i c al l y , onl y one s i d e wi l l be c o ns i d er ed i n t h i s
ex p l anat i o n ( Fi g . 5).
At i dl e, t he near at mo s p h er i c p r es s u r e i n t he float
c h amb er c au s es t he f u el t o flow t h r o u g h t he i d l e s y s -
t em t o t he g r eat l y r ed u c ed p r es s u r e ar ea b el o w
t hr ot t l e pl at e. F u e l flows f r o m t he float c h amb er
t h r o u g h a r es t r i c t i o n i nt o t he c u r b i dl e wel l .
Th e f u el flows u p t hi s v er t i c al i d l e wel l t h r o u g h t h e
i dl e f eed r es t r i c t i o n, and t h en i t i s mi x ed wi t h ai r
c o mi ng i n f r o m t he i d l e ai r b l eed . Th i s f u el -ai r mi x -
A
P R I M A R Y I D L E T R A N S F E R S Y S T E M
Fig. 5Idle System
t u r e t h en flows d o wn ano t h er v er t i c al p as s ag e. At t he
bot t om of t hi s v er t i c al pas s ag e t he f uel -ai r mi x t u r e i s
met er ed by an i dl e l i mi t er s c r ew. ( Th i s ad j u s t ment i s
mad e at t he f ac t or y and no field ad j u s t ment s h o u l d be
r eq u i r ed . Ho wev er , i f an ad j u s t ment i s nec es s ar y ,
r ef er to " Ro u g h Idl e and L o w Sp eed Su r g e " p ar a-
g r ap h , u nd er Gener al Inf o r mat i o n.
Th e mi x t u r e t h en flows t h r o u g h a c h annel i n t he
t hr ot t l e body t o t he c u r b i d l e d i s c h ar g e por t . T h e f u el
i s d i s c h ar g ed i nt o t he t hr ot t l e b o r e j u s t b el o w t h e
t hr ot t l e v al v e.
Th e ai r t hat i s s u p p l i ed t o t he c u r b i d l e s y s t em i s
s u p p l i ed t h r o u g h t wo i dl e ai r b l eed r es t r i c t i o ns and
b y a c u r b i d l e ai r b l eed ad j u s t i ng s c r ew.
Th i s i s t he onl y s c r ew u s ed t o ad j u s t c u r b i d l e mi x -
t ur e.
Th e s c r ew i s l oc at ed near t he p r i mar y b o wl v ent on
t he c h o k e ai r h o r n.
Tu r ni ng t he s c r ew c l o c k wi s e l eans t h e c u r b i d l e
mi x t u r e; c o u nt er -c l o c k wi s e enr i c h ens t h e mi x t u r e.
Primary Idle Transfer System (Fig. 5)
A s ep ar at e off-i dl e s y s t em i s u s ed i n t h e c ar b u r et o r
t o p r o v i d e f u el ai r mi x t u r e f r o m i d l e oper at i on u nt i l
t he mai n s y s t em i s i n f u l l oper at i on.
A-
HOLLEY 4160FUEL SYSTEM 14-41
F u e l f o r t he i dl e t r ans f er s y s t em ent er s t he mai n
wel l t h r o u g h t he mai n j et and t r av el s u p t h r o u g h t he
i dl e t r ans f er t ube and c r o s s es o v er a pas s ag e i nt o a
v er t i c al c h annel wh er e ai r i s ad d ed f r o m t he i dl e ai r
bl eeds . Th e f u el ai r mi x t u r e i s t h en d i s c h ar g ed
t h r o u g h t he p r i mar y t r ans f er s l ot s .
As t he t hr ot t l e v al v e i s o p ened s t i l l wi d er and en-
gi ne s p eed i nc r eas es , t he ai r flow t h r o u g h t he c ar -
bur et or i s al so i nc r eas ed . Th i s c r eat es an i nc r eas ed
v ac u u m i n t he v ent u r i t o b r i ng t h e mai n met er i ng
s y s t em i nt o oper at i on. T h e flow f r o m t he i dl e t r ans f er
s y s t em t aper s off as t he mai n met er i ng s y s t ems b eg i n
d i s c h ar g i ng f u el . T h e t wo s y s t ems ar e eng i neer ed t o
pr ov i de s moot h g r ad u al t r ans i t i o n f r o m i dl e t o c r u i s -
i ng s peeds .
Main Metering System
As t he eng i ne i s r u nni ng , t he i nt ak e s t r o k e of eac h
pi s t on d r aws t he ai r t h r o u g h t h e c ar b u r et o r v ent u r i
and boos t er v ent u r i . Th e ai r , p as s i ng t h r o u g h t he r e-
s t r i c t i on of t he v ent u r i , c r eat es a l o w p r es s u r e c o m-
mo nl y c al l ed a v ac u u m. Th e s t r eng t h of t hi s l ow p r es -
s u r e i s d et er mi ned p r i mar i l y b y t he v el oc i t y of t he ai r
flowing t h r o u g h t he v ent u r i . Th i s , i n t u r n, i s r eg u l at ed
by t he s p eed and p o wer out put of t he eng i ne. Th e
di f f er enc e, b et ween t he p r es s u r e i n t he boos t er v en-
t u r i and t he no r mal ai r p r es s u r e i n t he float c h amb er ,
c au s es f u el t o flow t h r o u g h t he mai n met er i ng s y s -
t em ( Fi g . 6).
At c r u i s i ng s p eed , t he f u el flows f r o m t he float
c h amb er t h r o u g h t he mai n j et , wh i c h meas u r es o r
met er s t he f u el flow, i nt o t he bot t om of t he mai n wel l .
Th e f u el mo v es u p t he mai n wel l pas t t he mai n wel l
ai r b l eed hol e i n t h e s i de of t he wel l . Fi l t er ed ai r ,
ent er s t h r o u g h t he h i g h s p eed ai r b l eed i n t he mai n
body and t hen i nt o t he mai n met er i ng body by i nt er -
c o nnec t i ng p as s ag es . Th i s mi x t u r e of f u el and ai r ,
b ei ng l i g h t er t h an r aw f u el , r es p o nd s f as t er t o any
c h ang e i n v ent u r i v ac u u m and v apor i zes mo r e r ead i l y
BOOSTER VENTURI
HIGH SPEED <
AIR BLEED
V=3 DISCHARGE
NOZZLE
wh en d i s c h ar g ed i nt o t he ai r s t r eam of t h e v ent u r i .
Th e mi x t u r e of f u el and ai r mo v es u p t he mai n wel l
and p as s es i nt o t h e s h o r t hor i zont al pas s ag e l ead i ng
t o t he mai n body , t h en t h r o u g h t h e hor i zont al c h an-
nel of t he d i s c h ar g e nozzl e. Th i s f u el i s d i s c h ar g ed
i nt o t h e boos t er v ent u r i and t h en i n t he ai r s t r eam of
t he c ar b u r et o r v ent u r i .
Th e t hr ot t l e v al v e c ont r ol s t he amount of f u el -ai r
mi x t u r e ad mi t t ed t o t he i nt ak e mani f o l d , r eg u l at i ng
t he s p eed and p o wer out put of t he eng i ne i n ac c o r d -
anc e wi t h ac c el er at o r p ed al mo v ement .
Power Enrichment System
Du r i ng h i g h p o wer oper at i on, t he c ar b u r et o r mu s t
p r o v i d e a mi x t u r e r i c h er t h an i s need ed wh en t h e
eng i ne i s r u nni ng at c r u i s i ng s p eed u nd er no g r eat
p o wer r eq u i r ement s . T h e added f u el f o r p o wer oper a-
t i on i s s u p p l i ed by t he p o wer enr i c h ment s y s t em
(Fi g. 7).
Th i s s y s t em i s c o nt r o l l ed by mani f o l d v ac u u m
wh i c h g i v es an ac c u r at e i ndi c at i on of t he p o wer de-
mand s p l ac ed u p o n t he eng i ne. Mani f ol d v ac u u m i s
s t r ong es t at i dl e and d ec r eas es as t he l oad on t h e
eng i ne i nc r eas es . As t he l oad on t he eng i ne i s i n-
c r eas ed , t he t hr ot t l e v al v e mu s t b e opened wi d er t o
mai nt ai n a g i v en s p eed . Mani f ol d v ac u u m i s t h u s r e-
d u c ed b ec au s e t he opened t hr ot t l e v al v e of f er s l es s
r es t r i c t i o n t o ai r ent er i ng t he i nt ak e mani f o l d .
A v ac u u m p as s ag e i n t he t hr ot t l e body t r ans mi t s
mani f o l d v ac u u m t o t he p o wer v al v e c h amb er i n t he
mai n body . Th e p o wer v al v e wh i c h i s l oc at ed i n t h e
mai n met er i ng body i s ef f ec t ed b y t hi s mani f o l d
v ac u u m. T h e mani f o l d v ac u u m, ac t i ng on t he di a-
p h r ag m at i dl e o r no r mal l o ad c ondi t i ons , i s s t r o ng
eno u g h t o h o l d t he d i ap h r ag m c l o s ed , and o v er c o mes
t he t ens i o n of t he p o wer v al v e s p r i ng . Wh e n h i g h
p o wer d emand s p l ac e a g r eat er l o ad on t h e eng i ne
and mani f o l d v ac u u m dr ops bel ow a p r ed et er mi ned
poi nt , t h e p o wer v al v e s p r i ng o v er c o mes t h e r ed u c ed
v ac u u m o p eni ng t he p o wer v al v e. F u e l flows f r o m t h e
float c h amb er , t h r o u g h t he v al v e and out t he s mal l
HIGH SPEED
AIR BLEED
/^ DI SCHARGE NOZZLE
BOOSTER
VENTURI
POWER VALVE
RESTRICTION
MAIN WELL NR557A
MAIN JET' MAIN WELL
MANIFOLD
VACUUM
NP602C
Fig. 6Main Metering System
Fig. 7Power Enrichment System
14-42 FUEL SYSTEMHOL L EY 4160-
hol es In t he s i d e of t he v al v e t h r o u g h t h e d i ag o nal
r es t r i c t i o ns i n t h e mai n met er i ng body and t h en i nt o
t h e mai n wel l . I n t he mai n wel l , t he f u el j o i ns t h e f u el
flow i n t he mai n met er i ng s y s t em, enr i c h i ng t he mi x -
t u r e. * .
As eng i ne p o wer d emand s ar e r ed u c ed , mani f o l d
v ac u u m i nc r eas es . T h e i nc r eas ed v ac u u m ac t s on t h e
d i ap h r ag m, o v er c o mi ng t he t ens i on of t he p o wer v al v e
s p r i ng . Th i s c l os es t he p o wer v al v e and s h u t s off t h e
ad d ed s u p p l y of f u el wh i c h i s no l o ng er r eq u i r ed .
Accelerating Pump System
Up o n ac c el er at i o n, t he ai r flow t h r o u g h t h e c ar -
b u r et o r r es p o nd s al mos t i mmed i at el y t o t h e i nc r eas ed
t hr ot t l e o p eni ng .
Th er ef o r e d u r i ng t he b r i ef i nt er v al b ef o r e t h e f u el ,
wh i c h i s h eav i er t h an ai r , c an g ai n s p eed and mai n-
t ai n t he d es i r ed b al anc e of f u el and ai r , t h e ac c el er -
at i ng p u mp s u p p l i es f u el u nt i l t he ot her s y s t ems c an
onc e ag ai n p r o v i d e t he p r o p er mi x t u r e ( Fi g . 8).
T h e ac c el er at i ng p u mp i s l oc at ed i n t h e bot t om of
t he p r i mar y f u el bowl . T h e p u mp beg i ns t o f u nc t i o n
wh en t he p u mp oper at i ng l ev er i s ac t uat ed b y t hr ot t l e
mo v ement . Wh e n t he t hr ot t l e i s opened, t he p u mp
l i nk ag e, ac t u at ed b y a c am on t h e p r i mar y t hr ot t l e
s haf t , f o r c es t he p u mp d i ap h r ag m up. As t h e di a-
p h r ag m mo v es u p , t he p r es s u r e f or c es t he p u mp i nl et
c h ec k b al l on i t s s eat p r ev ent i ng f u el f r o m flowing
b ac k i nt o t h e float c h amb er . T h e f u el flows f r o m t h e
s h o r t p as s ag e i n t he f u el b o wl i nt o t he l o ng d i ag o nal
p as s ag e i n t he p r i mar y met er i ng body . T h e f u el p as s es
i nt o t he mai n body and t h en i n t h e p u mp d i s c h ar g e
c h amb er . T h e p r es s u r e of t he f u el c au s es t h e d i s -
c h ar g e need l e v al v e t o r ai s e and f u el i s d i s c h ar g ed
i nt o t h e v ent u r i .
As t he t hr ot t l e i s mo v ed t o war d t he c l o s ed pos i t i on,
t he l i nk ag e r et u r ns t o i t s o r i g i nal pos i t i on and t h e
d i ap h r ag m s p r i ng f o r c es t he d i ap h r ag m down. As t h e
d i ap h r ag m r et u r ns t o i t s o r i g i nal pos i t i on t he p u mp
DISCHARGE
NOZZLE
PUMP
DISCHARGE
NEEDLE
DIAPHRAGM
RETURN
SPRING
i nl et c h ec k b al l i s mo v ed off i t s s eat and t h e d i a-
p h r ag m c h amb er i s filled wi t h f u el f r o m t h e float
b o wl .
Secondary Throttle Operating System
At l o wer s p eed s , t he s ec o nd ar y t hr ot t l e v al v es r e-
mai n near l y c l o s ed , al l o wi ng t he eng i ne t o mai nt ai n
s at i s f ac t or y f u el ai r v el oc i t i es and di s t r i but i on. Wh e n
eng i ne s p eed i nc r eas es t o a poi nt wh er e addi t i onal
b r eat h i ng c apac i t y i s need ed , t h e v ac u u m c o nt r o l l ed
s ec o nd ar y t hr ot t l e v al v es open aut omat i c al l y .
Va c u u m t ak en f r o m one of t he p r i mar y b ar r el s and
one of t he s ec o nd ar y b ar r el s ac t s u p o n a d i ap h r ag m
wh i c h c ont r ol s t he s ec o nd ar y t hr ot t l e v al v es . At h i g h
s peeds wh en eng i ne r eq u i r ement s ap p r o ac h t he c a-
pac i t y of t he t wo p r i mar y b o r es , t h e i nc r eas ed p r i -
mar y v ent u r i v ac u u m mo v es t he d i ap h r ag m, c o m-
p r es s i ng t he d i ap h r ag m s p r i ng . Th e d i ap h r ag m, ac t i ng
t h r o u g h t he d i ap h r ag m l i nk and l ev er , wi l l c o mmenc e
t o open t he s ec o nd ar y t hr ot t l e v al v es ( Fi g . 9).
T h e pos i t i on of t h e s ec o nd ar y t hr ot t l e v al v es de-
p end s on t he s t r eng t h of t he v ac u u m. Th i s i n t u r n, i s
d et er mi ned b y t he ai r -f l ow t h r o u g h t he bor es t o t h e
eng i ne. As t he ai r -f l ow i nc r eas es , a g r eat er s ec o nd ar y
t hr ot t l e v al v e o p eni ng wi l l r es u l t and t h e s ec o nd ar y
b ar r el s wi l l s u p p l y a g r eat er por t i on of t h e eng i ne' s
r eq u i r ement s . As t op s p eed i s r eac h ed , t h e s ec o nd ar y
t hr ot t l e v al v es wi l l ap p r o ac h wi d e open.
As t h e s ec o nd ar y t hr ot t l e v al v es b eg i n t o open, a
v ac u u m i s c r eat ed i n t he s ec o nd ar y b ar r el s , first at
t he t hr ot t l e v al v es and t h en, as ai r flow i nc r eas es , at
t he t hr oat of t he s ec o nd ar y v ent u r i . Th i s v ac u u m
as s i s t s t he s ec o nd ar y met er i ng s y s t em t o oper at e.
Wh e n eng i ne s p eed i s r ed u c ed , v ent u r i v ac u u m i n
t he b o r es b ec o me weak er . As t he v ac u u m ac t i ng o n
t he d i ap h r ag m i s l es s ened , t he l o ad on t h e d i ap h r ag m
s p r i ng wi l l c o mmenc e c l o s i ng t he s ec o nd ar y v al v es .
