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Well the fit was tight even when moving the pistons in the chambers by hand when OFF THE CARBS, so I knew it wasn't a jet/needle interference.
I took some 000 steel wool (very very fine) to the circumference of the pistons and the mating diameters of the pistons and chambers then cleaned with carb cleaner and lint-free rags. Put some light oil on the coontact surfaces, grabbed a beer, turned on the Miami v. Virginia Tech game and cycled the pistons in the chambers a couple hundred times each. The seem to slide pretty freely now while still sealing well. I was never "forcing" them, just working them. Both seem to slide freely now and I will attempt in installation again. Only thing I can think is that some minuscule amount of overspray or grit was prevent a slip fit and needed to be fully expunged.
I like fixing Volvos. It frequently involves drinking beer and watching football.
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