Installation Instructions for Holley 0-80453
Contents
1. nnne 10 VACUUM OPERATED SECONDARY TUNING 11 JE TTING MAINJETS tice ass ints cle ssisniels aa Eaa a 13 POWER VALVE S inusisa aaea 13 INTRODUCTION CONGRATULATIONS on your Holley carburetor purchase We feel that you have purchased the finest performance carburetor manufactured today Should you need information or parts assistance please contact our Technical Service Department at 1 270 781 9741 Monday through Friday 7 a m to 5 p m CST Please have the part number of the product you purchased hand when you call To preserve the warranty these instructions must be read and followed thoroughly before and during installation ATTENTION This carburetor is NOT designed for use with ANY automatic overdrive transmission If used on an automatic overdrive vehicle SEVERE transmission damage will result NOTE Not legal for street use in California on vehicles originally equipped with 2 barrel carburetors for which there was 4 barrel option These carburetors have been designed and calibrated as a multi purpose carburetor for Ford passenger cars and trucks only Holley Performance Products cannot and will not be responsible for the results of any misapplication Primary design attention has been given to good low end and mid range torque characteristics as well as good fuel economy and ease of installation These carburetors are onl2. CARBURETOR P N 0 80452 amp 0 80453 Model 4160 electric choke 600 CFM for Ford Passenger Cars amp Trucks V 8 INSTALLATION TUNING AND ADJUSTMENT MANUAL 199R 9883 NOTE These instructions must be read and fully understood before beginning installation If this manual is not fully understood installation should not be attempted Failure to follow these instructions including the pictures may result in subsequent system failure TABLE OF CONTENTS INTRODUCTION sirde wien ce alee eae are on en wm ele tecnica een eee cep ee ew estes 3 REMOVAL 3 INSTALLATION sister siisrnististiereienaic EEEE 4 INSTALLATION NOTES e a 7 CHOKE ADJUSTMENT 8 8 CHOKCS E a E no 8 IDLE MIXTURE NEEDLES eaten oa 8 FLOAT LEVEL CHECK AND ADJUSTMENT 10 VACUUM OPERATED SECONDARY
3. so that no foreign particles can enter Wrap the end of the fuel line with a clean lint free cloth B Disconnect and mark all vacuum lines and wiring if any to the carburetor noting the lines that ultimately go to the distributor spark delay valve temperature sensing valve EGR valve fuel vapor canister etc Use Diagram 1 as a guide 2 FRONT White Stripe 5 29 oe fo l 1 amp I a I Py 1 F 7 Ale Green Stripe Diagram 1 Motorcraft 2150 Diagram 2 Holley 4160 Disconnect the PCV hose and power brake hose D Disconnect the choke rod or heat tubes if equipped E Disconnect and remove the throttle linkage and automatic transmission kickdown linkage Save all retaining clips F Unbolt and remove the carburetor from the manifold 3 Ifthe intake manifold is being changed at this time install the new manifold according to the manifold manufacturer s directions Since we are not familiar with all manifold instructions Holley cannot accept responsibility for their validity INSTALLATION 1 Ford applications with an idle stop solenoid remove the solenoid and locking nut from the original carburetor and install them into the bracket on your new Holley carburetor 2 Take the short ground lead from the unassembled parts and connect the bayonet end to the proper terminal on the Holley electric choke cap See Figure 1 CAUTION The polarity of the choke cap termina
4. Throttle Stop Lever Retainer Black Clip Transmission Transmission Kickdown Kickdown Spring Adjusting Screw Figure 4 3 Remove the lock out screw from the kickdown lever Figure 6 4 Install the transmission kickdown spring between the transmission kickdown lever and spring perch Figure 4 THROTTLE TANG INSIDE VACANT TUNNEL KNUCKLES TUNNEL KNUCKLES FINGERS NOT CONTACTING LEVER INCORRECT ae Screw amp Clip will move 4 Lo ko ut CORRECT Screw Screw amp Clip firm and secure Figure 5 Figure 6 CHOKE ADJUSTMENT IMPORTANT Your Holley carburetor has been factory wet flowed and calibrated The out of the box settings should be very close for all adjustments The following tuning section is included ONLY to aid you in fine tuning adjustments Electric Choke 1 You can control the choke operation by rotating the choke cap If the choke comes off too soon loosen the three screws and rotate the cap counterclockwise one notch at a time until the choke operation is satisfactory If the choke comes off too late rotate the cap clockwise one notch at a time until the choke operation is satisfactory The choke setting from the factory is on index or at center position After making the final adjustments start the engine and make sure the choke plate opens completely A Achoke that comes off too soon could exhibit one or more of the following symptoms stalling surging backfiring stumbles