T h e d i ap h r ag m s p r i ng i s as s i s t ed b y t h e d es i g n of t h e
s ec o nd ar y v al v es . Ea c h s ec o nd ar y v al v e i s s l i g h t l y
DIAPHRAGM
CHAMBER
PRIMARY
VENTURI
PICK-UP
DIAPHRAGM
PUMP INLET CHECK BALL NP603C
DIAPHRAGM
DIAPHRAGM ROD
SECONDARY
THROTTLE PLATE NP604B
Fig. 8Accelerating Pump System
Fig. 9Secondary Throttle Operating System
A :
offset . Wh en t he v al v es ar e c l o s i ng , t h e c o mb i ned
f o r c e of mani f o l d v ac u u m and t he ai r s t r eam h as
g r eat er effec t on t h e l ar g er , u p s t r eam ar ea of t he
v al v es f o r c i ng t he v al v es t o a c l o s ed pos i t i on. T h e
s ec o nd ar y v al v es ar e r et ai ned i n t he c l os ed pos i t i on
wh en t he p r i mar y v al v es ar e f u l l y c l os ed b y t h e s ec -
ondar y t hr ot t l e c o nnec t i ng r o d . Th i s r o d , wh i c h i s
f as t ened t o t he p r i mar y t hr ot t l e l ev er , r i d es i n a sl ot
i n t he s ec o nd ar y t hr ot t l e l ev er .
Secondary Fuel Metering Systems
Th e s ec o nd ar y s y s t em i s s u p p l i ed wi t h f u el f r o m
t he s ec o nd ar y f u el bowl , wh i c h r ec ei v es i t s f u el
t h r o u g h a c o nnec t i ng t ube, f r o m t he p r i mar y f u el
i nl et .
Th e s ec o nd ar y f u el b o wl i s eq u i p p ed wi t h a f u el
i nl et as s emb l y wh i c h r eg ul at es t he flow of f u el i nt o
t he bowl , t he s ame as t he p r i mar y f u el bowl . T h e s ec -
o nd ar y f u el i nl et s y s t em mu s t mai nt ai n a s pec i f i ed
l ev el of f u el as t he t wo s ec o nd ar y f u el s y s t ems ar e
c al i b r at ed to d el i v er t he p r o p er mi x t u r e onl y wh en
t he f u el i s at t hi s l ev el .
As t he v al v es b eg i n t o open t h e f u el flows t h r o u g h
t he s ec o nd ar y met er i ng r es t r i c t i o ns i nt o t he i d l e wel l
( Fi g . 10).
A s ec o nd ar y fixed c u r b i dl e d i s c h ar g e pas s ag e s u p -
pl i es f u el d i r ec t l y t o t he i nt ak e mani f o l d , t h u s al l ow-
i ng a s moot her i dl e.
Wh e n t he s ec o nd ar y t hr ot t l e v al v es ar e opened
f u r t h er t he p r es s u r e di f f er ent i al c au s es t he s ec o nd ar y
mai n met er i ng s y s t em t o b eg i n f u nc t i o ni ng .
A u t o ma t i c Choke
Th e aut omat i c c h o k e s u p p l i es enr i c h ed f uel -ai r mi x -
t u r e f o r s t ar t i ng and oper at i ng a c ol d eng i ne ( Fi g . 11).
Most of t he f u el f r o m t he c ar b u r et o r of a c ol d eng i ne
i s l i q u i d . Th i s f u el i n l i q u i d f o r m b u r ns s l o wl y and
i nc ompl et el y . Po wer l os s and s t al l s r es u l t . T h e c h o k e
v al v e s u p p l i es t he ex t r a f u el b y r es t r i c t i ng ai r flow
HOLLEY 4160FUEL SYSTEM 14-43
d u r i ng c r ank i ng and war m-u p . Va c u u m c r eat ed b y t he
r es t r i c t i o n c au s es t hi s f u el flow f r o m bot h t h e mai n
met er i ng and i dl e s y s t ems .
T h e t her mos t at s p r i ng of a c ol d eng i ne p u s h es t he
c h o k e v al v e t o war d t he c l os ed pos i t i on. Wh e n t he
eng i ne i s s t ar t ed, mani f o l d v ac u u m ac t s on bot h t he
c h o k e v al v e and a v ac u u m d i ap h r ag m at t ac h ed t o t he
c ar b u r et o r body. Th i s v ac u u m ac t s t o oppose t he t her -
mos t at s p r i ng and p ar t i al l y opens t he c h o k e v al v e t o
p r ev ent s t al l s f r o m r i c h nes s . T h e c h o k e s h af t does
not p as s t h r o u g h t he c ent er of a c h o k e v al v e. Ins t ead ,
i t i s offset t o ex pos e a l ar g e ar ea at one s i d e t o mani -
f ol d v ac u u m. Du r i ng i d l e or l ow t emp er at u r e c r ank -
i ng , mani f o l d v ac u u m i s not suf f i c i ent l y s t r o ng t o
o p en t he c h o k e v al v e. B u t ai r i mp ac t ag ai ns t t h e v al v e
c au s es p ar t i al openi ng . Th es e t wo f ac t o r s , v ac u u m
and ai r i mp ac t al l ow amp l e ai r t o r u n t he eng i ne. Co n-
t i nu ed r u nni ng of t he eng i ne dev el ops h eat and
c au s es t he t her mos t at as s emb l y t o mo v e t o t h e open
c h o k e pos i t i on.
Du r i ng t he war m-u p p er i o d , ai r flow pas t t h e par -
t i al l y open offset c h o k e v al v e ac t s t o open t h e v al v e.
J u s t as i n t he s t ar t c y c l e, v ac u u m and ai r i mp ac t c o m-
b i ne t o c ont r ol t h e c h o k e v al v e. T h e eng i ne r eq u i r ed
l es s c h o k i ng at h i g h s p eed s . T h e offset c h o k e v al v e,
v ac u u m d i ap h r ag m and t her mos t at s p r i ng ar e eng i -
neer ed t o pr ov i de s at i s f ac t or y c h o k i ng f o r mos t c ondi -
t i ons of eng i ne s p eed , out put and t emp er at u r e.
Fast Idle
T h e c h o k e c o nt r o l l ev er at t he c ar b u r et o r ac t uat es
a f as t i d l e c am d u r i ng c h o k i ng . A c am h as a s er i es of
s t ep s d es i g ned to i nc r eas e c ar b u r et o r ai r flow t o mai n-
t ai n s at i s f ac t o r y c o l d eng i ne s p eed l ev el s . T h e pr op-
er c a m s t ep i s mo v ed i nt o pos i t i on as t he c h o k e r o d
i s mo v ed f r o m c l o s ed t o open c ondi t i ons . Ea c h s t ep
p er mi t s a s l o wer i d l e r p m as eng i ne t emp er at u r e
r i s es and c h o k i ng i s r ed u c ed .
NP606B
Fig. 10Secondary Fuel Metering System
Fig. I I Aut oma t i c Choice System
A- HOL L EY 4160FUEL SYSTEM 14-45
1 L ever , Pump Oper at i ng
2 L oc knut
3 Spr i ng, overri de
4 Sc r ew, Pump Adj ust i ng
5 Sc r ew, Fuel Bowl (Pri mary)
6 Gasket , Bowl Sc r ew
7 Fuel Bowl (Pri mary)
8 Gasket , Fuel Bowl
9 Met eri ng Body (Pri mary Si de)
10 Gasket , Met eri ng Body
11 Fuel Tube (Fl oat Bowl Connec t i ng)
12 " 0" Ri ngs, Fuel Tube
13 Sc r ew, Fuel Bowl (Sec ondar y)
14 Gasket , Bowl Sc r ew
15 Fuel Bowl (Sec ondar y)
16 Sc r ew, Met eri ng Body (Sec ondar y)
17 Met eri ng Body (Sec ondar y)
18 Gasket , Met eri ng Body (Sec ondar y)
19 Pl at e, Met eri ng Body (Sec ondar y)
20 Gasket , Met eri ng Body Pl at e
21 B al anc e Tube
22 Washer s, B al anc e Tube
23 " 0" Ri ngs, B al anc e Tube
24 Choke L i nk
25 Seal , Choke Rod
26 Thr ot t l e Body Sc r ews
27 Mai n Body
28 Throt t l e Body
29 Gasket , Mai n to Thr ot t l e Body
30 Sc r ew, Bowl Vent Val ve Rod Cl amp
31 Cl amp, Val ve Rod
32 Rod, Bowl Vent Val ve
33 Spr i ng Vent Val ve Rod
34 Val ve, Bowl Vent
35 Ret ai ner , Cl i p, Fl oat
36_Fl o at
37 Spr i ng, Fl oat
38 Baffl e, Fl oat
39 Needl e Val ve and Seat
40 Sc r ews , Fuel Pump Cover
41 Cover Assembl y, Fuel Pump
42 Di aphr agm, Fuel Pump
43 Spr i ng, Fuel Pump Di aphragm
44 Fi t t i ng, Fuel Inl et
45 Gasket , Fuel Inl et , Fi t t i ng
46 Val ve Assembl y, Power
Spark Advance
The d i s t ri but or ut i l i z es changes i n a i r pressure
w i t hi n t he ca rbure t or t o con t rol s park t i mi n g t o
sati sf y a l l engi ne speed and l oad condi t i ons.
I n orde r t o obt ai n a vacuum t o operat e t he s park
advance as di ct at e d by t he engi ne speed a nd l oad
condi t i ons, a port i s l ocat ed i n t he t hrot t l e bore j us t
above t he f ul l cl osed pos i t i on of t he t hr ot t l e val ves,
47 Gasket , Power Val ve
48 Pri mary J et s
49 Needl e, Idl e Adj ust i ng Mi xt ure
50 Gasket , Idl e Mi xt ure Needl e
51 Sc r ews , Choke Val ve
52 Choke Val ve
53 Choke Shaf t & L ever As s embl y
54 Di sc har ge Nozzl e Sc r ew, Pump
55 Gasket , Nozzl e Sc r ew
56 Nozzl e, Pump Di sc har ge
57 Needl e, Pump Di sc har ge J et
58 Cot t er Pi ns , Connec t i ng Rods
59 Rod, Sec ondar y Connec t i ng
60 Sc r ew and L oc kwasher , Fas t Idl e Cam L ever
61 L ever , Fas t Idl e Cam
62 Sc r ews , Pr i mar y Thr ot t l e Val ve
63 Throt t l e Val v es, Pri mary
64 Sc r ew, Pump Cam
65 Pump Cam
66 Sc r ew and L oc kwasher , Sec ondar y St op L ever
67 L ever , Sec ondar y St op
68 Sc r ews , Sec ondar y Thr ot t l e Val ves
69Throt t l e Val ves, Sec ondar y
70 Fas t Idl e Cam L ever
71 Fas t Idl e Cam
72 Ret ai ner (E-Cl i p)
73 Choke Di aphr agm L i nk
74 Choke Di aphr agm Assembl y
75 Choke Vac uum Hose
76 Choke Di aphragm B r ac ket Sc r ew
77 Sec ondar y Di aphr agm Cover Sc r ew
78 Di aphragm Cover (Mac hi ne)
79 Sec ondar y Di aphr agm Ret ur n Spr i ng
80 Sec ondar y Di aphr agm Assembl y
81 Sec ondar y Di aphr agm Housi ng (Mac hi ne)
82 Sec ondar y Di aphr agm Housi ng Gas k et
83 Sec ondar y Di aphr agm Assembl y Sc r ew
84 Throt t l e Connec t i ng Rod Ret ai ner Washer
85 Pump Oper at i ng L ever (E-Cl i p)
86 Sec ondar y St op Sc r ew
87 Thr ot t l e St op Sc r ew
88 Throt t l e St op Sc r ew Spr i ng
89 Baffl e
90 L i mi t er Cap
91 Bowl Vent Val ve Assy. (E. C. S. )
as t he t hrot t l e is opened, t hi s port i s subj ect t o ma ni -
f ol d vacuum, whi ch vari es w i t h changes i n engi ne
l oad. Thi s port i n t he t hrot t l e body is connect ed t o t he
ma i n body by a s hort ve rt i ca l passage, and t he n t o a
passage i n t he ma i n me t e ri n g body. Thi s passage
l eads t o an out l e t on t he si de of t he ma i n me t e ri n g
body whi ch connects t o a si ngl e flexible t ube t o t he
d i s t ri but or.
SERVICE PROCEDURES
Servicing Carburetor
D i r t , dust , wat e r and gummy deposi ts are some of
t he ma i n causes f or poor ca rbure t or ope rat i on. How-
ever, prope r cl e ani ng and t he i ns t a l l a t i on of ne w
part s , whe re re q ui re d , w i l l r e t ur n t he ca rbure t or t o
i t s ori gi n a l l y desi gned perf ormance.
Whe n ove rha ul i ng t he carbure t or, several i t e ms of
i mport ance s houl d be observed t o assure a good j ob:
(1) A l l part s s houl d be care f ul l y cl eaned i n a s ui t -
abl e sol vent , t he n i nspect ed f or damage or wear.
(2) Use a i r pressure onl y t o cl ear t he vari ous ori -
fices a nd channel s.
(3) Repl ace quest i onabl e part s w i t h Ne w Ones.
Whe n che cki ng part s re move d f r om t he ca rbure t or.
i t i s at t i mes ra t he r di f f i cul t t o be sure t he y are sati s-
f a ct ory f or f ur t he r servi ce. I t i s, t he re f ore , recom-
me nde d t ha t i n such cases, Ne w Part s be i ns t a l l e d .
(4) Al ways use a compl et e re pa i r k i t whe n over-
ha ul i n g t he ca rbure t or. Us i ng t he code n umbe r
st amped on t he a i rhorn , adj acent t o t he f ue l i n l e t ,
re f e r t o t he pa rt s cat al og and ord e r t he corre ct re pa i r
k i t f or t he ca rbure t or be i ng work e d on.
DI SASSEMBLI NG CARBURETOR
To di sassembl e t he ca rbure t or (Fi g. 1) f or cl eani ng
or ove rhaul , proceed as f ol l ows :
(1) I n s t a l l f our el evat i ng l egs, T ool T109-287S i n
14-46 FUEL SYSTEMHOLLEY4160
BOWL VENT VALVE PRIMARY METERING BALANCE
ASSEMBLY
BODY TUBE
FUEL
TRANSFER
TUBE
ACCELERATI NG
PUMP OPERATING
LEVER
NP755B
Fig. 2Removing orinstalling Primary Fuel Bowl
mo u nt i ng flange hol es i n t hr ot t l e body , or u s e Car b u -
r et o r St and C-3886. ( Th es e t ool s ar e u s ed t o pr ot ec t
t he t hr ot t l e v al v es f r o m d amag e and t o p r o v i d e a s ui t -
ab l e bas e f o r wo r k i ng ) .
(2) Remo v e p r i mar y f u el b o wl as s emb l y b y s l i d i ng
s t r ai g h t off b al anc e t ube ( Fi g . 2).
(3) Remo v e p r i mar y met er i ng b o d y b y s l i d i ng
s t r ai g h t off b al anc e t u b e ( Fi g . 3). Remo v e pl at e t o
body g as k et .
(4) Remo v e ac c el er at i ng p u mp o p er at i ng l ev er " E "
c l i p and s l i d e l ev er as s emb l y off s t u b s haf t . Remo v e
ad j u s t i ng nut , s p r i ng and s c r ew.
(5) Remo v e f u el t r ans f er t ube and " 0 " r i ng s ( Fi g .
3).
(6) Remo v e s ec o nd ar y f u el b o wl as s emb l y .
(7) Us i ng a c l u t c h h ead s c r ewd r i v er ( Tool CL -13)
r emo v e c l u t c h h ead s c r ews , c ar ef u l l y wo r k s ec o nd ar y
met er i ng body, pl at e and g as k et s off b al anc e t u b e
( Fi g . 4).
(8) Remo v e b al anc e t ube, was h er s and " 0" r i ng s
by s l i d i ng out of mai n body (ei t her end) .
(9) Di s c o nnec t c h o k e d i ap h r ag m hos e f r o m t hr ot t l e
body fitting, t h en r emo v e d i ap h r ag m as s emb l y , at t h e
s ame t i me di s eng ag i ng l i nk f r o m f as t i dl e c am l ev er .
BALANCE TUP^x
, 1\
f
GASKET
NP756C
TUBE
.-" J , MAIN BOOY
G A
/
K E T
' g- - s , / / P L A T E
f^, i4-k / I
GA
,
SKET
RALAVK
TUBE
NP757C
SECONDARY CLUTCH HEAD
METERI NG BODY SCREW
Fig. 4Secondary Metering Body, Plate and Gaskets
(10) Remo v e " E " c l u p t hat r et ai ns f as t i dl e c am
l ev er and c am. Sl i d e l ev er and c am off s t ub s haf t , and
at t he s ame t i me, di s eng ag e c h o k e r o d f r o m c a m
l ev er . (Not e pos i t i on of f as t i dl e c am t o c a m l ev er . )
(11) Remo v e s ec o nd ar y d i ap h r ag m at t ac h i ng s c r ews
and r emo v e d i ap h r ag m as s emb l y . Di s eng ag e di a-
p h r ag m s t em f r o m s ec o nd ar y st op l ev er . Remo v e gas -
k et .
