Note: A new gasket will be required on refitting.

Removal
1 Disconnect the battery negative lead.

2 Remove the air cleaner (Section 2).

3 Slacken the choke cable clamp bolt at the choke lever, detach the outer cable securing clip at the bracket and remove the cable from the carburettor.

4 Using a suitable Torx type key or socket bit, undo the three lever housing retaining screws and withdraw the lever housing, together with the choke cable bracket from the carburettor (see illustration).

10.4 Choke cable clamp bolt (A) and lever housing retaining screws (B) - Ford VV carburettor

5 Carefully unscrew the three Torx screws which secure the main choke unit to the carburettor and withdraw the choke unit together with the gasket (see illustration).

10.5 Choke unit retaining screw locations - Ford VV carburettor

Checking 6 With the choke removed clean the unit inside by gently blowing out dust and any dirt with an air line or foot pump.

7 Using a small screwdriver or thin rod, raise the pull-down piston and allow it to drop under its own weight, checking that it falls smoothly to the lower limit of its travel (see illustration).

10.7 Manual choke and lever assembly - Ford VV carburettor

A Choke linkage
B Tapered needle (metering rod) C Pull-down piston
D Spring-loaded lever

8 Repeat this check but with the choke linkage lever held in various positions. If the piston binds in any position throughout its total travel, try cleaning the unit once more with an air line, nothing else, then repeat the checks. Under no circumstances attempt to ease a sticking piston with lubrication of any kind otherwise the calibration of the piston will be affected and its operating characteristics radically altered. Check also that the choke control spring leg is seated in its slot in the choke lever (see illustration). If not, carefully slip it back into place. Check the operation of the piston once more and if it still sticks, renew the choke unit and lever housing as an assembly.

10.8 Correct position of choke control spring leg - Ford VV carburettor

A Correctly located B Incorrectly located

9 Check the choke metering rod by carefully moving the needle bracket through its full range of travel using a small screwdriver (see illustration).

10.9 Checking choke operation - Ford VV carburettor

A Linkage lever
B Metering rod
C Needle
bracket

As with the pull-down piston, the check should be made with the linkage lever held in various positions. Ensure that the rod does not bind in any position throughout its total travel. If binding does occur it may be lightly lubricated with “Ballistol Spray” which should be available from main Ford dealers.

Do not use any other lubricant otherwise a sludge build-up may occur, and do not allow overspray to contact the pull-down piston or linkage. If the metering rod is partially or completely seized, lubrication will not help and the choke unit and lever housing should be renewed as an assembly.

10 If both the metering rod and the pull-down piston are satisfactory but binding was noticed when moving the linkage lever, then the central shaft should be lightly lubricated from the rear of the choke unit using the “Ballistol Spray”.

Refitting
11 To refit the choke unit first position a new gasket onto the carburettor mating face, locate the choke unit and fit the retaining screws.

12 When refitting the lever housing, align the new gasket with the screw holes and with the tab of the gasket positioned as shown. With the linkage lever at its mid travel position, fit the lever housing ensuring that the linkage lever engages with the springloaded arm in the lever housing (see illustrations).

10.12a Correct location of choke lever housing gasket with tab (A) positioned as shown - Ford VV carburettor

10.12b Fitting lever housing to choke unit - Ford VV carburettor

13 Secure the lever housing and choke cable bracket with the three retaining screws.

14 Reconnect the choke cable and adjust it as described in Section 9.

15 Refit the air cleaner (Section 2), reconnect the battery, then adjust the idle speed and mixture settings (Chapter 1).