5. by opening to wide open throttle and back to closed throttle several times Correct any sticking or binding conditions before proceeding WARNING Any sticking binding or other interference in the throttle linkage could result in uncontrolled engine speed This could result in engine damage or personal injury 8 Reconnect the throttle and transmission kickdown linkage and throttle return spring Holley P N 20 89 Operate the carburetor throttle lever by hand to assure the correct travel no sticking or binding by opening to wide open throttle and back to closed throttle several times Correct any sticking or binding conditions before proceeding NOTE With the engine turned off have an assistant slowly press the accelerator pedal to the floor while you watch the throttle for any sticking or binding Correct any sticking or binding conditions before proceeding Also ensure that you are reaching full throttle Many performance problems are traced to partial throttle openings from improperly adjusted linkage Secondaries will not open mechanically during this procedure 9 Reconnect the appropriate vacuum hoses to the carburetor noting the correct fitting from Diagram 2 and Figure 3 Replace any cracked or dry rotted hoses at this time to prevent any vacuum leaks A full manifold vacuum source the front of the throttle FULL MANIFOLD body provides vacuum for proper operation of the air cleaner VACUUM PORT the pump diverter valve if
6. equipped AC Cruise and or the temperature sensing valve If vacuum for more than one component is needed use small plastic vacuum T s available at most automotive stores B The timed spark fitting in the choke side of the primary metering block provides vacuum for the operation of the distributor vacuum advance Connect the hose to the distributor spark delay valve and or temperature sensing valve as originally connected Again use T s as necessary any questions arise about the hose connections consult the proper service manual C Plug any vacuum source not used FULL MANIFOLD VACUUM PORT 10 Connect the PCV hose to the PCV fitting in the carburetor base POWER BRAKE plate OR PCV 11 Connect the power brake and or PCV hose to the fitting as shown in Figure 3 Figure 3 12 In some cases the existing fuel line will have to be cut and connected to a dual feed fuel line with a length of rubber fuel hose and a clamp WARNING During the fuel line installation DO NOT allow any foreign particles to enter the fuel lines which could then cause flooding and may result in a fire WARNING Keep the fuel line away from the EGR valve if equipped on the intake manifold If installation requires cutting the metal fuel line cut the fuel line with a good tube cutter This will minimize the chance of producing metal chip particles If a hacksaw must be used then metal chips must be removed WARNING In all cases
7. hold it in position Push the throttle lever rearward to its wide open throttle position and adjust the transmission kickdown screw to come in contact with the transmission kickdown lever tang WARNING With the engine off recheck the assembled linkage for sticking and or proper return to the idle position 10 Place the air cleaner gasket Supplied on the sealing flange and install the air cleaner 11 With some air cleaner configurations it may be necessary to use an air cleaner spacer to provide adequate clearance between the carburetor and the air cleaner Holley offers such a spacer Holley P N 17 13 Depending on the overall height obtain the proper length 1 4 x 20 stud and install in the carburetor airhorn Close the hood slowly to ensure adequate clearance between the air cleaner stud and the hood WARNING Inadequate clearance between the air cleaner and the throttle lever could result in throttle sticking and uncontrolled engine speed Check the clearance between the throttle lever and air cleaner for proper operation Check the clearance between the air cleaner and the hood before closing the hood completely MAINTENANCE WARNING Fuel system components including fuel lines and the carburetor should be inspected periodically to assure no fuel leakage and to ensure the soundness of the hoses Today s clean emissions engines provide higher temperatures in the engine compartment These high temperatures promote faster aging of non meta