(12) Remo v e p u mp d i s c h ar g e nozzl e r et ai ni ng s c r ew,
t hen l i f t out d i s c h ar g e nozzl e. Remo v e g as k et f r o m
nozzl e (top and bot t om).
(13) Remo v e s c r ews t hat at t ac h hot i dl e c o mp ens a-
t or v al v e c o v er t o mai n body. L i f t off c o v er , t h en r e-
mo v e v al v e and g as k et . ( Fi g . 5). If so eq u i p p ed .
(14) Remo v e c u r b i dl e s peed s c r ew and s p r i ng . T h e n
r emo v e i ns u l at i ng was h er f r o m b et ween l ead t er mi nal
and st op. Remo v e di s t r i but or g r o u nd s wi t c h l ead . Us -
i ng a t h i n bl ade s c r ew d r i v er , r emo v e i ns u l at o r b u s h -
i ng f r o m boss on body. ( Fi g . 5).
(15) Inv er t c ar b u r et o r and dr op out p u mp d i s c h ar g e
j et need l e f r o m d i s c h ar g e pas s ag e.
(16) Wi t h c ar b u r et o r i nv er t ed , r emo v e s c r ews t hat
DISTRIBUTOR GROUND
SWITCH LEAD
CURB IDLE SPEED
'ADJUSTING SCREW
GASKET
VALVE
VALVE ;
t
p* 7 \ \
COVER' | /
N
SWITCH \ '
TERMINAL flflg
BUSHING
NSULATING
WASHER
SCREWS
PY903
Fig. 3Removing or Installing Primary Metering
Body and Plate
Fig. 5Removing or Installing Hot Idle
Compensator Valve
HOLLEY 4160FUEL SYSTEM 14-47
at t ach t he t hr ot t l e body t o ma i n b o d y (Fi g. 5). Remo v e
t hr ot t l e b o d y and d i s c ar d g as k et .
Disassembling Fuel Bowls (Primary
and Secondary)
Primary
(1) Remo v e p r i mar y b o wl v ent v al v e as s emb l y (Fi g.
6). On E. C . S. , r emo v e oper at i ng r o d as s emb l y .
(2) Remo v e float r et ai ner " E " c l i p , t h en s l i d e float
and s p r i ng out of float c h amb er . ( As float i s b ei ng
r emo v ed , t he f u el i nl et need l e may d r o p out of s eat
as s emb l y . ) Remo v e float baffl e.
(3) Remo v e f u el i nl et need l e v al v e s eat . Di s c a r d
t he g as k et .
(4) Remo v e s c r ews at t ac h i ng ac c el er at o r p u mp
c ov er . Remo v e c ov er , t h en c ar ef u l l y r emo v e d i a-
p h r ag m and s p r i ng .
(5) Remo v e f u el i nl et fitting and d i s c ar d g as k et .
(6) Remo v e s c r ews at t ac hi ng b o wl v ent v al v e c o v er
t o f u el bowl . L i f t off c o v er and r emo v e v ent v al v e,
s p r i ng and s eal . ( Fi g . 1). Remo v e s eal f r o m bot t om of
v al v e.
S e c o n d a r y
(1) Remo v e float r et ai ner " E " c l i p , t h en s l i de float
and s p r i ng out of float c h amb er . ( As float i s b ei ng r e-
mo v ed , t he f u el i nl et need l e may dr op out of s eat as -
s embl y . ) Remo v e float baffl e.
(2) Remo v e f u el i nl et need l e v al v e s eat . Di s c ar d
g as k et .
It should be noted that the Primary and Secondary
fuel bowl baffles are of a different design and should
be installed in the correct bowl at reassembly.
Disassembling Main Metering Body
Primary
(1) Us i ng To o l C-3747, r emo v e p o wer v al v e as s em-
b l y f r o m p r i mar y met er i ng body ( Fi g . 7).
(2) Us i ng To o l C-3748, r emo v e mai n met er i ng j et s .
(Fig. 8).
(3) Remo v e i dl e ad j u s t i ng needl es and g as k et s .
(4) T u r n i dl e l i mi t er c ap s t o st ops. Remo v e c ap s b y
BOWL VENT -
VALVE
/ I F L O A T
4 -|
JHIHBIMMIE
FLOAT PI VOT L ;v
PI N

FLOAT RETAI NER:
"E" CLI P
R
FUEL
I NLET ^>^
:
' -
;
'V;\
ACCELERATOR
PUMP COVER *
K O A T
AND LEVFR SPRING ASSEMBLY N P 7 5 9

-4- -
m
wmSL
$r ..4,
4
i . .
F
POWER V A L V E S
TOOL NY41B
Fig. 7Removing or Installing Power Valve
p r y i ng off end s of s c r ews , u s i ng a s ui t abl e t ool . ( B e
c ar ef u l not t o b end s c r ews . ) B e s u r e and c ount nu m-
b er of t u r ns t o s eat t he s c r ews , as t he s ame nu mb er
of t u r ns (f r om t he s eat ) mu s t be mai nt ai ned at i ns t al l a-
t i on. Remo v e s c r ews and s p r i ng s f r o m met er i ng body.
Secondary
No d i s as s emb l y r eq u i r ed , b u t i t i s v er y i mp o r t ant
t hat t h e wel l b l eed p ar t s , mai n met er i ng r es t r i c t i o ns
and i dl e f eed r es t r i c t i o ns ar e c l ean ( Fi g . 9).
Disassembling Secondary Diaphragm
(1) Remo v e t he d i ap h r ag m c o v er s c r ews and s ep a-
r at e d i ap h r ag m c o v er f r o m h o u s i ng .
(2) Remo v e d i ap h r ag m r et u r n s p r i ng f r o m c o v er ,
t h en s l i d e d i ap h r ag m out of h o u s i ng .
Disassembling Throttle Body
CAUTI ON: In normal routine cleaning and overhaul
of the carburetor, do not remove the throttle valves
unless they are nicked or damaged. If necessary to
remove, proceed as follows:
(1) Remo v e s c r ews t hat h o l d t hr ot t l e v al v es t o
t hr ot t l e s haf t s . These screws are staked to prevent
MAI N METERI NG
BODY (PRI MARY) ^
POWER
VALVE rVJi ] 4^. . 4.
TOO;.
\
i ;.\Y
MAI N METERI NG
JETS
MY43C
Fig. 6Primary Fuel Bowl Assembly Fig. 8Removing or Installing M@in Metrasd$}J &ts
14-48 F UEL SYSTEMHOL L EY 4160-
A
M A I N A I R
WEL L
MAIN WELL
FUEL AND AIR
I
IDLEFEED
RESTRICTION
S IDLE FUEL
i ' V WELL
DOWL
WELL BLEED
S C R E W
H O L E S
N P 7 6 1 A
Fig. 9Secondary Metering Body
loosening and care is necessary to avoid breaking off
in shaft. Remove staking with a file.
(2) Sl i d e d amag ed t hr ot t l e v al v es out of b o r es . It
s h o u l d b e not ed at t hi s t i me, t hat t h e s ec o nd ar y
t hr ot t l e v al v es ar e t h i c k er t h an t h e p r i mar y v al v es .
Do not install secondary valves in primary bores or
visa versa as the relationship of the primary valves to
the idle transfer port and spark advance control ports
is carefully established for one particular assembly.
CLEANI NG CARBURETOR PARTl
T h e r ec o mmend ed s ol v ent f o r g u m depos i t s i s de-
nat u r ed al c o h o l wh i c h i s eas i l y obt ai nabl e. Ho wev er ,
t h er e ar e ot her c o mmer c i al s o l v ent s , ( s u c h as Met al -
c l ene) wh i c h may b e u s ed wi t h s at i s f ac t o r y r es u l t s .
T h e c h o k e d i ap h r ag m c an be d amag ed b y s o l v ent s .
Av o i d p l ac i ng t he d i ap h r ag m as s emb l y i n A NY l i q u i d .
Cl e a n t h e ex t er nal s u r f ac es wi t h a c l ean c l ot h o r sof t
wi r e b r u s h . Sh ak e di r t or ot her f o r ei g n mat er i al f r o m
t h e s t em s i d e of t he d i ap h r ag m. Dep r es s i ng t he di a-
p h r ag m s t em t o t he r et r ac t ed pos i t i on, wi l l p r o v i d e an
ad d i t i o nal hol e f o r t he r emo v al of di r t . Co mp r es s ed
ai r c an be u s ed t o r emo v e l oos e di r t , but should not
be connected to the vacuum inlet fitting.
I MPORTANT: If the commercial solvent or cleaner
recommends the use of water as a rinse, i t should be
" HOT" . After rinsing, all trace of water must be
blown from the passages with air pressure. It is fur-
ther advisable to rinse all parts in clean gasoline or
kerosene t o be certain no trace of moisture remains.
Never clean jets with a wire, drill or other mechanical
means b ec au s e the orifices may become enlarged,
making the fuel mixture too rich for proper perform-
ance.
DO NOT c l ean any r u b b er d i ap h r ag ms or p l as t i c
p ar t s i n c l eani ng s ol v ent b ec au s e of pos s i bl e d amag e.
INSPECTION AND REASSEMB L Y
Throttle Body
If t he t hr ot t l e v al v es wer e r emo v ed b ec au s e of
d amag e, i ns t al l new v al v es as f ol l ows :
(1) Sl i d e new p r i mar y t hr ot t l e v al v es i n pos i t i on on
t hr ot t l e s haf t , wi t h t he v al v e nu mb er on t h e bot t om
(fl ange s i de) and t o war d i dl e t r ans f er and s p ar k ad -
v anc e c o nt r o l por t s .
(2) Ins t al l new at t ac hi ng s c r ews b u t do not t i g ht en.
(3) Ho l d v al v es i n p l ac e wi t h fingers. ( Fi ng er s p r es s -
i ng on h i g h s i d e of v al v es . )
(4) Ta p v al v es l i g ht l y wi t h s c r ewd r i v er i n t hi s pos i -
t i on t o c ent er i n bor es . Ti g h t en s ec u r el y . Op er at e t h e
t hr ot t l e s haf t s . F r o m c l o s ed t o open pos i t i on, t h ey
mu s t oper at e s moot hl y wi t hout d r ag o r s t i c k i ng . Ho l d
t hr ot t l e body u p t o a s t r o ng l i g ht . T h e l i g ht wh i c h i s
v i s i bl e ar o u nd t he out er d i amet er of t he v al v es and
t he bor es s h o u l d be u ni f o r m.
(5) Ins t al l s ec o nd ar y t hr ot t l e v al v es i n t h e s ame
manner as d es c r i b ed p r ev i o u s l y . T h e nu mb er s
s t amp ed on t he v al v es mu s t b e t o war d i d l e t r ans f er
and s p ar k ad v anc e por t s i n p r i mar y bor es . F o r ad j u s t -
ment (See Sec o nd ar y Th r o t t l e Ad j u s t ment ) .
Assembling Main Metering Body
(Primary)
(1) Ins t al l i dl e mi x t u r e s c r ews and s p r i ng s i n met er -
i ng body. ( Th e t ap er ed por t i on mu s t be s t r ai g ht and
s moot h. If t ap er ed por t i on i s g r oov ed or r i d g ed , a new
i dl e mi x t u r e s c r ew s h o u l d be i ns t al l ed t o i ns u r e hav -
i ng c o r r ec t i dl e mi x t u r e c ont r ol . ) DO NOT USE A
SCREW DRI VER. T u r n s c r ews l i g ht l y ag ai ns t t h ei r
s eat s wi t h fingers. B a c k off t he nu mb er of t u r ns
c o u nt ed at d i s as s emb l y . Ins t al l new pl as t i c c ap s wi t h
t abs ag ai ns t st op.
(2) Sl i de a new g as k et ov er p o wer v al v e and i ns t al l ,
u s i ng To o l C-3747. Ti g h t en s ec u r el y ( Fi g . 7).
(3) Ins t al l mai n met er i ng j et s ( Fi g . 8), u s i ng To o l
C-3748. Ti g h t en s ec u r el y .
Assembling Fuel Bowls
Primary
(1) Ins t al l ac c el er at o r p u mp s p r i ng i n pos i t i on i n
f u el bowl , f ol l owed b y d i ap h r ag m and p u mp c ov er .
( Wh en i ns t al l i ng d i ap h r ag m, be s u r e c ont ac t but t on i s
t o war d p u mp l ev er i n c ov er . ) ( Fi g . 10).
(2) Pl ac e c o v er ov er d i ap h r ag m (wi t h l ev er on f u el
i nl et fitting s i de) ( Fi g . 10). Ins t al l at t ac h i ng s c r ews and
t i ght en s ec u r el y .
(3) Ins t al l new g as k et on f u el i nl et need l e s eat ( Fi g .
11) t hen i ns t al l i n f u el bowl . Ti g h t en s ec u r el y . Sl i d e
f u el i nl et need l e i nt o s eat .
(4) Ins t al l float baffl e i n pos i t i on, t h en s l i d e float
h i ng e ov er pi v ot and s ec u r e wi t h " E " c l i p. Ins t al l
float s p r i ng .
(5) Ins t al l new g as k et ov er f u el i nl et fitting, t hen
i ns t al l fitting i n p r i mar y f u el bowl . Ti g h t en s ec u r el y .
(6) Ins t al l b o wl v ent v al v e as s emb l y on f u el b o wl ,
b ei ng s u r e v ent v al v e s p r i ng i s h o o k ed i nt o b r ac k et
and l oop of s p r i ng u nd er oper at i ng r o d . Po s i t i o n
-HOL L EY 4160FUEL SYSTEM 14-49
FUEL INLET
FITTING
PUMP INLET
CHECK BALL
(NOT REMOVABLE)
PRIMARY FUEL
BOWL
DI APHRAGM
RETURN SPRING
ACCELERATOR
. PUMP DI APHRAGM
* ^CONTACT BUTTON
ACCELERATOR
PUMP COVER
ASSEMBLY
GASKET
PUMP LEVER
/
PUMP
NP762
COVER SCREWS
Fig. 10Accelerating Pump (Exploded View)
c l amp t h en i ns t al l at t ac h i ng s c r ew and t i g ht en s e-
c u r el y . ( C. A. S. ) Car b u r et o r s . ( Fi g s . 1 or 2).
(7) On E. C. S. c ar b u r et o r s , i ns t al l s eal on bot t om of
v ent v al v e. Sl i d e p l as t i c v al v e and s eal i nt o c o v er ,
wi t h v al v e r ec es s , mat i ng wi t h s h o u l d er on u nd er s i d e
of c ov er .
(8) Ins t al l bowl v ent v al v e s p r i ng i n pos i t i on i n
openi ng i n bowl , t h en i ns t al l v al v e and c o v er o v er
s p r i ng . Ins t al l at t ac hi ng s c r ews and t i g ht en s ec u r el y .
(9) Ins t al l bowl v ent oper at i ng r o d , c l amp and
s p r i ng i n pos i t i on on bowl . Ins t al l at t ac hi ng s c r ew and
t i g ht en s ec u r el y .
SECONDARY
FUEL BOWL
FUEL INLET
SEAT
FUEL INLET
NEEDLE
FLOAT
RETAINER
\
PRIMARY
FUEL BOWL
r-LOAT
SPRING
BAFrLE
FLOAT
"ASSEMBLY
NP763
Fig. I1Float, Needle, Seat and Baffle
(Exploded View)
Secondary
(1) Ins t al l new g as k et on f u el i nl et need l e s eat ( Fi g .
11), t h en i ns t al l i n f u el bowl . Ti g h t en s ec u r el y . Sl i d e
f u el i nl et need l e i nt o s eat .
(2) Ins t al l float baffl e i n pos i t i on, t h en s l i d e float
h i ng e o v er pi v ot and s ec u r e wi t h " E " c l i p . I ns t al l float
s p r i ng .
Adjusting Floats
(1) I nv er t t he p r i mar y f u el bowl and u s i ng a 15/64
i nc h d r i l l s h ank o r g aug e, meas u r e t h e c l ear anc e be-
t ween t oe of float and s u r f ac e of f u el b o wl . ( Fi g . 12).
" E" CLIP BAFFLE
FUEL
BOWL-
FUEL
INLET
FLOAT
FLOAT
SPRING
ACCELERATOR
PUMP COVER
AND LEVER
NEEDLE
AND SEAT
ASSEMBLY
V. .
PRIMARY
FUEL BOWL
HEEL OF
FLOAT
15/64" DRILL
17 64" DRILL OR GAUGE
TOE OF
FLOAT
NP764A
Fig. 12Checking Float Setting (Primary and Secondary)
14-50 FUEL SYSTEMHOLLEY 4160 A
I f an ad j u s t ment i s nec es s ar y , be nd float t a n g u nt i l
corre ct cl earance h as b een obt ai ned.
