(Page 1 of 3) State of California AIR RESOURCES BOARD

EXECUTIVE ORDER D-133-7 Relating to Exemptions under Section 27156

of the Vehicle Code

REDLINE, INC., A SUBSIDIARY OF IMPAC REDLINE CARBURETOR CONVERSION KITS #K8605 AND #K8606

USING ONE (1) WEBER MODEL 32/34 DFT9 A

Pursuant to the authority vested in the Air Resources Board by Section 27156of the Vehicle Code; and

Pursuant to the authority vested in the undersigned by Sections 39515 and39516 of the Health and Safety Code and Executive Order G-45-5;

IT IS ORDERED AND RESOLVED: That the installation of the Redline Carburetor Conversion Kits #K8605 and #K8606 using one (1) Weber 32/34 OFT9 A carburetor have been found not to reduce the effectiveness of required motor vehicle pollution control devices and, therefore, are exempt from the prohibitions of Section 27156 of the Vehicle Code for the vehicles listed below:

Make ModelYear Engine (liter, CID) Redline Kit No. 1972-1978 Ford Courier 1.8, 109.6 K86051979-1980 Ford Courier 2.0, 120.21971-1978 Mazda K850681600 1.6, 96.81971-1978 Mazda K860581800 1.8, 109.61979-1984 Mazda K8605B2000 2.0, 120.2 K8606

The following modifications to the exhaust emission control system are permitted:

1) The throttle positioner (dashpot), on vehicles so equipped, may beremoved.

2) The throttle opener control system, on vehicles so equipped, may bedisconnected and removed.

The deceleration control valve (Coasting Richer valve ) andaccelerator microswitch, on vehicles so equipped, may be disconnected and removed.

The vacuum hose routing may be changed as specified in theinstallation instructions.

A!! other original equipment emission control devices must be retained. T vehicle must be tuned to the vehicle manufacturer's specifications.

REDLINE, INC. EXECUTIVE ORDER D-133-7 (Page 2 of 3)

This Executive Order is valid provided that installation instructions for this device will not recommend tuning the vehicle to specifications different from those submitted by the device manufacturer.

Changes made to the design or operating conditions of the device, as exemptedby the Air Resources Board, that adversely affect the performance of a vehicle's pollution control system shall invalidate this Executive Order.

Marketing of this device using an identification other than that shown in this Executive Order or marketing of this device for an application other than those listed in this Executive Order shall be prohibited unless prior approval is obtained from the Air Resources Board. Exemption of a kit shall not beconstrued as an exemption to sell, offer for sale, or advertise any componentof a kit as an individual device.

This Executive Order does not constitute any opinion as to the effect that the use of this device may have on any warranty either expressed or implied by the vehicle manufacturer.

THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION, ACCREDITATION, APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESOURCES BOARD OF ANY CLAIMS OF THE APPLICANT CONCERNING ANTI-POLLUTION BENEFITS OR ANY ALLEGED BENEFITS OF THE REDLINE CARBURETOR CONVERSION KITS #K8605 AND #K8606.

No claim of any kind, such as "Approved by Air Resources Board" may be made with respect to the action taken herein in any advertising or other oral orwritten communication.

Section 17500 of the Business and Professions Code makes untrue or misleading advertising unlawful, and Section 17534 makes violation punishable as a misdemeanor .

Section 43644 of the Health and Safety Code provides as follows:

"43644. (a) No person shall install, sell, offer for sale, or advertise, or, except in an application to the state board for certification of a device, represent, any device as a motor vehicle pollution control devicefor use on any used motor vehicle unless that device has been certified by the state board. No person shall sell, offer for sale, advertise, orrepresent any motor vehicle pollution control device as a certified device which, in fact, is not a certified device. Any violation of this subdivision is a misdemeanor."

REDLINE, INC. EXECUTIVE ORDER D-133-7 (Page 3 of 3)

Any apparent violation of the conditions of this Executive Order will be submitted to the Attorney General of California for such action as he deems advisable.

Executed at El Monte, California, this 2, CFday of May, 1986.