8. or poor vehicle driveability when the vehicle is cold B Achoke that comes off too late could exhibit one or more of the following symptoms black smoke from the tail pipe poor driveability when cold poor gas mileage misses or rough idle Manual and Electric Chokes 2 the fast idle RPM is too low or too high for your preferences SHUT DOWN THE ENGINE Advance the throttle to wide open exposing the fast idle set screw below the choke housing See Figure 7 3 Using a 1 4 open end wrench turn the screw clockwise to increase the RPM or counterclockwise to decrease the RPM The factory setting should give you a 1500 1600 RPM fast idle speed NOTE All vacuum ports must be plugged at this time FAST IDLE SPEED SCREW Figure 7 IDLE MIXTURE NEEDLES Idle mixture needles control the air fuel mixture at idle These have been preset at the factory and SHOULD NOT need adjustments However if you feel that adjustment is necessary you can use the following procedure to do so When tuning the idle mixture you re actually tuning for the best manifold vacuum Idle mixture needles are found on the primary metering blocks If you change one idle mixture needle you must change the other idle mixture needle by the same amount Here are the proper steps for setting the idle mixture needles NOTE This carburetor is equipped with a reverse idle system Screwing the idle adjustment needles IN will richen the mixture Backing
9. where fuel has been cut is essential that it be clean to insure that no metal particles enter the fuel bowl after the new carburetor installation Remove the fuel line at the pump and blow the line clean with compressed air DO NOT use the procedure where the coil wire is disconnected the engine cranked for a few revolutions and the fuel collected in a container This procedure is unsafe because sparking can occur either at the coil or at the distributor end of the coil wire and ignite any fuel spilled in the engine compartment CAUTION The use of a quality in line fuel filter such as Holley P N 162 523 is mandatory as a safeguard against possible flooding which could result from unfiltered particles becoming lodged between the fuel inlet needle and its seat This can result in fire if a spark is present or backfire occurs the engine compartment Air cleaner filter elements should be blown clean with compressed air at 6 000 miles and replaced at 12 000 miles to assure maximum protection Now would be the perfect time to upgrade to a Holley Powershot air filter Holley P N 120 146 13 Connect the electric choke lead supplied to the positive terminal of the choke cap The other end must be connected to a good ignition activated 12 volt source Hookup of this wire is not optional WARNING Connecting the choke cap to the ignition or ignition coil could result in unacceptable choke operation poor fuel economy and possible engine
10. 00 rom approx 6 0 Hg At this point the main nozzles are starting to feed and richen the mixture Supplied by the power valve and the engine will probably load up To correct this problem install a 45 or 35 power valve If the engine has a manifold vacuum of 12 Hg or less a good way to determine power valve size is take the manifold vacuum at idle and divide that number by two The answer is the power valve size This will provide idling and proper fuel flow under wide open throttle conditions when manifold vacuums seldom rise above 1 Hg Holley Performance Products Inc P O Box 10360 Bowling Green KY 42102 7360 Technical Service 1 270 781 9741 Fax 1 270 781 9772 For online help please refer to the Tech Service section of our website www holley com Printed in U S A Holley Copyright 2002 Performance Products Date 2 21 02 199R 9883 13
11. could cause a change in these settings The following procedure shows how to make these adjustments WARNING Extreme caution must be exercised while adjusting the float levels as fuel spillage may occur 1 Start the vehicle Turn on the electric fuel pump if equipped 2 Carefully remove the float level sight plug 3 Observe the sight plug hole for the fuel level If none is seen the level is too low Fuel should be even with the bottom of the sight plug hole If fuel comes pouring out of the sight hole the float is set too high NOTE A properly set float level will have the fuel level located at the bottom edge of the sight hole as shown by the line Figure 11 FLOAT LEVEL SIGHT PLUG LOCK SCREW FLOAT LEVEL ADJUSTING NUT PROPER FUEL LEVEL Figure 11 4 adjust shut down the engine 5 Loosen the lock screw on top of the fuel bowl just enough to allow you to turn the adjusting nut Hold the screw in position with the screwdriver 6 Using a 5 8 wrench turn the adjusting nut in the appropriate direction Clockwise to lower float level and counterclockwise to raise float level 7 Turn the adjusting nut in increments of 1 4 of a rotation 8 Retighten the lock screw 9 Restart the vehicle and observe the sight plug hole 10 Repeat steps 1 through 8 as necessary 11 Reinstall sight plug when complete VACUUM OPERATED SECONDARY THROTTLES Many people have the misconception that opening the s