(2) I n ve rt t he s ec o nd ar y f ue l bowl and us i ng a
17/64 i nc h d r i l l s h ank or g aug e, meas u r e t he c l ear -
anc e bet ween h eel of float and surf ace of f u el b o wl
( Fi g . 12). If an ad j u s t ment i s nec es s ar y , b end float
t ang u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
Assembling Main Body
(1) Pl ac e a new g as k et on t hr ot t l e body , t h en l o wer
mai n body ( Fi g . 13) d o wn on t hr ot t l e body , al i g ni ng
r o l l p i n g ui des wi t h openi ng s i n mai n body . B e s u r e
p r i mar y bor es of t hr ot t l e body ar e on t he s ame s i d e
as p r i mar y v ent u r i .
(2) Ho l d i ng as s emb l y t oget her , i nv er t as s emb l y and
i ns t al l at t ac h i ng s c r ews . Ti g h t en s ec u r el y .
(3) Ins t al l b al anc e t ube i nt o mai n body and i ns t al l
new " 0" r i ng s and was h er s at eac h end . B e s u r e " 0 "
r i ng s ar e s eat ed i n r ec es s es , f o l l o wed b y was h er s .
(4) Ins t al l a new s ec o nd ar y met er i ng body t o mai n
body g as k et ( Fi g . 4) f ol l owed b y met er i ng body pl at e,
pl at e g as k et and body . Ins t al l c l u t c h h ead s c r ews and
t i g ht en s ec u r el y . (B e s u r e t he mai n met er i ng r es t r i c -
t i on por t s ar e at t he bot t om).
(5) Po s i t i o n b al anc e t ube so t hat onl y 1 i nc h ex-
t ends b ey o nd t h e s ec o nd ar y met er i ng body ( Fi g . 14).
( Us e a 6 i nc h r u l er f o r t hi s meas u r ement . )
(6) Pl ac e a new g as k et o v er p r i mar y met er i ng body
al i g ni ng p i n. ( Rear ) Car ef u l l y s l i d e met er i ng body
o v er b al anc e t ub an d d o wn i nt o pos i t i on ag ai ns t mai n
body .
(7) Sl i d e a new g as k et o v er met er i ng body al i g n-
ment s t uds and c ar ef u l l y pos i t i on ag ai ns t body .
(8) Car ef u l l y i ns t al l p r i mar y f u el b o wl o v er b al anc e
t ube and d o wn ag ai ns t met er i ng body . Sl i d e new g as -
k et s o v er t he l o ng f u el b o wl mo u nt i ng s c r ews , t h en
i ns t al l i n pos i t i on t h r o u g h f u el b o wl . Ti g h t en s ec u r el y .
Fig. 13Main Body Identification (Bottom View)
Fig. 14Positioning Balance Tube
If new g as k et s ar e not u s ed , a f u el l eak wi l l dev el op.
(B e s u r e and i ns t al l di s t r i but or g r o u nd s wi t c h l ead
and l ead c l amp on l ong s c r ew ad j ac ent t o f u el i nl et . )
(9) Sl i d e a new " 0 " r i ng on eac h end of f u el t ube,
t h en i ns t al l f u el t ube i nt o o p eni ng i n p r i mar y f u el
b o wl . Pr es s i n on t ube end u nt i l s eat ed .
(10) Car ef u l l y s l i d e s ec o nd ar y f u el b o wl o v er bal -
anc e t ube and f u el t ube and s eat ag ai ns t g as k et . In-
s t al l s ec o nd ar y f u el b o wl at t ac h i ng s c r ews af t er i n-
s t al l i ng new g as k et s . Ti g h t en s ec u r el y .
(11) Ins t al l ac c el er at i ng p u mp d i s c h ar g e need l e i n
t h e d i s c h ar g e p as s ag e i n t he c ent er of p r i mar y v en-
t u r i .
To t est need l e f o r s eal i ng , p o u r c l ean g as ol i ne i nt o
p r i mar y f u el b o wl t h r o u g h v ent v al v e openi ng . Pu s h
d o wn on ac c el er at o r p u mp a r m to ex p el ai r f r o m t h e
p u mp p as s ag es . Us i ng a s mal l c l ean b r as s r o d , h o l d
t h e d i s c h ar g e c h ec k need l e firmly on i t s s eat . Ag a i n
p r es s d o wn on p u mp ar m. No f u el s h o u l d b e emi t t ed
f r o m t he d i s c h ar g e p as s ag e. F u e l l eak ag e at t h e di s -
c h ar g e need l e i nd i c at es t he p r es enc e of di r t or a
d amag ed c h ec k needl e. Cl ean ag ai n and i ns t al l a new
need l e. Ret es t f o r l eak ag e.
If f u el c ont i nues t o l eak pas t d i s c h ar g e c h ec k
need l e, at t empt t o r es eat as f ol l ows :
Wi t h t he d i s c h ar g e c h ec k need l e i ns t al l ed , i ns er t a
p i ec e of d r i l l r o d d o wn on t he need l e. L i g h t l y t ap t h e
d r i l l r o d wi t h a h a mme r t o f o r m a new s eat . Remo v e
and d i s c ar d ol d need l e and i ns t al l a new one. Ret es t
as d es c r i b ed p r ev i o u s l y . If t he s er v i c e fix does not
c o r r ec t t he c ondi t i on, a new c ar b u r et o r wi l l h av e t o
be i ns t al l ed .
(12) Ins t al l p u mp d i s c h ar g e nozzl e g as k et , nozzl e
and mo u nt i ng s c r ew and g as k et . Ti g h t en s c r ew s e-
c u r el y . Tes t nozzl e oper at i on. Pr es s p u mp l ev er d o wn.
T h e t wo s t r eams f r o m t he nozzl e s h o u l d b e i d ent i c al
and s h o u l d s t r i k e t he t wo v ent u r i i n t he s ame s pot .
(13) Sl i d e t he b o wl v ent v al v e s haf t d o wn b et ween
f u el t ube and c ar b u r et o r body. Ho l d i n pos i t i on, t h en
A
i ns t al l c l amp , af t er eng ag i ng s t ub end of s p r i ng i n
c l amp . Ins t al l r et ai ni ng s c r ew and t i ght en s ec u r el y .
(14) L o o s en c h o k e v al v e at t ac h i ng s c r ews s l i g ht l y .
(15) Tap l i g ht l y on c hok e v al v e t o c ent er v al v e i n
ai r h o r n. Ho l d i ng c h o k e v al v e wi t h t he fingers, t i g ht en
at t ac hi ng s c r ews s ec u r el y . St ak e by s queezi ng wi t h
pl i er s .
(16) Eng ag e f as t i dl e c am wi t h f as t i dl e c am l ev er ,
t h en s l i d e as s emb l y ont o s t ub s haf t pos i t i oni ng f as t
i dl e c am b eh i nd f as t i dl e c am l ev er . At t he s ame t i me
engage f as t i dl e c am l ev er wi t h c h o k e r od. Ins t al l " E "
c l i p to s ec u r e.
Choke Vacuum Diaphragm
Ins p ec t t he d i ap h r ag m v ac u u m fitting t o be s u r e
t hat t he pas s ag e i s not pl ug g ed wi t h f or ei g n mat er i al .
L e a k c h ec k t he d i ap h r ag m t o d et er mi ne i f i t h as i n-
t er nal l eak s . To do t hi s , first d ep r es s t he d i ap h r ag m
s t em, t h en p l ac e a finger o v er t he fitting t o s eal t he
openi ng . Rel eas e t he s t em. If t h e s t em mo v es mo r e
t h an 1/16 i nc h i n t en (10) s ec o nd s , t he l eak ag e i s
ex c es s i v e and t he as s emb l y mu s t b e r ep l ac ed .
Ins t al l t he d i ap h r ag m as s emb l y on t he c ar b u r et o r
as f ol l ows :
(1) Eng ag e c h o k e l i nk i n sl ot i n c hok e l ev er .
(2) Pl ac e t he d i ap h r ag m on t he mo u nt i ng s u r f ac e.
Ins t al l and t i g ht en t he at t ac hi ng s c r ews s ec u r el y .
(3) Ins p ec t t he r u b b er hos e f o r c r ac k s bef or e p l ac -
i ng i t on t he c o r r ec t c ar b u r et o r fitting. Do not c o nnec t
t he v ac u u m h o s e t o t he d i ap h r ag m fitting u nt i l af t er
t he v ac u u m k i c k ad j u s t ment h as b een made.
(4) Ins t al l hot i dl e c o mp ens at o r v al v e g as k et i n
pos i t i on i n r ec es s i n mai n body, f ol l owed by v al v e. (B e
s u r e v al v e i s pos i t i oned wi t h l eg s t owar d out s i de of
mai n body.) ( Fi g . 5). Pl ac e c o v er ov er openi ng and
i ns t al l at t ac hi ng s c r ews . Ti g h t en s ec u r el y . (If so
equi pped. )
(5) Sl i d e a new di s t r i but or g r o u nd s wi t c h i ns u l at ed
b u s h i ng i nt o st op on mai n body, wi t h t he no t c h al i g ned
wi t h r ai s ed por t i on of boss. F o r c e i nt o posi t i on ag ai ns t
st op.
(6) Pl ac e i ns u l at i ng was h er ov er t ang s on l ead wi r e
t er mi nal , t h en i ns t al l c u r b i dl e s peed s c r ew wi t h
s p r i ng t h r o u g h t er mi nal and was h er .
(7) T u r n s c r ew i nt o bos s , at t he s ame t i me, k eep
i ns u l at i ng was h er al i g ned.
Assembling Secondary Diaphragm
(1) Sl i d e d i ap h r ag m i nt o h o u s i ng ( Fi g . 15).
(2) Pos i t i on d i ap h r ag m so t hat t he v ac u u m hol e i n
h o u s i ng i s al i g ned wi t h v ac u u m hol e i n d i ap h r ag m.
(3) Ins t al l d i ap h r ag m r et u r n s p r i ng wi t h c oi l ed end
s nap p ed ov er but t on i n c o v er .
(4) Su p p o r t d i ap h r ag m s t em i n o r d er t o k eep di a-
p h r ag m flat as s p r i ng and c o v er ar e i ns t al l ed.
(5) Al i g n v ac u u m por t i n c o v er wi t h por t i n h o u s i ng
HOL L EY 4160FUEL SYSTEM 14-51
VACUUM HOLE NP767
F i g . 15Secondary Throttle Diaphragm
(Exploded View)
t h en c ar ef u l l y l o wer c ov er . I ns t al l at t ac h i ng s c r ews
and t i g ht en s ec u r el y .
(6) Ch ec k d i ap h r ag m b y p r es s i ng in o n s t em and
p l ac i ng finger ov er por t . Di ap h r ag m s h o u l d s t ay i n
r et r ac t ed pos i t i on.
(7) Ins t al l a new g as k et i n v ac u u m p as s ag e r ec es s
i n d i ap h r ag m h o u s i ng , t h en i ns t al l s ec o nd ar y di a-
p h r ag m on mai n body of c ar b u r et o r and at t h e s ame
t i me engage s t em wi t h s ec o nd ar y st op l ev er . Ins t al l
s c r ews and t i g ht en s ec u r el y .
(8) Ins t al l p u mp l ev er on s t u b s h af t and s ec u r e
wi t h " E " c l i p. Sl i d e s p r i ng and l o c k nu t b et ween f u el
p u mp l ev er and p u mp oper at i ng l ev er . Op en t hr ot t l e
v al v e and i ns t al l ad j u s t i ng s c r ew. Ti g h t en 2 or 3
t h r ead s to hol d. Th e c o r r ec t s et t i ng of t h e ad j u s t i ng
s c r ew wi l l be c o v er ed u nd er ad j u s t ment s .
CARBURETOR ADJUSTMENTS
It i s v er y i mp o r t ant t hat t he f o l l o wi ng ad j u s t ment s
be mad e on a r ec o nd i t i o ned c ar b u r et o r :
Qu al i f y i ng t he Ch o k e Co nt r o l L e v e r
Ch o k e Unl o ad er Ad j u s t ment (wi de open k i c k )
F a s t Idl e Ca m Pos i t i on Ad j u s t ment
Va c u u m K i c k Ad j u s t ment (On or off v eh i c l e)
F a s t Id l e Sp eed Ad j u s t ment ( On t h e v eh i c l e)
Ch ec k i ng t he B o wl Vent Va l v e Cl ear anc e.
Ch ec k i ng t he Pu mp L e v e r Cl ear anc e
Id l e Sp eed Ad j u s t ment ( Cu r b i dl e)
Ad j u s t i ng t he Fl o at
Sec o nd ar y Th r o t t l e Ad j u s t ment
Id l e Mi x t u r e Ad j u s t ment
Ch ec k i ng Wet F u e l L e v e l
Checking Bowl Vent Valve Clearance
(C.A.S.)
To c h ec k t he b o wl v ent v al v e c l ear anc e ( Fi g . 16),
p r o c eed as f ol l ows :
(1) Wi t h t hr ot t l e v al v es at c u r b i dl e, i t s h o u l d b e
pos s i bl e t o i ns er t a 1/16 i nc h d r i l l s h ank b et ween
b o wl v ent v al v e and t op of p r i mar y f u el b o wl , wi t h
t he i d l e s p eed p r o p er l y s et .
(2) If an ad j u s t ment i s nec es s ar y , b end r o d t o
14-52 FUEL SYSTEMHOLLEY 4160
c h ang e ar c of c ont ac t wi t h t hr ot t l e l ev er , u s i ng To o l
T109-213 u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
Checking Bowl Vent Valve Clearance (E.C.S.)
To c h ec k t he bowl v ent v al v e c l ear anc e ad j u s t ment ,
p r o c eed as f ol l ows :
(1) Wi t h t he t hr ot t l e v al v es at c u r b i dl e, i t s h o u l d
be pos s i bl e t o i ns er t a nu mb er 72 d r i l l s h ank (.005 t o
.025 i nc h ) b et ween bowl v ent v al v e p l u ng er s t em and
oper at i ng r o d , ( Fi g . 16).
(2) If an ad j u s t ment i s nec es s ar y , b end r o d t o
c h ang e ar c of c ont ac t wi t h t hr ot t l e l ev er , u s i ng To o l
T109-213, u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
Checking Accelerator Pump Lever Clearance
To c h ec k ac c el er at o r p u mp l ev er c l ear anc e ( Fi g .
17), p r o c eed as f ol l ows :
(1) Wi t h t hr ot t l e v al v es wi d e o p en, and t he p u mp
l ev er h el d d o wn, i t s h o u l d be pos s i bl e t o i ns er t a . 015
i nc h g aug e b et ween ad j u s t i ng nu t and l ev er .
(2) If an ad j u s t ment i s nec es s ar y , ad j u s t p u mp ov er -
r i d e s c r ew u nt i l c o r r ec t c l ear anc e h as b een obt ai ned.
(3) Th e r e mu s t be no f r ee mo v ement of p u mp
l ev er ag e wh en t hr ot t l e i s at c u r b i dl e.
DRILL O-
GA JG'
\
> T 7
ADJUST VENT
/AI.VE ROD HERE
4
BOWL VENT
VALVE
SEAT ON
AIR HORN
- "7 %-
CARBURETOR p
IDENTIFICATION I
NUMBER
C.A.S. CARBURETOR
BOWL VENT VALVE
PLUNGER STEM
THROTTLE
VALVES IN
CLOSED
POSfTiON NP768C
BOWL VENT VALVE
OPERATINGROD
E.CS.
CARBURETOR
THROTTLE VALVES AT
CLOSED CURB IDLE
PY873
Fig. 16Checking Bowl Vent Valve Clearance
(C.A.5. and E.C.S.)
PUMP OVERRIDE
"HRC ' ALVES
GAUGE :
4P OVERRIDE
.STING SCREW NP769B
Fig. 17Checking Accelerator Pump Lever Clearance
Qualifying Choke Control Lever
Ad j u s t ment of t he c h o k e c ont r ol l ev er i s nec es s ar y
to pr ov i de c o r r ec t r el at i o ns h i p b et ween c h o k e v al v e,
t her mos t at i c c oi l s p r i ng and t he f as t i dl e c am. It
s h o u l d be c h ec k ed and ad j u s t ed (i f nec es s ar y ) af t er
c ar b u r et o r as s emb l y or as p r ep ar at i o n of t he c h o k e
s y s t em l i nk ag e bef or e mak i ng t he Va c u u m K i c k , C a m
Po s i t i o n or Unl o ad er Ad j u s t ment . Th es e t h r ee ad j u s t -
ment s mu s t and s h o u l d be mad e af t er qual i f i c at i on of
t he c h o k e c o nt r o l l ev er .
