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6C-36
1977 PONTIAC SERVICE MANUAL
gasket, tighten three screws evenly and securely. Make
certain center screw is fitted with a gasket to prevent pump
discharge leakage.
6. Install two main metering jets and vacuum operated
power valve into bottom of float bowl.
Air Horn
1. Install the upper choke rod lever and collar assembly
onto choke shaft. Install the choke shaft assembly into the
air horn from the throttle lever side. Then install the choke
valve onto the choke shaft with the letters R P or part number
facing upward.
Install the choke valve attaching screws. Center the
choke valve before tightening choke valve screws. Tighten
choke valve screws and stake lightly in place. Check choke
valve and shaft for freedom of movement.
2. If removed, install the outer pump shaft and lever
assembly into air horn casting. Make sure the plastic washer
is in place before installing the outer pump shaft and lever
assembly.
3. Install the pump plunger to the inner lever and retain
with clip provided in the repair kit. End of pump plunger
shaft should point inward towards center of carburetor when
installed correctly. Install inner pump lever onto the pump
shaft and tighten set screw securely.
4. Position the float needle seat gasket on the needle seat
and install seat in the air horn using Tool 5-22769. Tighten
securely.
5. Install the power piston assembly into the air horn
casting and lightly stake the retaining washer to casting.
Make sure the piston travels up and down freely and is not
bent.
6. Install fuel inlet bame next to needle seat. Make sure
bame is seated in grooves in air horn casting.
7. Install air horn gasket onto air horn casting.
8. Install float needle into needle seat. On 2GC models
with pull clip, install pull clip and needle, in slot on float arm.
Then install float assembly on air horn and insert hinge pin.
Check float action and for free movement of needle in the
seat.
9. Check float level and drop adjustments. See
adjustment chart.
10. Install choke rod in upper choke lever and collar
assembly rotating rod until tang on end of rod aligns with
slot in lever.
Completion of Carburetor Assembly
1. Place the air horn assembly on bowl, making certain
that the accelerator pump plunger is correctly positioned into
pump well and will move freely.
2. Install lockwashers and eight air horn attaching
screws. Tighten evenly and securely.
3. Install filter relief spring into air horn casting, then
install fuel inlet filter and fuel inlet nut. Tighten to 25 ft. lbs.
4. Install fast idle cam to lower end of choke rod (part
number identification faces out toward fast idle cam
assembly). Then install the fast idle cam to float bowl
retaining with the fast idle cam attaching screw. Tighten
securely.
NOTE: Move linkage up and down to make sure that
it will fall freely.
5. Install pump rod into upper pump lever by rotating
offset end into hole in lever and install lower end of pump
rod to throttle lever and retain with spring clip.
6. 2GE models (throttle lever side)
-
Install primary
vacuum break diaphragm link into lever on choke shaft and
other end of link to vacuum break diaphragm stem. Then
install the vacuum break diaphragm assembly onto air horn
with two attaching screws. Tighten securely.
7.2GE-2GC (choke housing side)
-
Install vacuum break
diaphragm assembly onto air horn securing with two
attaching screws. Tighten securely.
8. Install lower end of intermediate choke rod into
intermediate choke lever on choke housing and connect upper
end of rod to upper choke lever. Install vacuum break
diaphragm link into stem of vacuum break diaphragm and
upper choke lever.
9. Install the upper choke lever onto end of choke shaft
making sure that the lever fits over flats on shaft. Install
attaching screw and tighten securely.
10. Connect vacuum break hoses to each diaphragm
unit.
11. On 2GE models, install the vent valve cover and
gasket. Install two attaching screws and tighten securely.
12. Torque choke pipe nut to 15 Ibs.
NOTE: After complete carburetor assembly, check and
reset, if necessary, all choke adjustments and pump rod
adjustments as outlined in adjustment charts.
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