12. crews attaching secondary vacuum diaphragm to the main body Figure 13 Figure 12 Figure 13 3 Remove the clip retaining the diaphragm plunger to the secondary throttle lever using a small flat blade screwdriver Figure 14 VACUUM PASSAGE CORK GASKET WITH CHECK BALL Figure 14 Figure 15 4 Remove the four screws securing diaphragm cover 11 5 Gently remove the cover Take care not to tear the diaphragm or loose check ball Figure 15 6 Change the spring Make sure that the new spring seats on the stud cast into the underside of the cover The stiffer the spring the later the secondaries will open 7 When reassembling secondary diaphragm parts exercise care to properly align the vacuum passage in the casting with the cut out in the rubber diaphragm and make sure the check ball is in place DO NOT pinch or tear the rubber diaphragm TIP To make reassembling the diaphragm easier push the diaphragm arm into the housing and form the diaphragm into a mushroom shape Figure 16 Then position the diaphragm over the bolt holes and vacuum port Hold the diaphragm in that position with your fingers while inserting the spring cover and bolts to avoid disturbing the position of the diaphragm CORRECT Figure 16 8 Make sure the cork gasket in the secondary diaphragm housing mates with the main body casting and reassemble the housing and choke to the main body 9 Reinstall the air cleaner and tes
13. econdary throttles sooner will provide increased performance and quicker drag strip times Others think they must feel a kick when the secondaries engage Still others believe that they should disconnect the vacuum diaphragm and make the secondaries open mechanically Before going any further lets discuss these points in a reverse order First if we could make our vacuum operated secondary carburetors perform better by opening the secondaries mechanically it would be to our advantage to do so since all that vacuum actuating hardware is expensive and requires much time and money to calibrate Mechanical secondary carburetors all utilize a secondary pump shot to prevent bogging when the secondaries are opened Secondly those who feel a kick when 10 secondaries engage are actually feeling a flat spot during initial acceleration because secondaries have already begun to open and have weakened the fuel delivery signal to the primary boosters The engine is struggling to increase speed and what they actually feel are the secondary nozzles crashing in as the engine finally reaches the speed where it provides the proper fuel delivery signal to primary and secondary venturi Third opening the secondaries early causes the situation described above The secondaries must not open until the engine requires the additional air This allows torque to increase along the peak torque curve Performance is compromised less by holding the seco
14. llic materials Hoses that exhibit surface cracks when bent to 180 should be replaced The presence of liquid fuel demands tightening of fittings hose replacement and retorquing of the fuel system component flange nuts Periodically check the torque on the fuel bowl screws to 25 30 in lbs to assure proper fuel metering GENERAL Some very important factors to optimize efficiency and performance include Correct engine timing correct spark plug gap and heat range ignition components in good working order and correct operation of exhaust heat valve INSTALLATION NOTES WARNING This carburetor is not designed for use with any Ford automatic overdrive transmission SEVERE transmission damage may result from improper application use NOTE Unless replacing an existing Holley Carburetor you may need to purchase Holley P N 20 91 spring and perch kit for Ford automatic transmissions 1 Install the throttle lever ball lockwasher and retaining nut to the carburetor throttle lever in the same position as the existing carburetor Tighten the nut to 36 in Ibs of torque 2 Insert the transmission kickdown adjusting screw with the black retaining clip on the transmission kickdown lever Figure 4 This assembly must be installed according to the detailed drawing Figure 5 Y pe TE G A 7 5 la gt Transmission Kickdown nl Lever Spring Perch Transmission Kickdown Adjusting Screw