(1) Op en t he t hr ot t l e t o mi d-pos i t i on.
(2) Cl o s e t he c h o k e v al v e b y s l i g ht p r es s u r e on
c h o k e c ont r ol l ev er .
(3) Th e t op of c h o k e r o d hol e i n c o nt r o l l ev er
s h o u l d b e 1-11/16 1/64 i nc h abov e c h o k e as s emb l y
( c ar b u r et o r on eng i ne) or 1-23/32 1/64 i nc h abov e
c ar b u r et o r b as e ( Car b u r et o r on benc h) ( Fi g . 18).
(4) Ad j u s t i f nec es s ar y by b end i ng c h o k e s haf t r o d
at poi nt i nd i c at ed .
CAUTI ON: Improper bending will cause binding of
rod. Test for free movement between open and closed
TO ADJUST, BEND
AT THIS POINT
TOPEDGE OF CHOKE
CONTROL ROD HOLE
M M 6 <1/64 INCH
ABOVE CHOKE
ASSEMBLY (CARBURETOR
ON ENGINE)
>f ~ ~ 1-23/32 - i - 1/64 INCH $
(CARBURETOR ON BENCH) NR452A
Fig. 18Qualifying Choke Control Lever
HOLLEY 4160FUEL SYSTEM 14-53
choke positions and rebend i f necessary to eliminate
any interferences.
Choke Unloader Adjustment (wide open kick)
T h e c h o k e u nl o ad er i s a mec h ani c al d ev i c e t o par -
t i al l y open t he c h o k e at wi de open t hr ot t l e. It i s u s ed
to el i mi nat e c h o k e enr i c h ment d u r i ng c r ank i ng of an
eng i ne. Eng i nes wh i c h hav e b een flooded or s t al l ed
by ex c es s i v e c h o k e enr i c h ment c an be c l ear ed b y u s e
of t he u nl o ad er . Ad j u s t t he s y s t em as f ol l ows .
(1) Qual i f y t he c h o k e c ont r ol l ev er , i f nec es s ar y .
(See Qu al i f y i ng Ch o k e Co nt r o l L e v e r Par ag r ap h ) .
(2) Ho l d t he t hr ot t l e v al v es i n t he wi d e open pos i -
t i on. Ins er t t he s pec i f i ed d r i l l b et ween t he u p p er edge
of t he c h o k e v al v e and t he i nner wal l of t h e ai r h o r n
(see s pec i f i c at i ons ).
(3) Wi t h a finger l i g ht l y p r es s i ng ag ai ns t t he c h o k e
c ont r ol l ev er , a s l i g ht dr ag s h o u l d be f el t as t he d r i l l
i s b ei ng wi t h d r awn. If an ad j u s t ment i s nec es s ar y ,
b end t he i nd i c at ed t ang u nt i l c o r r ec t o p eni ng h as
b een obt ai ned ( Fi g . 19).
Fast Idle Speed Adjustment (On Vehicle)
F a s t i dl e eng i ne s p eed i s u s ed t o o v er c o me c ol d
eng i ne f r i c t i on, s t al l s af t er c ol d s t ar t s and s t al l s be-
c au s e of c ar b u r et o r i c i ng . Set t hi s ad j u s t ment af t er
t he v eh i c l e odomet er i ndi c at es o v er 500 mi l es t o i n-
s u r e a no r mal eng i ne f r i c t i on l ev el . Pr ep ar e t h e en-
g i ne by d r i v i ng at l eas t 5 mi l es . Co nnec t a t ac h o met er
and s et t he c u r b i d l e s peed and mi x t u r e, t h en p r o c eed
as f ol l ows :
(1) Wi t h t he eng i ne off and t he t r ans mi s s i o n i n t he
P A R K or NEUT R A L pos i t i on, open t h e t hr ot t l e
s l i g ht l y .
(2) Cl o s e c h o k e v al v e u nt i l f as t i dl e s c r ew t ang c an
be pos i t i oned on t he s ec ond hi g hes t -s peed s t ep of t he
f as t i dl e c am ( Fi g . 20).
(3) St ar t t he eng i ne and d et er mi ne t he s t abi l i zed
CHOKE VALVE
fr~-GAUGE OR DRILL
WALL OFAIR-
HORN
SEND ATTHIS POINT
CHOKE- ^
CONTROL
LEVER
\ -
THROTTLE VALVES WIDE
OPEN POSITION
NR453A
Fig. I 9 - Chofce Unloader Adjustment (Wide
Open Kick)
FASTIDLE CAM
2ND HIGHEST ^
SPEED STEP
if T%
FAST IDLE SPEED
ADJUSTING TANG
7 . '/viaA
'-li
1
^< SCREWDRIVER
USTMENT
FAST IDLE -
SPEED LEVER
NP772B
Fig. 20Fast Idle Speed Adjustment (On Vehicle)
s p eed . B end t he f as t i dl e t ang b y u s e of a s c r ewd r i v er
p l ac ed i n t he t ang sl ot to s ec u r e t he s pec i f i ed s p eed . *
CAUTI ON: Bend only in a direction perpendicular to
the contact surface of the cam. Movement in any other
direction changes the CAM POSI TI ON ADJ USTMENT
described earlier.
(4) St oppi ng t he eng i ne b et ween ad j u s t ment s i s not
nec es s ar y . Ho wev er , r epos i t i on t he f as t i dl e t ang on
t he c am af t er eac h s p eed ad j u s t ment t o p r o v i d e c or -
r ec t t hr ot t l e c l o s i ng t or que.
Fast Idle Cam Position Adjustment
Th e f ast i dl e eng i ne s p eed ad j u s t ment s h o u l d be
mad e on t he v eh i c l e as d es c r i b ed i n t he F a s t Id l e
Sp eed Ad j u s t ment (on t he v eh i c l e) p ar ag r ap h . How-
ev er , t he F as t Id l e Ca m Po s i t i o n Ad j u s t ment c an be
mad e on t he b enc h . Th i s ad j u s t ment i s i mp o r t ant t o
as s u r e t hat t he s peeds of eac h s t ep of t he c am o c c u r
at t he pr oper t i me d u r i ng eng i ne war m-u p .
(1) Qual i f y t he c hok e c o nt r o l l ev er , i f nec es s ar y .
(See Qu al i f y i ng t he Ch o k e Co nt r o l L e v e r Par ag r ap h ) .
(2) Wi t h f ast i dl e s p eed ad j u s t i ng t ang c ont ac t i ng
s ec o nd hi g hes t s p eed st ep on f as t i dl e c am, mo v e
c h o k e v al v e t o war d t he c l o s ed pos i t i on wi t h l i g ht
p r es s u r e on c h o k e c ont r ol l ev er .
(3) Ins er t s pec i f i ed d r i l l b et ween t he c h o k e v al v e
and wal l of t he ai r h o r n (see s pec i f i c at i ons ).
An ad j u s t ment wi l l be nec es s ar y i f a s l i g ht d r ag i s
not obt ai ned as t h e d r i l l i s b ei ng r emo v ed .
(4) To ad j u s t , b end t he i nd i c at ed t ang ( Fi g . 21) u n-
t i l t h e c o r r ec t c h o k e v al v e o p eni ng has b een obt ai ned.
Vacuum Kick Adjustment
(ON or OFF Vehicle)
T h e c hok e d i ap h r ag m ad j u s t ment c ont r ol s t he f u el
d el i v er y wh i l e t he eng i ne i s r u nni ng . It pos i t i ons t h e
* Se e s pec i f i c at i ons .
14-54 FUEL SYSTEMHOLLEY 4160
FAST
- IDLE
CAM
2ND HIGHEST
SPEED STEP
FAST IDLE SFFFD
ADJ USTING TANG
CAM POSHON
ADJ USTING TANG
DRILL OR
^GAUGE
CHOKE VALVE
AIR HORN
DRILL OR
GAUGE
7
CHOKE CONTROL
LEVER (LIGHT
CLOSING PRESSURE)
JFAST IDLE SPEED
ADJ USTING TANG
^FAST IDLE CAM
2ND HIGHEST
SPEED STEP
NR454A
Fi g. 21Fast I d l e Com Position Adjustment
c h o k e v al v e wi t h i n t he ai r h o r n b y u s e of l i nk ag e be-
t ween t he c h o k e s haf t and t he d i ap h r ag m. T h e di a-
p h r ag m mu s t be ener g i zed t o meas u r e t he v ac u u m
k i c k ad j u s t ment . Va c u u m c an b e s u p p l i ed b y a di s -
t r i but or t est mac h i ne, ano t h er v eh i c l e or v eh i c l e t o
b e ad j u s t ed .
(1) If t he ad j u s t ment i s t o be mad e wi t h t he eng i ne
r u nni ng , pos i t i on t he f as t i dl e t ang ( Fi g . 21) ( Cam
pos i t i on ad j u s t ment ) t o al l ow c h o k e c l o s u r e t o k i c k
pos i t i on. If au x i l i ar y v ac u u m s o u r c e i s t o be u s ed ,
open t hr ot t l e v al v es , (engi ne not r u nni ng ) and mo v e
c h o k e t o c l o s ed pos i t i on. Rel eas e t hr ot t l e first, t h en
r el eas e c h o k e.
(2) Wh e n u s i ng an au x i l i ar y v ac u u m s o u r c e, d i s c o n-
nec t t he v ac u u m hos e f r o m t he c ar b u r et o r and c o n-
nec t i t t o t he h o s e f r o m t h e v ac u u m s u p p l y wi t h a
s mal l l eng t h of t ube t o ac t as a fitting. Remo v al of
t he hos e f r o m t he d i ap h r ag m may r eq u i r e f o r c es
wh i c h d amag e t he s y s t em. Ap p l y a v a c u u m of 10 o r
mo r e i nc h es of h o s e.
(3) I ns er t t he s pec i f i ed d r i l l (see s pec i f i c at i ons ) be-
t ween t he c h o k e v al v e and t he wal l of t he ai r h o r n.
( Fi g . 22). Ap p l y suf f i c i ent c l o s i ng p r es s u r e on t h e
l ev er t o wh i c h t he c h o k e r o d at t ac hes t o p r o v i d e a
mi ni mu m c h o k e v al v e o p eni ng wi t hout di s t or t i on of
t h e d i ap h r ag m l i nk . Not e t hat t he c y l i nd r i c al s t em of
t he d i ap h r ag m wi l l ex t end as an i nt er nal s p r i ng i s
c o mp r es s ed . Th i s s p r i ng mu s t be f u l l y c o mp r es s ed f o r
p r o p er meas u r ement of t he v ac u u m k i c k ad j u s t ment .
(4) An ad j u s t ment wi l l be nec es s ar y i f a s l i g h t d r ag
i s not obt ai ned as t he d r i l l i s b ei ng r emo v ed . Sh o r t en
o r l eng t h en t h e d i ap h r ag m l i nk t o obt ai n t h e c o r r ec t
c h o k e openi ng . L e ng t h c h ang es s h o u l d b e mad e b y
c ar ef u l l y o p eni ng or c l o s i ng t he b end p r o v i d ed i n t h e
d i ap h r ag m l i nk . CAUTI ON: DO NOT AP P LY TWI ST-
I NG OR BENDI NG FORCE TO DI APHRAGM.
VACUUM DIAPHRAGM
(STEM RETRACTED)
BEND AT
THIS POINT
LIGHTLY PRESS
UP ON CHOKE
CONTROL LEVER
NP773B
Fi g. 22Vacuum Kick Adjustment
(5) Rei ns t al l t he v ac u u m hos e on t he c o r r ec t c ar -
b u r et o r fitting.
(6) Mak e t he f o l l o wi ng c h ec k . Wi t h no v ac u u m ap-
pl i ed to t he d i ap h r ag m, t he C H O K E V A L V E S HOUL D
MOV E F R E E L Y b et ween t he open and c l o s ed pos i -
t i ons. If mo v ement i s not f r ee, ex ami ne t he l i nk ag e
f or mi s al i g nment or i nt er f er enc es c au s ed b y t he b end -
i ng oper at i on. Rep eat t he ad j u s t ment i f nec es s ar y t o
pr ov i de p r o p er l i nk oper at i on.
Secondary Throttle Adjustment
Th i s ad j u s t ment no l o ng er r eq u i r ed as v al v es ar e
p r e-ad j u s t ed and need no f u r t h er ad j u s t ment .
Idle Speed Adjustment (Curb Idle)
Ref er to Gener al Inf o r mat i o n at f r ont of Gr o u p .
Checking Wet Fuel Level (On Vehicle)
B ef o r e c h ec k i ng wet f u el l ev el , c h ec k t he f u el p u mp
p r es s u r e t o be c er t ai n 5 p o u nd r ead i ng i s obt ai ned.
To c h ec k wet f u el l ev el , r emo v e l o wer bol t f u r t h es t
f r o m f u el s u p p l y ( Pr i mar y and Sec o nd ar y ) and i ns t al l
C-4051 wet f u el l ev el g aug e ( Fi g . 23). As s c r ew i s be-
PRIM AT-'Y F
BOW!
1 r
SECONDARY
Fi.'H BOWL
WET LEVEL
GAUGE
AKE READING
O N GRADUATED
SCALE
NP788B
Fi g. 23Checking Wet fuel Level (on Vehicle)
A
FUEL PUMPFUEL SYSTEM 1455
i ng r emo v ed , f u el wi l l be l ost . St ar t or c r ank eng i ne
and al l ow f u el bowl s t o fill. T h e r ead i ng on l ev el gauge
s h o u l d be 9/16 f or Pr i mar y and 13/16 i nc h f or Sec -
ondar y , wi t h 5 pounds f u el p u mp p r es s u r e. *
If an ad j u s t ment i s nec es s ar y r emo v e f u el b o wl and
b end t ang on float u nt i l c o r r ec t s pec i f i c at i ons ar e ob-
t ai ned.
*Fuel level will vary 1/32 inch tor every pound of fuel pump
pressure under or over specifications.
FUEL PUMP
1NDEI
Pag e
As s emb l i ng Fu el Pu mp (RD-267A) 57
Di s as s emb l i ng Fuel Pu mp (RD-267A) 57
Gener al Inf or mat i on 55
GENERAL INFORMATION
F u e l p u mp Model MS-4589SA and MS-4845S or
Ai r t ex RD-267A (Opt i onal ) ( Fi g s . 1 or 2), i s u s ed on al l
Ch r y s l er and Imp er i al eng i nes . T h e MS-4589SA and
MS-4845S f u el p u mp ar e of t he p r es s ed s t eel t y pe and
c annot be d i s as s emb l ed f or s er v i c e. If a p u mp mal -
f u nc t i o n o c c u r s , r emo v e t he ol d p u mp and i ns t al l a
new one. Ai r t ex Model RD-267A (Opt i onal ) i s s er v i c e-
abl e.
Th e f u el p u mp s ar e d r i v en b y an ec c ent r i c c am
t hat i s c as t on t he c ams h af t i n t h e 383 and 440 c u b i c
i nc h eng i nes .
As t he c ams h af t r ot at es , t he ec c ent r i c c a m p r es s es
d o wn on t h e p u mp r o c k er ar m. ( On t he 383 and
440 c u b i c i nc h eng i ne, a p u s h r o d oper at es b et ween
Page
Ser v i c e Di ag nos i s 55
Sp ec i f i c at i o ns 67
Tes t i ng Fu el Pu mp (on c ar ) 56
t he c ams h af t and t h e f u el p u mp r o c k er ar m. ) Th i s ac -
t i on l i f t s t h e p u l l r o d and d i ap h r ag m u p war d s ag ai ns t
t he f u el p u mp mai n s p r i ng , t h u s c r eat i ng a v ac u u m
i n t he v al v e h o u s i ng and opens t he i nl et v al v e and
f u el i s d r awn i nt o t he v al v e h o u s i ng c h amb er . On t he
r et u r n s t r o k e t he mai n s p r i ng f o r c es t he d i ap h r ag m
t o t he d o wn pos i t i on, wh i c h c l os es t he i nl et v al v e
and ex p el s t he f u el i n t he v al v e h o u s i ng c h amb er
t h r o u g h t he out l et v al v e, t o t he f u el filter and t he
c ar b u r et o r .
Th e f u el filter s h o u l d be c h ang ed ev er y 24,000
mi l es , t o i ns u r e h av i ng an u nr es t r i c t ed flow of f u el at
al l t i mes . Do not attempt to clean.
Condition
SERVICE DIAGNOSIS
Possible Cause Correction
F UEL PUMP L EAK S -
F UEL
F UEL PUMP L EAK S -
OI L
I NSUF F I CI ENT F UEL
DEL I VERY
F UEL PUMP NOI SE
(a) Wor n, r upt ur ed or t or n di aphr ag m.
(b) L o o s e di aphr ag m mount i ng pl at es .
