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How to Rebuild a Holley 4150 780-cfm Carburetor

How to Rebuild a Holley 4150 780-cfm Carburetor

Jeff Smith Dec 7, 2018
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The most ubiquitous speed part on the planet has to be the Holley four-barrel carburetor. While millions have been produced, there are a few that are special. In our case, we’ve been harboring a factory-spec’d 780-cfm Holley carb for our 1966 SS 396 Chevelle for over 40 years—someday intending to bring it back to life. The job called for some serious intensive care. The carb was missing nearly all of its small parts, including the throttle shafts, vacuum secondary diaphragm housing, and the entire choke mechanism. Plus, the main body had been dropped and bent.

To resurrect this gem, we called our buddy Sean Murphy at Sean Murphy Induction (SMI) in Huntington Beach, California, and he willingly took on the job of resurrecting our beyond-dead carburetor. The numbers on the choke housing was what made this carb worth saving. The GM factory list number 3613 and accompanying 3883229 choke housing stamping called this out as a 4150, dual-inlet, 780-cfm Holley for a 375hp 396 Chevelle in 1966. The 4150 number refers to the overall configuration as a squarebore Holley with metering blocks on both ends. This carburetor is also commonly referred to as the 3310, which is the original aftermarket part number for this style 780-cfm carburetor. Later version 0-33310’s were designated 750-cfm carburetors. Our Chevelle is the 360hp version that used a smaller, single-inlet, 600-cfm version (a 4160 version) so we planned to use this larger carb as a “Day Two” upgrade for our big-block resto project.

“As beat-up Holleys go, you’ve probably seen worse, right?” we asked Murphy as he quickly disassembled our lump of missing parts.

“Well, this is pretty bad!” Murphy said.

We were chagrined but he dove right in. The first issue was that the choke housing appears to have been dropped and bent the housing so the choke blade would not fit. Murphy worked on it with light hammer taps on a large punch and then with some mild polishing of the housing on the inside and some minor tweaks to the choke blade. It all fit again.

But rather than perform just a straight restoration, Murphy discovered a kindred spirit because we were more than willing to modify this OE piece to make our Rat run better.

Among the big mods were idle circuit changes. Murphy relocated the idle feed restrictor from underneath a plug in the top of the primary metering block to a replaceable jet that could be easily changed to fine-tune the idle circuit. He also modified the signal side of the primary idle transition slot circuit. This is located in the main body and is another way to improve the driveability of these carburetors at part throttle. The size of this restrictor would depend upon the application, but for our big-block he reduced the channel size from 0.120-inch to 0.093-inch. This reduces the signal to the idle feed on the channel side, essentially reducing the fuel demand through the transition slot.

There is also a non-adjustable factory idle feed system for the secondary side on almost all Holley four-barrels. This is added to ensure that the fuel in the secondary bowl is constantly refreshed. Instead of the original 0.040-inch restrictor, Murphy reduced this to 0.036-inch, which is still located under the cup plug in the top of the metering block.

He also modified the idle bleeds to improve idle quality. There are two air bleeds located on the top of each venturi on a typical Holley carburetor. The outboard position is the idle air bleed while the inboard one is for the high-speed circuit. This carb employed a large 0.076 idle bleed but Murphy exchanged the primary bleeds for smaller, 0.068-inch versions. A smaller bleed allows less air, which richens the circuit. Murphy does this to compensate for modern, reformulated gasoline that now includes 10 percent ethanol. The added ethanol tends to make the original calibration slightly leaner.

He also showed us a technique where he blows compressed air across the primary venturi that locates the signal to open the vacuum secondaries. He uses a small air nozzle blowing across a very small hole (or sometimes a small brass tube) in the middle of the passenger side primary venturi. This creates a siphon/vacuum effect that pulls against spring pressure in the vacuum pod and opens the secondary.

Another tip when assembling any Holley carburetor is to make sure that there is no clearance or gap between the accelerator pump linkage and the accelerator pump arm at idle. The accelerator pump arm should move and squirt fuel the moment the throttle linkage moves. This ensures that fuel is squirted to compensate for added throttle opening before the main metering system kicks in. If there is clearance between the throttle linkage and the accelerator pump arm, this will result in a slight hesitation at throttle opening, which is annoying.