15. ls must be observed to avoid damaging the heating element 3 Fasten the other end of the ground wire to a suitable location such as under the head of one of the screws retaining the secondary diaphragm housing FUEL BOWL VENTS TIMED SPARK VACUUM SOURCE TO DISTRIBUTOR VACUUM AD VA LOCK SCREW FUEL LEVEL ADJUSTING NUT ee FUEL LEVEL FUEL LEVEL p EEE C SIGHT PLUG SIGHT PLUG puna ws SECONDARY FUEL BOWL PRIMARY FUEL BOWL SECONDARY DLAPHRA GM HOUSING POWER BRAKE IDLE MX TURE POSITIVE OR PCV VACUUM PORT CHOKE TERMINAL CHOKE FRESH MUST HAVE 12V AIR INTAKE HOSE o gt CREW ONE EACH SIDE NEGATIVE CHOKE CHOKE TERMINAL THERMOSTAT MUST BE GROUNDED Figure 1 0 80452 shown 4 Install the carburetor mounting studs provided the proper location on the intake manifold carburetor flange 5 Place the new carburetor flange gasket provided with the carburetor in the proper position on the intake manifold 6 Place the carburetor on top of the flange gasket on the manifold Install the hold down nuts and snug down progressively in a crisscross pattern 60 80 6 as shown in Figure 2 ENGINE Figure 2 Carburetor torque sequence all Holley carburetors WARNING Overtightening may result in a warped or cracked carburetor throttle body 7 Before connecting the linkage operate the throttle lever to assure the correct travel no sticking or binding
16. misfiring since the voltage delivered to the spark plugs will be severely reduced by the drain imposed by the choke cap Suitable ignition activated 12 volt sources are most electrical relays as well as the leads to accessories such as windshield wipers DO NOT connect this wire to the original equipment O E electric choke source This may not be a 12V source 14 Check the voltage source with a volt ohm meter to assure proper voltage and choke operation Provision of a good ground and 12 volt source that can supply enough current to the choke cap is essential for proper choke operation 15 Start the engine and check the fuel lines and inlet fitting for possible leaks NOTE The recommended fuel pressure is 5 7 psi Use an adjustable fuel pressure regulator Holley P N 12 803 if it is higher than 7 psi 16 Recheck to assure all existing vacuum hoses are attached properly Plug any fittings not used 17 With the engine at operating temperature set the idle speed to the manufacturer s specifications see page 8 for idle adjustment 18 Shut off the engine and readjust the throttle operated transmission linkage if necessary On installations that have a kickdown actuating switch on the passenger s side of the firewall it might be necessary to readjust it according to the manufacturer s service manual FORD APPLICATIONS WITH AUTOMATIC TRANSMISSIONS With the engine off push the transmission kickdown rod rearward until it stops and
17. ndaries closed a little longer than by opening them a little too soon If the opening rate of the vacuum operated secondaries is properly calibrated there should not be a kick only a smooth increase in power should be felt In general heavier cars require stiffer secondary diaphragm springs than light cars Air cleaner configuration and restriction plays an important part in spring selection also so be sure to use your air cleaner when evaluating your vehicles performance after each change DO NOT expect to wing the throttle and see the secondaries begin to open If they do they will probably open too soon Secondaries should open only when the engine is under a load DO NOT clip or trim a spring in an effort to make a spring lighter so that the secondaries will open sooner Strange as it may seem clipping springs actually increases spring rate and will delay opening So in order to tune the secondaries follow the steps below A secondary spring kit is available from your local Holley retailer Holley P N 20 13 VACUUM OPERATED SECONDARY TUNING NOTE The Holley Quick Change Diaphragm Housing Cover makes swapping secondary springs a matter of loosening two screws It is available under P N 20 59 1 Remove the choke cap electric choke choke fresh air hose electric choke and choke housing manual and electric choke to gain access to the third screw retaining the vacuum diaphragm to the main body Figure 12 2 Remove three s
18. t drive the vehicle 12 JETTING MAIN JETS Due to varied applications that a universal performance carburetor will work with a few tips on jetting are provided to help you understand their purpose 1 Out of the box jetting is extremely close for most applications 2 Carburetors are calibrated at 70 at sea level Decrease the jet size primary and secondary one number for every 2000 ft increase in altitude 3 Holley jets are broached flowed and stamped according to flow rate NEVER drill jets as this seriously alters flow characteristics Stamped numbers are reference numbers and DO NOT indicate drill size 4 most cases it will be unnecessary to increase jet size more than four numbers greater than out of the box jetting Exceptions could arise when the carburetor is mounted on a very large volume plenum ram manifold 5 Spark plugs provide the best indication of proper jetting Consult an ignition manual for proper reading of spark plugs POWER VALVES The number stamped on a power valve such as 65 indicates the manifold vacuum below which the power valve is operational In this case all manifold vacuums below 6 5 Hg the power valve is operating Generally a 65 power valve is sufficient for most high performance applications that have a manifold vacuum of 12 Hg or higher However some problems can result with radically cammed machines equipped with automatic transmissions These vehicles often idle at 20