(c ) L o o s e i nl et or out l et l i ne fi t t i ngs.
(a) Inst al l new pump.
(b) Inst al l new pump.
(c ) Ti g ht en l i ne fi t t i ngs.
(a)
(b)
(c)
(d)
(a)
(b)
(c)
Cr ac k ed or det er i or at ed pul l rod oi l (a) Inst al l new pump,
s eal .
L o o s e r oc k er ar m pi vot pi n.
L o o s e p u mp mount i ng bol t s.
Faul t y pump t o bl oc k g as k et .
(b) Inst al l new pump.
(c ) Ti g ht en mount i ng bol t s s ec u r el y .
(d) Ins t al l new g as k et .
Vent s i n t ank or f i l l er c ap r es t r i c t ed.
( Th i s wi l l al s o c au s e c o l l ap s ed f uel
t ank.)
L eak s i n f uel l i ne or fi t t i ngs.
Di r t or r es t r i c t i on i n f uel t ank.
(d) Wor n, r upt ur ed, or t or n di aphr ag m.
(e) Fr o zen g as l i nes .
(f) Impr oper l y s eat i ng v al v es .
(g) Vapor l oc k.
(h) L ow p r es s u r e.
(i ) Inc or r ec t f uel pump,
(j) Res t r i c t ed f uel fi l t er.
(a) L o o s e mount i ng bol t s.
(b) Sc o r ed or wor n r oc k er ar m.
(c ) Weak or br oken r oc k er ar m s pr i ng .
(a) Ins t al l new c ap , or unpl ug v ent s and
i ns p ec t t ank for l eak s .
(b) Ti g ht en l i ne fi t t i ngs.
(c ) Ins t al l new f uel fi l t er and c l ean out
t ank.
(d) Ins t al l new pump.
(e) Th aw l i nes and dr ai n t ank.
(f) Ins t al l new f uel pump.
(g) Inst al l heat s h i el d wh er e l i nes or
pump ar e near ex h au s t .
(h) Ins t al l new f uel pump.
(i ) Ins t al l c o r r ec t f uel pump,
(j) Ins t al l new fi l t er.
(a) Ti g ht en mount i ng bol t s.
(b) Ins t al l new f uel pump.
(c ) Ins t al l new s p r i ng .
14-56 F UEL SYSTEMF UEL PUMP
A
SERW1CE PROCEDURES
TESTING FUEL PUMP (On Car)
I f t he f ue l pump f ai l s t o s uppl y f ue l prope rl y t o t he
ca rbure t or, t he f ol l owi n g tests s houl d be made be-
f ore re movi n g t he f ue l pump f r om t he vehi cl e.
Pre s s ure Test
I f l eakage Is n ot appare nt , t est pump f or pressure,
as f ol l ows ;
(1) I ns e rt a " T " fitting i n f ue l l i n e at ca rbure t or,
(Fi g. 3).
(2) Connect a 6 I n ch pi ece of hose bet ween " T "
fitting a nd gauge C-3411. (The hose s houl d not exceed
6 i nches. A l onge r hose ma y col l ect f ue l and a d d i t i on a l
we i ght of f ue l w oul d be added t o pressure of pump
a nd re s ul t i n an i naccurat e readi ng.)
(3) Ve n t pump f or a f e w seconds (t hi s rel i eves a i r
t ra ppe d i n f ue l chamber) . I f t hi s Is not done, pump
w i l l n ot operat e at f ul l capaci t y a nd l ow pressure
re a d i n g w i l l re s ul t .
(4) Connect a t achome t e r, t he n s t a rt e ngi ne a nd r un
at 500 r. p. m. T he re a d i n g s houl d be f r om 3-1/2 t o 5
p.s.i . a nd re ma i n const ant or r e t ur n t o zero ve ry, ve ry
s l owl y whe n engi ne i s st opped. An i ns t a nt d rop t o zero
i ndi cat es a l e aky out l e t val ve. I f pressure is t oo l ow a
weak d i a phra gm ma i n s pri n g, or i mprope r assembl y of
t he d i a phra gm may be t he cause. I f pressure Is t oo
hi gh, ma i n s pri n g Is t oo s t rong.
V acu u m Test
The va cuum t est s houl d be made w i t h t he f ue l l i n e
di sconnect ed f r om t he ca rbure t or. (Thi s w i l l al l ow t he
pump t o operat e at f ul l capaci t y, w hi ch i t mus t do t o
pr i me a d r y ca rbure t or. The m i n i m um re a d i n g s houl d
be at l east 10 i nches of va cuum at 500 r. p. m. w i t h t he
f ue l l i n e di sconnect ed at t he carbure t or.)
NH415B
Fig. 1Fuel Pump Assembly (383, and 440 Cu. In.
Engine)
Volume Test
The f ue l pump s houl d s uppl y 1 q ua rt of f ue l i n 1
mi n ut e or less at 500 r. p. m.
fnfef Valve Test
To t est t he i n l e t val ve, connect a va cuum gauge on
t he i n l e t fitting whi l e t he l i n e i s di sconnect ed.
(1) St a rt engi ne or t ur n over w i t h s t a rt i n g mot or.
(2) The re s houl d be a not i ceabl e va cuum present ,
n ot a l t e rna t e d by bl owback.
(3) I f bl owback i s present , i n l e t val ve i s n ot s e at i ng
prope rl y a nd a new pump s houl d be i ns t a l l e d .
I f f ue l pump does n ot pe r f or m t o above t est re -
q ui re me nt s , f ue l pump s houl d be re move d f r om
vehi cl e.
" 7
NR2A
Fig. 2- Fuel Pump Assembly (RD-267A) Optional 383
and 440 Cu. In. Engine
R.P.M
TACHOMETER
(ENGINE SPEED)
KR345A
Fig. 3Pressure Testing Fuel Pump
A
FUEL TANKFUEL SYSTEM 14-57
DISASSEMBLINGFUEL PUMP (RD-267A)
Before disassembly, mar k housi ngs i n such ma nne r
t hat t he ma rk "I nlet" wi l l bef ac i ng i nl et f ue l l i ne
wh en reassembl ed. Thi s i s i mpor t ant !
(1) Gr i nd o r file off p eened end of pi v ot p i n, t h en,
d r i v e out pi v ot p i n. Remo v e was h er .
(2) Remo v e r o c k er ar m f o l l o wer s p r i ng .
(3) Remo v e s c r ews hol di ng r o c k er ar m h o u s i ng t o
v al v e body. Sep ar at e body and h o u s i ng .
(4) Pr es s in on d i ap h r ag m and di s eng ag e r o c k er
ar m f r o m d i ap h r ag m p u l l r o d . Remo v e r o c k er a r m
and s p ac er was h er s .
(5) Sl i d e d i ap h r ag m and s p r i ng out of r o c k er a r m
h o u s i ng .
(6) Remo v e s l eev e f r o m t wo p i ec e r o c k er ar m, t h en
s ep ar at e r o c k er ar m p u l l l ev er f r o m ec c ent r i c ar m.
Cleaning Fuel Pump Parts
Cl ean al l f u el p u mp par t s ( ex c ept d i ap h r ag m) i n a
s ui t abl e s ol v ent , t h en bl ow d r y wi t h c o mp r es s ed ai r .
Ch ec k t he c ondi t i on of t he v al v e s eat s and p ar t s f o r
g u m depos i t s . If g u m deposi t s ar e f o u nd , r emo v e wi t h
d enat u r ed al c ohol . If t he v al v es ar e b ad l y wo r n or
d amag ed , i ns t al l a c ompl et e new v al v e body as s em-
bl y. The valves are not serviced individually. Ex a m-
i ne t he d i ap h r ag m f o r c r ac k s , t o r n s c r ew hol es o r
r u p t u r es . Ch ec k t he r u b b er oi l s eal ( d i ap h r ag m p u l l
r od) i n h o u s i ng f o r det er i or at i on. If unf i t f o r f u r t h er
s er v i c e, i ns t al l a new r o c k er a r m h o u s i ng . Ch e c k t he
r o c k er a r m f o r s c o r i ng or g al l i ng on t he c ams h af t
p u s h r o d b ear i ng s u r f ac e.
ASSEMBLINGFUEL PUMP
(1) As s emb l e r o c k er a r m b y s l i d i ng t he p u l l a r m
i nt o ec c ent r i c c am and i ns t al l s l eev e. (B e s u r e t he
hook on t he a r m i s f ac i ng up) .
(2) Gr eas e s p ac er was h er s and s l i de ov er eac h s i d e
of s l eev e s h o u l d er .
(3) Ins t al l d i ap h r ag m and s p r i ng r o c k er a r m h o u s -
i ng .
(4) Sl i d e r o c k er a r m i n pos i t i on and eng ag e h o o k
of a r m wi t h sl ot i n p u l l r o d . ( Co mp r es s d i ap h r ag m
and s p r i ng t o eng ag e a r m wi t h p u l l r od. )
(5) Us i ng s ui t abl e dr i f t , al i g n r o c k er ar m and was h -
er s t h en i ns t al l pi v ot p i n. Ins t al l r et ai ni ng was h er ,
t h en p een pi v ot p i n t o r et ai n.
(6) Pl ac e v al v e body on d i ap h r ag m. Al i g n, t h en i n-
s t al l at t ac h i ng s c r ews . Dr a w d o wn ev enl y .
(7) Wi t h p u mp h el d i n v i s e, c o mp r es s r o c k er a r m
t o i t s f u l l t r av el . Ho l d i n t hi s pos i t i on, t h en t i g ht en
s c r ews s ec u r el y . ( Th i s wi l l p r ev ent t ear i ng d i ap h r ag m
wh en p u mp i s oper at ed at f u l l s t r ok e. )
(8) Ins t al l p u mp a r m f o l l o wer s p r i ng b et ween r oc k -
er a r m and h o u s i ng . ( B e s u r e s p r i ng i s s eat ed. )
(9) Tes t p u mp as d es c r i b ed p r ev i o u s l y .
FUEL TA N K
(C.A.S.) CLEANER AIR SYSTEM
GENERAL INFORMATION
Th e f u el t ank on al l model s ex c ep t St at i on Wag o n mo d el s , t he f u el t ank i s mo u nt ed i n t he l ef t r ear
Model s i s l oc at ed at t he r ear of t h e body , u nd er t h e q u ar t er p anel b ey o nd t h e wh eel h o u s e, ( Fi g . 2).
t r u nk c o mp ar t ment floor, ( Fi g . 1). I n St at i on Wag o n If the vehicle is to be stored for any appreciable
GROMMET
NK554 C
Fig. I - Fue l Tank Mounting (119. 5 i nch W/ B Vehicles)
14-58 FUEL SYSTEMFUEL TANK
CA P A SSEM BL Y
T A N K A SSEM B L Y -
ST RA P "
NR15
Fig. 2- fu ef Tank Assembly (121.5 Inch W/B Vehicles}
length of t i me, t h e gasoline s houl d be d r ai ned f r om
the entire system, i n order to p r ev ent g u m formation.
If the vehicle h as been undercoated, be s u r e the fuel
t ank vent t u b e ( u nd er kickup in f l oor pan) i s open. I f
t hi s i s not done, ac o l l ap s ed f uel t ank wi l l r es u l t .
The f ue l t a n k on a l l model s except St a t i on Wa gon
has a 24 ga l l on (20 I mpe ri a l ) capaci t y. T he St a t i on
Wa gon capaci t y i s 22 (18-1/4 I mpe ri a l ) gal l ons. T he
filler t ube on t he conve nt i ona l model s i s accessi bl e
t hr ough t he ce nt e r of t he deck ope ni ng l owe r pane l ,
whi l e t he St at i on Wagon fills at t he l e f t re a r uppe r
q ua rt e r pa ne l bet ween t he q ua rt e r post a nd t he fin.
T he f ue l t a n k i s fitted w i t h a gauge un i t , i n cl ud i n g
t he s uct i on pi pe , (Fi g. 3) . T he filter on t he e nd of t he
s uct i on pi pe i s repl aceabl e un i t a nd pre ve nt s t he
e n t r y of wa t e r a nd d i r t . Whe n i n s t a l l i n g a t a n k un i t , be
s ure t he filter i s pus he d on t he e n d of t he t ube un t i l
seated.
SERVICE P ROCEDURES
REMOVING THE FUEL TANK (Exempt
Station Wagon)
C AUT I ON: Be sure the ignition switch is turned off
before disconnecting or connecting the gauge wire.
R emoval
(1) D r a i n t a n k i n t o a saf et y can, t he n di sconnect
f ue l l i n e a nd wi re l e ad t o gauge un i t .
(2) Di s conne ct ve n t t ube at hose conne ct i on at
l e a d i n g edge of t a n k .
(3) Remove screw t ha t attaches filler t ube bra ck e t
t o re a r crossmember.
(4) Remove n ut s t ha t hol d ends of f ue l t a n k hol d
d own st raps t o f ra me . L owe r f r on t e n d of t a n k f a r
e nough t o di sengage filler t ube f r om re a r pa n e l a nd
s l i de out f r om un d e r ve hi cl e .
(5) Remove t a n k gauge un i t , us i n g spanner wre n ch
T ool C-3582 (Fi g. 3) . Check rubbe r gromme t a roun d
filler t ube . I f cracke d or de t e ri ora t e d, i n s t a l l a ne w
gromme t at reassembl y.
installation
Be f ore i n s t a l l i n g t he t a n k gauge un i t , check t he
con d i t i on of t he filter on t he e nd of s uct i on t ube . I f
t he filter i s pl ugge d, i n s t a l l a ne w filter.
(1) Pos i t i on f ue l t a n k gauge un i t i n t a nk , us i n g a
ne w gasket. T i ght e n securel y, us i ng T ool C-3582. (I f
t a n k i n s ul a t or was t or n or damaged d ur i n g re mova l
of t a nk , be sure a nd i n s t a l l a ne w i ns ul a t or at re -
assembl y.)
(2) Sl i de f ue l t a n k un d e r vehi cl e. Rai se t a n k f a r
e nough t o engage filler spout w i t h ope ni ng i n re a r
FUEL TANKFUEL SYSTEM 14-59
FUEL SUPPLY TUBE
CUP-FUEL GAUGE
GROUNDING
l.OCATINC
TANGS
SUCTION TUBE
NY 1280
FLOAT
Fig. 3Fuel Gauge (Tank Unit)
p anel , and l oc at or emb o s s ment s on floor p an.
(3) Pu s h t ank t o war d r ear t o f u l l y eng ag e filler
spout i n openi ng .
(4) Ho l d f u el t ank i n t h i s pos i t i on, and pl ac e
hol d down s t r ap s i n pos i t i on, f eed i ng at t ac hi ng s t uds
t h r o u g h hol es i n end of s t r ap s . Ins t al l nu t s but do
not t i ght en.
(5) Gu i d e but t on h ead of s t u d s i nt o sl ot s i n f r ame
and down i nt o pos i t i on. Ti g h t en h o l d d o wn s t r ap at -
t ac hi ng nut s s ec u r el y . (40 i n. -l bs. )
(6) Ins t al l filler t ube mo u nt i ng s c r ew and t i g ht en
s ec u r el y .
(7) Co nnec t v ent t ubes and h o s e c onnec t i ons at
l ead i ng edge of t ank .
(8) Co nnec t l ead wi r e t o t ank g aug e uni t , r ec o n-
nec t f u el l i ne and g r o u nd s t r ap .
(9) Ref i l l t ank and c h ec k f o r l eak s .
FUEL TANK (Station Wagon) (Fig. 2)
Removal
CAUTI ON: Be sure the Ignition Switch is turned OFF
before disconnecting or connecting the gauge wire.
(1) Remo v e filler c ap and s y p h o n f u el i nt o s af et y
c an.
(2) Rai s e v eh i c l e on hoi s t and r emo v e f end er s k i r t
(i f s o equi pped).
(3) Remo v e l ef t r ear t i r e and wh eel .
(4) Remo v e s c r ews t hat at t ac h s t one s h i el d t o wh eel
hous e. Sl i d e s h i el d d o wn and away f r o m v eh i c l e.
(5) Di s c o nnec t f u el l i ne, g r o u nd s t r ap and gauge
wi r e.
(6) Pl ac e s t and s u nd er f r ame at r ear t o s u p p o r t
v eh i c l e as hoi s t i s l o wer ed .
(7) Remo v e r ear s h o c k ab s o r b er s l o wer at t ac h i ng
nu t s , t h en s l i d e off l o wer pi v ot .
TUBE-FUEL LINE
WIRING-FUEL GAUGE J A NK UNIT
TUBE-FUEL GAUGE TANK i t
// //,
TUBE-FUEL LINE
J l III i>
CUP-FUEL GAUGE
GROUNDING
STUD-FUEL GAUGE
TUBE-FUEL GAUGE TANK UNIT
STUD-FUEL GAUGE UNIT
NR11
Fig. 4Fuel Tank Ground Strap
(8) Remo v e l ef t r ear b r ak e d r u m.