If we could put all of Murphy’s knowledge down in printed form, it could easily fill a 140-page tech book with all his Holley carburetor secrets. But for now, we’ll just celebrate one more muscle car Holley that has been resuscitated. CHP

SMI Holley Street Mods
 Stock SpecsSMI Spec
Primary Jet7272
Secondary Jet7683
Primary PV6.56.5
Primary PVCR0.0620.062
Secondary PV8.5Blocked
Secondary PVCR0.068*Blocked
Primary Idle Res.0.0320.032
Secondary Idle Res.0.0400.036
*With rear power valve - equivalent jetting to around 85 or 86 jet

002 Holley Carubuetor Rebuild 2/16

1. There wasn’t much to our original carburetor beyond a stripped throttle plate, the main body, metering blocks, and the float bowls. Most of the other pieces were missing, but luckily we came to the right place.

003 Holley Carubuetor Rebuild 3/16

2. Sean Murphy laid out all the new parts needed to bring this 3310 back to life. He keeps a collection of electroplated small parts to give the carburetor a new look and better-than-new performance.

004 Holley Carubuetor Rebuild 4/16

3. The biggest issue was where the carb had been dropped and cracked at the base of the choke housing on the passenger side. Murphy had to lightly hammer the housing back into place and then lightly trim the choke blade so it would operate correctly. This was doubly critical because the choke housing contains all the factory identification.

005 Holley Carubuetor Rebuild 5/16

4. The throttle bores were heavily scored, so Murphy removed the notches and made sure the surface was flat before reassembling the throttle shafts.

006 Holley Carubuetor Rebuild 6/16

5. Murphy says that all Holleys should be milled to ensure the sealing surface is flat. Our carb only needed about a 0.005-inch trim, but he’s seen carbs that needed as much as 0.060-inch removed to make the gasket surface flat. He says over-tightening the bowl screws causes this deflection.

007 Holley Carubuetor Rebuild 7/16

6. Murphy blasted all the body parts and then submerged them in a quick dip in an acid wash that restores the outside appearance to much like the original. The original zinc dichromate process involves carcinogenic chemicals that the EPA really frowns on now.

008 Holley Carubuetor Rebuild 8/16

7. Murphy prefers to add tiny restrictors in the primary idle circuit channel in the main body to the transition slot. The original diameter was 0.120-inch and he reduces this to 0.093 to reduce the signal from the transition slot so less fuel is introduced in this “cruise” primary throttle position. This improves fuel mileage and driveability.

009 Holley Carubuetor Rebuild 9/16

8. After the main body and metering blocks have been cleaned and recolored, Murphy adds threaded 6-31 jets sized with a 0.032-inch restrictor into the idle circuit after removing the original restrictors located under the brass plugs in the metering block. These are easier to access and can be quickly changed to fine-tune the idle circuit.

010 Holley Carubuetor Rebuild 10/16

9. Later drop-leg boosters (below) create a small radius at the juncture where the two drilled passages meet. This radius improves the flow through the booster along with a slightly larger inside diameter of 0.160-inch versus the original booster’s 0.140-inch. The larger passage improves fuel aeration.

011 Holley Carubuetor Rebuild 11/16

10. Two of the original boosters were not square in the venturi, which can drastically affect WOT metering. Murphy uses this custom-made tool to install the boosters properly in the venturi.

012 Holley Carubuetor Rebuild 12/16

11. This shows the smaller drill size of the original booster (center) at 0.140-inch compared to the new booster (right) at 0.160-inch. The third drill bit (left) is the original 0.136-inch passage from the main metering well. Murphy says this smaller passage enhances aeration of the fuel when it hits the booster and improves throttle response.

013 Holley Carubuetor Rebuild 13/16

12. Once the new throttle shaft and butterflies are in place, Murphy checks their position. A perfect light-tight fit is not necessary since a slight gap around the blades allows the throttle to be more closed so the blades just touch the idle transfer slot.

014 Holley Carubuetor Rebuild 14/16

13. For this big-block application, Murphy retained the stock 72 primary jets and added a new 6.5 power valve. On the secondary side, he blocked the power valve and increased the jetting from 76 to 83 to compensate. The larger jets in the secondary also help provide initial “tip-in” fuel as the vacuum secondary begins to open.

015 Holley Carubuetor Rebuild 15/16

14. Murphy showed us this simple way to assemble the secondary diaphragm. Insert the rubber diaphragm into the housing and then with the diaphragm sitting evenly on the housing, place the base on top of the vise and clamp the diaphragm shaft lightly in the vise. Place the spring into the locating bung in the lid and coat the screws with WD-40 to prevent them from grabbing the rubber and carefully assemble the lid. Murphy prefers the purple spring for most street applications.

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15. Here’s the finished Holley complete with its fuel bowl vent that was only used on GM engines through the mid ’60s. This Holley is ready to rock thanks to Sean Murphy’s practiced hand.

Photos by Jeff Smith


Sean Murphy Induction (SMI)
Huntington Beach, CA



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