19. the screws OUT will lean the mixture There is a sticker around each needle showing the correct direction to turn the screw This system has two peculiar characteristics 1 It is frequently impossible to kill an engine by leaning the mixture Likewise it is often difficult to make an engine lope by richening the mixture 2 Itis possible to adjust the mixture within the range of the limiter caps The mixture needles affect the delivered fuel mixture up to approximately 45 mph Fuel economy for low speed driving can be improved in most but not all cases by a leaner adjustment of the needles Trial and error is the best approach CAUTION Adjusting the mixture screws beyond the rich stop of the limiter cap will cause the engine to emit illegal amounts of air pollutants Adjusting them beyond the lean stops may result in engine damage due to a lean misfire NOTE If the limiter caps are removed for any reason the idle mixture is best set with an exhaust analyzer available in most dealer garages and many independent garages The analyzer should read 2 6 CO using the following procedure 1 Attach the vacuum gauge to a manifold vacuum port on the throttle body Figure 3 2 Adjust each idle mixture screw Figures 9 amp 10 1 8 turn at a time alternating between each screw Turn them equally until you achieve the highest possible vacuum reading without adjusting the curb idle speed screw Turn screws in to lean the mixture Turn
20. them out to richen the mixture CURBIDLE SPEED SCREW Figure 8 3 Now that the idle mixture is set it may be necessary to go back and reset the idle speed using the curb idle speed screw as shown in Figure 8 4 gauge is not available use a tachometer to obtain the highest RPM re Da IDLE MIXTURE SCREW IDLE MIXTURE SCREW Figure 9 Figure 10 ROUGH IDLE AND VACUUM LEAKS If a rough idle persists after the engine has been started and mixture screws adjusted check for manifold vacuum leaks These could result from unplugged vacuum fittings or a carburetor flange gasket that was torn during installation Recheck for proper attachment of all vacuum lines and check the lines for cracks If the manifold was changed a manifold vacuum leak could occur at the cylinder head manifold surface due to damaged gaskets or improper torquing Frequently manifold vacuum leaks occur from the valley side of the manifold These are very difficult to detect unless a discernible whistle can be heard NOTE In most cases when rough idle occurs after a carburetor manifold change they result from manifold vacuum leaks similar to those described above Assuring a proper manifold installation rather than assuming the carburetor is not functioning properly will ultimately save time FLOAT LEVEL CHECK AND ADJUSTMENT Float adjustments are set at the factory but variations in fuel pressure
21. y calibrated or certified for specific cataloged applications and they must be used on square flange intake manifolds Carburetor adapters are not recommended to adapt to spread bore intake manifolds since adapters may have an adverse effect on cylinder to cylinder distribution and ultimately total performance MAINTENANCE WARNING Fuel system components including fuel lines and the carburetor should be inspected periodically to ensure that no fuel is leaking and that all hoses are sound Today s controlled emissions engines create higher temperatures in the engine compartment which will contribute to a faster aging of non metallic materials Hoses that exhibit surface cracks when bent to a 180 position should be replaced The presence of liquid fuel demands a re tightening of loose fittings hose replacement when needed and re torquing of all fuel system screws nuts and bolts regularly Tighten the Holley carburetor fuel bowl screws to 25 30 in Ibs of torque in a clockwise direction Periodically recheck the torque of the fuel bowl screws at regular maintenance intervals REMOVAL 1 Remove the air cleaner exercising care to carefully detach any vacuum lines from the air cleaner and marking them so they can be reassembled to the air cleaner in the same manner 2 Remove the existing carburetor by the following procedure A Carefully disconnect the fuel line WARNING Carefully protect the open end of the fuel lines
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