(9) Remo v e l ef t r ear s p r i ng h ang er at t ac h i ng bol t s
t o f r ame.
(10) L o w e r hoi s t and al l ow r ear ax l e t o f al l away
f r o m v eh i c l e f ar eno u g h so as not t o s t r et c h b r ak e
hos e.
(11) Remo v e f u el t ank s uppor t s t r ap nut s f r o m ey e-
bol t s.
(12) Sl i d e f u el t ank f o r war d and t i l t l ead i ng edg e
d o wn. Wo r k f u el t ank out f r o m u nd er r ear q u ar t er
p anel .
(13) L o o s en t ank gauge uni t , u s i ng s p anner w r e nc h
To o l C-3582. Sl i d e u ni t u p and out of t ank .
Installation
(1) Po s i t i o n f u el t ank g aug e u ni t i n t ank , u s i ng a
new g as k et . Ti g h t en s ec u r el y , u s i ng To o l C-3582.
(2) Wo r k f u el t ank u p i nt o pos i t i on i n q u ar t er
p anel . Mov e r ear war d u nt i l filler t ube i s c ent er ed i n
o p eni ng of q u ar t er p anel . Pl ac e s t r ap s i n pos i t i on and
i ns t al l nu t s . Ti g h t en t o 40 i nc h -p o u nd s . B o t t o m s t r ap
s h o u l d be t i g h t ened first.
(3) Ins t al l f u el l i ne and c o nnec t g r o u nd s t r ap ( Fi g .
4), and f u el g aug e wi r e.
(4) Rai s e hoi s t f ar eno u g h t o eng ag e s p r i ng h ang er
wi t h f r ame.
(5) Po s i t i o n l ef t r ear s p r i ng h ang er at f r ame and
i ns t al l at t ac h i ng bol t s . Ti g h t en t o 30 f oot p o u nd s .
(6) Sl i d e s h o c k abs or ber s o v er pi v ot s and s ec u r e
wi t h nu t s . Ti g h t en t o 50 f oot -pounds.
(7) Ins t al l b r ak e d r u m on ax l e flange.
(8) Sl i d e s t one s h i el d u p i nt o pos i t i on. Ins t al l at -
t ac h i ng s c r ews and t i g ht en s ec u r el y .
(9) Ins t al l wh eel and t i r e and t i g ht en wh eel nu t t o
65 f oot -pounds , i n s eq u enc e.
(10) Rai s e h o i s t and r emo v e c ar s t and s .
(11) Ins t al l f end er s k i r t (i f so equi pped) and l o wer
v eh i c l e t o floor.
(12) Ref i l l f u el t ank and c h ec k f o r l eak s .
(13) F o r t es t i ng f u el g aug e (t ank uni t ) r ef er t o
El ec t r i c al Gr o u p 8 " Gau g es " .
14-60 FUEL SYSTEMFUEL TANK-
F U E L TANKS ( E.C.S.) EVAPORATION
CONTROL SYSTEM
GENERAL INFORMATION
Cer t ai n Ch r y s l er Co r p o r at i o n Veh i c l es ar e equi pped
wi t h an Ev ap o r at i o n Co nt r o l Sy s t em ( ECS) t o r ed u c e
t he l os s of f u el f r o m t he f u el s y s t em t o t he at mo-
s p h er e b y ev apor at i on. Th i s i s a c l o s ed s y s t em wh i c h
c ont r ol s f u el ex p ans i o n and f eed s f u el ev apor at i on
emi s s i o ns f r o m t he c ar b u r et o r o r f u el t ank . Th e
v ap o r s pas s t h r o u g h v ent l i nes t o t he c r ank c as e by
way of t he c r ank c as e i nl et ai r c l eaner . Si nc e f u el
v ap o r s ar e t wo to f o u r t i mes h eav i er t h an ai r , t hey
set t l e to t he bot t om of t he c r ank c as e. Wi t h t he eng i ne
r u nni ng t he f u el v ap o r s ar e p u r g ed f r o m t he c r ank -
c as e and t oget her wi t h t he no r mal c r ank c as e v ap o r
ar e d r awn v i a t he c r ank c as e v ent i l at i on s y s t em, wh i c h
i s an ex i s t i ng par t of t he Cl eaner Ai r Sy s t em ( CAS)
i nt o t he bas e of t he c ar b u r et o r t o be b u r nt by eng i ne
c ombus t i on.
Th e pos s i bl e ex p ans i o n of f u el i n a f u l l f u el t ank ,
d u e t o a r i s e i n t emp er at u r e, i s al l o wed f or by a 1.4
g al l on ov er -f i l l l i mi t er t ank i ns i d e t he mai n f u el t ank
wh i c h f i l l s mu c h s l o wer t h an t he mai n t ank . Wh e n t he
mai n t ank i s f i l l ed, i t r emai ns es s ent i al l y emp t y t o al -
l o w f or t h er mal ex p ans i o n ( Fi g . 1).
CRANKCASE
AIR CLEANER
Th e l os s of any f u el or v ap o r out of t he f i l l er nec k
i s p r ev ent ed by t he us e of a filler c ap wh i c h wi l l r e-
l eas e onl y u nd er s i g ni f i c ant p r es s u r e ( 1/2 t o 1 ps i ) o r
v ac u u m ( 1/4 t o 1/2 ps i ). Th i s c ap i s i dent i f i ed b y t he
wo r d s p r es s u r e-v ac u u m and mu s t be r ep l ac ed by a
s i mi l ar u ni t i f r ep l ac ement i s nec es s ar y , i n o r d er f o r
t he s y s t em t o r emai n ef f ec t i ve ( Fi g . 1).
B ec au s e t he f u el t ank i s fl at on t op, f o u r v ent s ar e
u s ed , one i n eac h c o r ner of t he t ank and ar e c on-
nec t ed to a v apor -l i qui d s ep ar at o r by r u b b er h o s es .
Th e v apor -l i qui d s ep ar at o r i s a pi ec e of t wo i nc h s t eel
t u b i ng mo u nt ed at an ang l e i ns i d e t he t r u nk of t he
v eh i c l e (quar t er panel ) , wh i c h i nt er nal l y hol ds f o u r
v ent l i nes f r o m t he t ank and a v ent l i ne wh i c h l ead s
t o t he c r ank c as e i nl et ai r c l eaner . Th es e l i nes ar e of
di f f er ent hei g ht s so t he t ank wi l l al way s be v ent ed
r eg ar d l es s of v eh i c l e at t i t ude and f u el v ap o r wi l l be
t r ans f er r ed t o t he c r ank c as e. One v ent l i ne f r o m t he
t ank i s s hor t t o pr ov i de a d r ai n b ac k t o t he t ank f or
any l i q u i d f u el wh i c h may get i nt o t he s ep ar at o r dur -
i ng maneu v er s or i nc l i ne p ar k i ng . Th e v ent t o t he
c r ank c as e i s at t he hi g hes t poi nt i n t h e s ep ar at o r and
VAPOR-LI QUI D
SEPARATOR
VENT-LI QUI D
RETURN LINE
PCV VALVE PRESSURE -
VACUUM
RELIEF CAP
THERMAL -
EXPANSI ON
VOLUME TANK
PY940
Fig. 1Evaporation Controi System
FUEL TANKFUEL SYSTEM 14-61
has a s mal l or i f i c e t o mi ni mi ze l i q u i d f u el t r ans f er t o
t he c r ank c as e ( Fi g . 1).
Th e EC S s y s t em al so i nc l u d es c l os ed v ent i l at i on of
f u el v apor f r o m t he c ar b u r et o r bowl . On ei g ht c y l i n-
d er eng i nes t hi s i s ac c o mp l i s h ed v i a a h o s e c onnec -
t i on f r o m t he c ar b u r et o r b o wl t o t he c r ank c as e i nl et
ai r c l eaner .
SERVI CE DI A GN OSI S
Th e EC S s y s t em s h o u l d not r eq u i r e any mai nt e-
nanc e i n no r mal s er v i c e. Any l os s of f u el o r v ap o r
f r o m t he f u el filler c ap wo u l d i ndi c at e one or mo r e of
t he f ol l owi ng :
(1) An u ns at i s f ac t o r y s eal bet ween c ap and filler
nec k .
(2) A mal f u nc t i o n of EC S c ap r el eas e v al v e.
A q u i c k c h ec k of t he EC S f u el c ap may be mad e by
p l ac i ng ag ai ns t t he mo u t h and bl owi ng i nt o t he hol e
i n t he r el eas e v al v e h o u s i ng . An i mmed i at e l eak wi t h
l i g ht b l o wi ng o r l ac k of r el eas e wi t h h ar d bl owi ng
i ndi c at es a def ec t i v e or i nc o r r ec t uni t .
(3) Al l EC S l i nes pl ug g ed b et ween f u el t ank and
v ap o r s epar at or .
(4) Pl u g g ed EC S l i nes b et ween t he v ap o r s ep ar at o r
and t he c r ank c as e ai r i nl et filter.
(5) Pl u g g ed f u el t ank ex p ans i o n c h amb er i nl et hol e
i n mai n t ank. A r emo v ab l e p l u g i s p r o v i d ed i n t he t op
s u r f ac e of EC S f u el t ank s , f o r ac c es s to ex p ans i o n
c h amb er i n ev ent of pl ug g i ng of i t s fill/drain hol e. If
p u r g i ng of t he f u el t ank i s r eq u i r ed , t he ex p ans i o n
c h amb er mu s t be p u r g ed s ep ar at el y t h r o u g h t he t op
ac c es s p l u g hol e.
SERVICE PROCEDURES
Th e f u el t ank on al l mo d el s ex c ep t St at i on Wag o n
Model s i s l o c at ed at t he r ear of t he body , u nd er t he
t r u nk c o mp ar t ment floor, ( Fi g . 1). I n St at i on Wag o n
model s , t he f u el t ank i s mo u nt ed i n t he l ef t r ear
q u ar t er p anel b ey o nd t he wh eel hous e, ( Fi g . 2).
FRAME BRACKET
If the vehicle is to be s t ore d f or any appreciable
length of time, the gasoline should be drained from
t he e n t i re syst em, in ord e r t o pre ve nt gum f orma t i on .
I f t he vehi cl e has been undereoat ed, be sure the fuel
t a n k ve nt tube (unde r k i ck up i n f l oor pan) is open. I f
FILLER TUBE- CLAMP
CROSS MEMBER
VAPOR TUBES F L ( $ O R
PAN
SIDE RAIL I NSULATOR
^X ^SH I EL D
HOSE CLAMP
WHEELHOUSE
Z
SCR EW (4)
GASKET
SIDE EXTENSI ON
PY878
F i g . IF uel Tank Assembly (E.C.S.) Evaporation Control SystemSedans
14-62 FUEL SYSTEMFUEL TANK-
WHEELHOUSE
GROMMETS
VAPOR TUBE
TO FRONT OF VEHI CLE
PY879
Fig. 2Fuel Tank Asemhly (E.C.S.) Evaporation Control SystemStation Wagons
thisi s not done, a collapsed fuel t a n k will r es u l t .
Th e f u el t ank on al l mo d el s ex c ep t St at i on Wag o n
h as a 23 g al l on (20 Imp er i al ) c ap ac i t y . Th e St a-
t i on Wag o n c ap ac i t y i s 22 ( 18-1/4 Imp er i al ) g al l ons .
T h e f i l l er t ube on t he c o nv ent i o nal mo d el s i s ac -
c es s i b l e t h r o u g h t he c ent er of t he d ec k o p eni ng l o wer
p anel , wh i l e t h e St at i on Wag o n fills at t he l ef t r ear
u p p er q u ar t er p anel b et ween t he q u ar t er post and t he
fin. T h e f u el t ank i s fitted wi t h a g aug e u ni t , i nc l u d i ng
t he s u c t i o n pi pe, ( Fi g . 3). Th e filter on t he end of t he
s u c t i o n pi pe i s r ep l ac eab l e u ni t and p r ev ent s t he ent r y
of wat er and di r t . Wh e n i ns t al l i ng a t ank u ni t , be s u r e
t he filter i s p u s h ed on t he end of t h e t ube u nt i l s eat ed .
REMOVING THE FUEL TANK (Except
Station Wagon)
CAUTION: Be sur e the i gni ti on swi t c h i s t urned off
before di sc onnec t i ng or c onnec ti ng t he gauge wi r e.
Removal
(1) Dr a i n t ank i nt o a s af et y c an, t h en d i s c o nnec t
f u el l i ne and wi r e l ead t o g aug e uni t .
(2) Remo v e k ey s t o ne c l amp s f r o m v ent h o s es at
v ap o r s ep ar at o r , t h en s l i de v ent t u b es out of f r ame
s i d e r ai l . ( Fi g . 1).
(3) Remo v e s c r ew t hat at t ac h es filler t ube b r ac k et
t o r ear c r o s s memb er .
(4) Remo v e nu t s t hat h o l d end s of f u el t ank hol d
d o wn s t r ap s t o f r ame. L o w e r f r ont end of t ank f ar
eno u g h t o di s eng ag e filler t ube f r o m r ear p anel and
s l i de out f r o m u nd er v eh i c l e.
(5) Remo v e t ank g aug e u ni t , u s i ng s p anner wr enc h
To o l C-3582 ( Fi g . 3). Ch e c k r u b b er g r o mmet ar o u nd
filler t ube. If c r ac k ed or d et er i o r at ed , i ns t al l a new
g r o mmet at r eas s emb l y .
Installation
B ef o r e i ns t al l i ng t he t ank g aug e uni t , c h ec k t he
c ondi t i on of t he filter on t he end of s u c t i o n t ube. If
t he filter i s p l u g g ed , i ns t al l a new filter.
(1) Pos i t i on f u el t ank g aug e u ni t i n t ank , u s i ng a
new g as k et . Ti g h t en s ec u r el y , u s i ng To o l C-3582. (If
t ank i ns u l at o r was t o r n or d amag ed d u r i ng r emo v al of
t ank , be s u r e and i ns t al l a new i ns u l at o r at r eas s em-
bl y . ) Ins t al l v ent h o s es on t ank , (i f r emov ed. )
(2) Sl i d e f u el t ank u nd er v eh i c l e. Rai s e t ank f ar
eno u g h t o eng ag e filler s pout wi t h o p eni ng i n r ear
p anel , and l oc at or emb o s s ment s on floor p an.
(3) Pu s h t ank t o war d r ear t o f u l l y eng ag e filler
s pout i n openi ng .
(4) Ho l d f u el t ank i n t hi s pos i t i on, and p l ac e hol d
d o wn s t r ap s i n pos i t i on, f eed i ng at t ac h i ng s t u d s
t h r o u g h hol es i n end of s t r ap s . Ins t al l nu t s but do not
t i g ht en.
A FUEL TANKFUEL SYSTEM 14-63
FUEL SUPPLY TUBE
LOCATING
TANGS
SUCTION TUBE
NY 1280
FLOAT"
FILTER
F i g . 3fuel Gauge (Tank Unit)
(5) Ins t al l new k ey s t o ne c l amp s o v er v ent h o s es ,
t h en s l i de v ent t ubes t h r o u g h f r ame s i d e r ai l and i n-
s t al l o n v ap o r s ep ar at o r fittings. Us i ng k ey s t o ne c l amp
p l i er s , t i g ht en hos e c l amp s s ec u r el y . ( Fi g . 1).
(6) Gu i d e but t on h ead of s t uds i n s l ot s i n f r ame
and d o wn i nt o posi t i on. Ti g h t en h o l d d o wn s t r ap at -
t ac h i ng nu t s s ec u r el y . (40 i n-l bs. )
(7) Ins t al l filler t ube mo u nt i ng s c r ew and t i g ht en
s ec u r el y .
(8) Co nnec t l ead wi r e t o t ank g aug e u ni t , r ec o nnec t
f u el l i ne and g r o u nd s t r ap ( Fi g . 4).
(9) Ref i l l t ank and c h ec k f or l eak s .
FUEL TANK (Station Wagon) (Fig. 2)
Removal
C AUT I ON: B e s u r e t he Igni t i on Switch is t u r ned O F F
bef or e d i s c o nnec t i ng or c onnec t i ng the gauge wire.
(1) Remo v e filler c ap and s y p h o n f u el i nt o s af et y
c an.
(2) Rai s e v eh i c l e on hoi s t and r emo v e f end er s k i r t
(i f so equi pped) .
(3) Remo v e l ef t r ear t i r e and wh eel .
(4) Remo v e s c r ews t hat at t ac h st one s h i el d t o wh eel
hous e. Sl i d e s h i el d d o wn and away f r o m v eh i c l e.
(5) Di s c o nnec t f u el l i ne, g r o u nd s t r ap and g aug e
wi r e. Di s c o nnec t v ent t ubes .
(6) Pl ac e s t and s u nd er f r ame at r ear t o s u p p o r t
v eh i c l e as hoi s t i s l o wer ed .
(7) Remo v e r ear s h o c k ab s o r b er s l o wer at t ac h i ng
CLIPFUEL GAUGE
GROUNDI NG
TUBE-FUEL LINE
WI RI NG-FUEL GAUGE J AN K UNIT
TUBE-FUEL GAUGE TANKTjNI T-
TUBE-FUEL LINE
7/ /// V
CUP-FUEL GAUGE
GROUNDI NG
STUD-FUEL GAUGE
TUBE-FUEL GAUGE TANK UNIT
STUD-FUEL^GAUGE UNIT
NR11
F i g . 4- f uel Tank Ground Strap
nu t s , t h en s l i de off l o wer pi v ot .
(8) Remo v e l ef t r ear b r ak e d r u m.
(9) Remo v e l ef t r ear s p r i ng h ang er at t ac hi ng bol t s
t o f r ame.
(10) L o w e r hoi s t and al l ow r ear ax l e t o f al l away
f r o m v ehi c l e f ar eno u g h so as not t o s t r et c h b r ak e
h o s e.
(11) Remo v e f u el t ank s u p p o r t s t r ap nu t s f r o m eye-
bol t s.
(12) Sl i de f u el t ank f o r war d and t i l t l ead i ng edge
down. Wo r k f u el t ank out f r o m u nd e r r ear q u ar t er
p anel .
(13) L o o s en t ank g aug e u ni t , u s i ng s p anner wr enc h
To o l C-3582. Sl i d e u ni t u p and out of t ank .
Installation
(1) Pos i t i on f u el t ank g aug e u ni t i n t ank , u s i ng a
new g as k et . Ti g h t en s ec u r el y , u s i ng To o l C-3582.
(2) Wo r k f u el t ank u p i nt o pos i t i on i n q u ar t er
p anel . Mov e r ear war d u nt i l filler t ube i s c ent er ed i n
o p eni ng i n q u ar t er p anel . Pl ac e s t r ap s i n pos i t i on and
i ns t al l nu t s . Ti g h t en t o 40 i nc h -p o u nd s . B o t t o m s t r ap
s h o u l d be t i g ht ened first.
(3) Ins t al l f u el l i ne and c o nnec t g r o u nd s t r ap ( Fi g .
4), and f u el g aug e wi r e. Ins t al l new c l amp s on v ent
t ubes , t hen i ns t al l t ubes o n t ank fittings. Ti g h t en
c l amp s s ec u r el y .
(4) Rai s e hoi s t f ar eno u g h t o eng ag e s p r i ng h ang er
wi t h f r ame.
(5) Pos i t i on l ef t r ear s p r i ng h ang er at f r ame and
i ns t al l at t ac hi ng bol t s. Ti g h t en t o 30 f oot pounds .
(6) Sl i de s h o c k ab s o r b er s ov er pi v ot s and s ec u r e
wi t h nut s . Ti g h t en t o 50 foot p o u nd s .
(7) Ins t al l b r ak e d r u m on ax l e flange.
(8) Sl i de st one s h i el d up i nt o pos i t i on. Ins t al l at-
t ac h i ng s c r ews and t i g ht en s ec u r el y .
(9) Ins t al l wh eel and t i r e and t i g ht en wh eel nu t t o
65 foot p o u nd s i n s eq u enc e.
(10) Rai s e hoi s t and r emo v e c ar s t and s .
(11) Ins t al l f end er s k i r t (i f so equi pped) and l o wer
v eh i c l e t o floor.
(12) Ref i l l f u el t ank and c h ec k f o r l eak s .
(13) F o r t es t i ng f u el g aug e (t ank uni t ) r ef er t o
El ec t r i c al Gr o u p 8 " Ga u g e s " .
THROTTLE LI NKAGE ADJ USTMENT
Automatic Transmission
F o r ad j u s t ment of t hr ot t l e l i nk ag e, r ef er t o Tr ans -
mi s s i o n Sec t i o n of t hi s Manu al .
Manual Transmission (Fig. 1)
(Chrysler with 383 or 440 Cu. In. Eng.)
(1) Ap p l y a t h i n film of mu l t i -p u r p o s e g r eas e o n
b al l end and p o c k et (14) at r ear end of t hr ot t l e c abl e.
(2) Di s c o nnec t c h o k e (8) at c ar b u r et o r o r b l o c k
c h o k e v al v e i n f u l l open pos i t i on. Op en t hr ot t l e
14-64 SPECI FI CATI ONS A
NU347
g . I Throttle Linkage Adjustment {383 and 440 Engines)
s l i g h t l y t o r el eas e f as t i d l e c am, t h en r et u r n c ar b u -
r et o r t o c u r b i d l e.
(3) L o o s e n c ab l e c l amp nu t (4), ad j u s t p o s i t i o n of
c ab l e h o u s i ng f er r u l e (5) i n t h e c l amp so t hat al l s l ac k
i s r emo v ed f r o m c ab l e wi t h c ar b u r et o r at c u r b i d l e.
T o r emo v e s l ac k f r o m c ab l e, mo v e f er r u l e (5) i n t he
c l amp i n d i r ec t i o n away f r o m c ar b u r et o r l ev er .
(4) B a c k off f er r u l e (5) 1/4" . Th i s p r o v i d es 1/4"
c ab l e s l ac k at i dl e. Ti g h t en c ab l e c l amp nu t (4) t o
45 i nc h -p o u nd s .
(5) Co nnec t c h o k e (8) r o d o r r emo v e b l o c k i ng fix-
t u r e.
S P E C I F I C A T I O N S
HOLLEY MODEL 4160 4-BARREL DOWN DRAFT CARBURETOR
Model
Eng i ne Di s p l ac ement ( c u . i n.)
Tr ans mi s s i o n Ty p e
Thr ot t l e B or e
Pr i mar y . . . . . . . .
Sec o nd ar y
Mai n Vent ur i
Pr i mar y
Sec o nd ar y
Mai n Met er i ng J et
St and ar d
1 Si ze L ean
2 Si ze L ean (5,000-10,000 ft.)
Ad j u s t ment s
Cu r b Idl e Sp eed
C A S . E. C. S.
R-4366A R-4360A
440 440
Aut omat i c Aut omat i c
1-9/16" 1-9/16"
1-9/16" 1-9/16"
1-1/4" 1-1/4"
1-5/16" 1-5/16"
64 64
63 63
62 62
650 650
A
SPECI FI CATI ONS 14-65
Fas t Idl e Sp eed (No. 2 St ep )
B owl Vent Val v e .
Unl oader Adj us t ment (wi de open t hr ot t l e)
Vac u u m K i c k Adj us t ment
Fas t Idl e Cam Posi t i on
Fl oat Set t i ng (Dry)
Pr i mar y
Sec o nd ar y . . . . . . . .
Fl oat Set t i ng (Wet )
Pr i mar y
Sec o nd ar y
Ac c el er at or Pu mp
Ov er r i de Adj us t ment (wi de open t hr ot t l e) .
Power Val v e ( s t amped)
Chok e
Ty p e
Cont r ol
Set t i ng
1600
5/64"
#25 Dr i l l
#46 Dr i l l
#53 Dr i l l
15/64"
17/64"
9/16"
13/16"
.015 Mi n.
65
Wel l
Coi l Sp r i ng
2-Not c hes Ri c h
1600
#72 Dr i l l
#25 Dr i l l
#46 Dr i l l
#53 Dr i l l
15/64"
17/64"
9/16"
13/16"
.015 Mi n.
65
Wel l
Coi l Sp r i ng
2-Not c hes Ri c h
SPECIAL TOOLS
T109-287 El ev at i ng L eg s
C-3886 St and
C-3747 Power Val v e Remov er -Ins t al l er
C-3748 Mai n Met er i ng J et Remov er -Ins t al l er
C-4051 Wet Fu el Gau g e
CL -13 Cl u t c h Head Sc r ewd r i v er
BALL AND BALL VA INCH BBD CARBURETOR
Ty pe
Eng i ne Di s p l ac ement ( c u . i n.)
Manual Tr ans . . . . .
Aut omat i c Tr ans .
B or e
Vent ur i
Mai n Met er i ng J et
St and ar d
One St ep L ean .
Two St ep s L ean
St ep -Up Wi r e ( St andar d) . . . . . . . . .
Di amet er (2 St ag e)
ADJ UST MENT S
Ac c el er at or Pu mp Set t i ng
Fl oat Set t i ng (at Cent er of Fl oat s ) .
Vac u u m K i c k Adj us t ment
Fas t Idl e Ca m Posi t i on Adj us t ment
B owl Vent Val v e (at c u r b i dl e)
Ch o k e Unl oader
Idl e Sp eed RPM ( Cur b i dl e)
Fas t Idl e Sp eed RPM
C HOK E
Ty p e
Cont r ol
Set t i ng
C AS . C.A.S. C.A.S. E. C. S. E. C. S.
Bal l and Bal l Dual Downdraft
383 383 383 383 383
BBD-4725S
_
,
BBD-4727S


**BBD-4726S ***B B D-4894S BBD-4728S
1-9/16" 1-9/16" 1-9/16" 1-9/16" 1-9/16"
1-5/16" 1-5/16" 1-5/16" 1-5/16" 1-5/16"
120-329S 120-306S 120-306S 120-329S 120-306S
120-313S 120-304S 120-304S 120-313S 120-304S
120-303S 120-329S 120-329S 120-303S 120-329S
75-1652 75-1730 75-1730 75-1652 75-1730
.035 x .027" .042" x .039" .042" x .039" .035" x .027" .042" x .039"
1.00" 1.00" 1.00" 1.00" 1.00"
5/16" 5/16" 5/16" 5/16" 5/16"
#20 #28 #28 #20 #28
#28 #28 #28 #28 #28
1/16" 1/16" 1/16" 1/16" 1/16"
1/4" 1/4" 1/4" 1/4" 1/4"
750 650 650 750 650
1700* 1700 1700* 1700* 1700*
Wel l
Th er mo s t at i c
Coi l Sp r i ng
2 Not c hes Ri c h
Wel l
Th er mo s t at i c
Coi l Sp r i ng
2 No t c h es Ri c h
Af t er Appr ox. 500 Mi l es (If Nec es s ar y )
**Wi f hout Ai r Condi t i oni ng
* * * Wi t h Ai r Condi t i oni ng
14-66 SPECI FI CATI ONS
HOLLEY 2210 SERIES 2-BARRELL DOWNDRAFT CARBURETOR
Type
Engi ne Di spl ac ement (c u. in.)
Manual Transmi ssi on
Automati c Transmi ssi on
Bore
Venturi
Main Metering Jet
Standard
One St ep L ean . .
Two St eps L ean
ADJ USTMENTS
Ac c el erator Pump Setti ng
Fl oat Setti ng
Vac uum K i c k Adjustment
Fast Idl e Cam Posi ti on Adjustment . .
Bowl Vent Val ve (at Curb i dl e) . . . . . .
Choke Unl oader
Idl e Mixture Sc r ews (Turns Open) . .
Idl e Speed RPM (Curb Idl e)
Fast Idl e Speed RPM
CHOK E
Type
Control
Setti ng
* After Approx. 500 Mi l es (If Nec essary)
CAS.
Dual Downdraft
383
R-4371A
1-9/16"
1-13/32"
#63 #65
#62 #64
#61 #63
9/16" (1/4" Travel )
#7 dri l l (.200)
#28 dri l l
#35 dri l l
5/64"
11/64"
1-1/2
650
1700*
Wel l
Thermostati c
Coi l Spri ng
2 Notches Ri c h
CARTER AVS SERIES CARBURETORS
C.A.S. CAS. E.C.S. CAS.
Type Carter 4 Barrel Downdraft
Model **AVS-4736S ***AVS-4732S AVS-4734S AVS-4737S
Transmi ssi on Ty p e Automati c Automati c Automati c Manual
Engi ne Di spl ac ement (Cu. In.) 383 383 383 440
THROTTL E B ORE ^
Primary 1-7/16" 1-7/16" 1-7/16" 1-11/16"
Sec ondary 1-11/16" 1-11/16" 1-11/16" 1-11/16"
MAIN VENTURI
Primary 1-3/16" 1-3/16" 1-3/16" 1-3/16"
MAIN J ET
Pri mary 089" .089" .089" .089"
Sec ondary 098" .098" .098" .095"
LOW SPEED J ET
Primary #68-.031" #68-.031" #68-.031" #65.035"
STEP-UP ROD (2-Stage) _
m
Standard 16-546 16-546 16-546 16-617
ADJ USTMENTS
Ac c el erator Pump (top of pl unger to , .
ai r horn) 7/16" 7116" 7116" 7116"
Fast Idle Cam Posi ti on (dril l si ze) . . . #50 #50 #50 #50
Choke Unl oader 1/4" 1/4" 1/4" 1/4"
Vac uum K i c k (dril l si ze) #44 #44 #44 #20
Bowl Vent Val ve Setti ng 3/64" 3/64" 3/4" 3/64"
Fast Idl e Speed (r.p.m.) 1700* 1700* 1700* 2000*
Idl e Speed (r.p.m.) 700 700 700 900
Sec ondary Throttl e Lever Adj 19/64" 19/64" 19/64" 23/64"
Sec ondary Throttl e Loc kout Adj 020" .020" .020" .020"
Fl oat Setti ng 5/16" 5/16" 5/16" 7/32"
Fl oat Drop 1/2" 1/2" 1/2" 1/2"
Air Val ve Spri ng Tensi on(from
Vert i c al -Turns) 2 2 2 2
SPECI FI CATI ONS 14-67
CHOK E
Type
Control
Setti ng
* After Approx. 500 Mi l es (If Nec essary)
Wel l
Coi l Spri ng
2 Notches Ri c h
^ Wi thout Air Condi ti oni ng
Wel l
Coi l Spri ng
2 Notches Ri c h
***Wi t h Ai r Condi ti oni ng
CARTER AVS SERIES CARBURETOR
Type
Model
Transmi ssi on Type
Engi ne Di spl ac ement (Cu. In.)
THROTTL E B ORE
Primary
Sec ondary
MAIN VENTURI
Primary . . . i .
MAIN J ET
Primary
Sec ondary
LOW SPEED J ET
Primary . .
STEP-UP ROD (2-Stage)
Standard
ADJUSTMENTS
Ac c el erator Pump (top of pl unger to
ai r horn)
Fast Idl e Cam Position (dril l si ze) . . .
Choke Unl oader
Vac uum K i c k (dril l si ze)
Bowl Vent Val ve Setti ng
Fast Idl e Speed (r.p.m.)
Idl e Speed (r.p.m.)
Sec ondary Throttl e Lever Adj.
Sec ondary Throttl e Lockout Adj
Fl oat Setti ng
Fl oat Drop
Air Val ve Spri ng Tensi on(from
Verti c al -Turns)
CHOK E
Type
Control
Setti ng
* After Approx. 500 Mi l es (If Nec essary)
C A S .
**AVS-4738S
C A S . E. C. S.
Carter 4 Barrel Downdraft
***AVS-4741S AVS-4739S
E. C. S.
AVS-4740S
Automatic
440
Automati c
440
Manual
440
Automati c
440
1-11/16"
1-11/16"
1-11/16"
1-11/16"
1-11/16"
1-11/16"
1-11/16"
1-11/16"
1-7/16" 1-7/16" 1-7/16" 1-7/16"
.101"
.095"
.101"
.095"
.101"
.095"
.101"
.095"
#69-.029" #69-.029" #65-.035" #69-.029"
16-575 16-575 16-617 16-575
7/16"
#50
1/4"
#20
3/64"
1800*
800
23/64"
.020"
7/32"
1/2"
7/16"
#50
1/4"
#20
3/64"
1800*
800
23/64"
.020"
7/32"
1/2"
Wel l
Coi l Spri ng
2 Notches Ri c h
" *Without Air Condi ti oni ng
7/16"
#50
1/4"
#20
3/4"
2000*
900
23/64"
.020"
7/32"
1/2"
7/16"
#50
1/4"
#20
3/4"
1800*
800
23/64"
.020"
7/32"
1/2"
Wel l
Coi l Spri ng
2 Notc hes Ri c h
*With Air Condi ti oni ng
FUEL PUMP
Make
Model
Type
Number of Val ves
Driven by
Pump Pressure . .
383 and 440 cu. in. Engine
Carter Airtex
MS-4589SA RD-267A
Di aphragm Diaphragm
2 2
Camshaft Camshaft
3-1/2 to 5 psi 3-1/2 to 5 psi