K. D. Drachand, Chief Mobile Source Division

..-

State of California AIR RESOURCES BOARD

EVALUATION OF THE REDLINE CARBURETOR CONVERSION KITS NO. K8605 AND NO. K8606 USING ONE (1) 32/34 DFT9 A

WEBER CARBURETOR FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13

OF THE CALIFORNIA ADMINISTRATIVE CODE

MAY , 1986

EVALUATION OF THE REDLINE CARBURETOR CONVERSION KIT NO. K8605 AND NO. K8606 USING ONE (1) MODEL 32/34 DFT9 A

WEBER CARBURETOR FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13

OF THE CALIFORNIA ADMINISTRATIVE CODE

by

Mobile Source Division State of California AIR RESOURCES BOARD 9528 Telstar Avenue El Monte, CA 91731

This report has been reviewed by the staff of the California Air ResourcesBoard and approved for publication. Approval does not signify that the contents necessarily reflect the views and policies of the Air Resources Board, nor does mention of trade names or commercial products constituteendorsement or recommendation for use. )

SUMMARY

Redline, Inc., a distributor of Italian made Weber carburetors, has

applied for exemption from the prohibitions of Vehicle Code Section 27156 for

the Redline Carburetor Conversion Kits No. K8605 and No. K8606 using one (1)

Weber model 32/34 DFT9 A carburetor.

These Redline Carburetor Conversion Kits are designed to replace the

Zenith-Stromberg, Nikki-Stromberg, Nikki or Hitachi carburetors found on

1971-1984 Ford Courier or Mazda pick-up trucks with engines up to 2.0 liters

in displacement.

Comparative exhaust emission tests and other information submitted

demonstrate that the aftermarket Redline Carburetor Conversion Kits No. K8605

and No. K8606 using one (1) Weber model 32/34 DFT9 A carburetor do not

adversely affect emissions of the applicable vehicles. Based on the results

of the tests and the evaluation of the Redline Carburetor Conversion Kits, the

staff recommends that the exemption be granted as requested for the following

vehicle applications:

Year Make Model Engine (liter, CID) Redline Kit No.

1972-1978 Ford Courier 1.8, 109.6 K8605 1979-1980 Ford Courier 2.0, 120.2 K8606 1971-1978 Mazda B1600 1.6, 96.8 K8605 1971-1978 Mazda B1800 1.8, 109.6 K8605 1979-1984 Mazda B2000 2.0, 120.2 K8606

i .

CONTENTS

Page Number

SUMMARY

CONTENTS ji .

I. INTRUODUCTION

II. CONCLUSION -d

III. RECOMMENDATION

IV. DEVICE DESCRIPTION

V . DEVICE EVALUATION

VI. DISCUSSION

APPENDIX

OEM Carburetor Diagrams A-1

Weber 32/34 DFT9 A A-2

Installation Instructions: K8605, K8606 A-3

Underhood label A-4

Carburetor Calibrations: K8605, K8606 A-5

Identification Labels: K8605, K8606 A-6

ii .

EVALUATION OF THE REDLINE CARBURETOR CONVERSION KITS NO. K8605 AND NO. K8606 USING ONE ( 1) MODEL 32/34 DFT9 A WEBER CARBURETOR FOR EXEMPTION FROM THE PROHIBITIONS OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13 OF THE CALIFORNIA ADMINISTRATIVE CODE

I. INTRODUCTION

Redline, Inc. of Compton, California, a subsidiary of Imported Parts and

Accessories Corporation (IMPACJ, is a distributor of Italian made Weber

carburetors. The company has applied for exemption from the prohibitions of

Vehicle Code Section 27156 for two Carburetor Conversion Kits designated as

Redline Kits No. K8605 and No. K8606 using one (1) Weber model 32/34 DFT9 A

carburetor to replace the original equipment manufacturer (OEM) Zenith-

Stromberg, Nikki-Stromberg, Nikki or Hitachi two-barrel carburetors found on

the following vehicles:

Year Make Model Engine (liter, CID) Redline Kit No.

1972-1978 Ford Courier 1.8, 109.6 K8605 1979-1980 Ford Courier 2.0, 120.2 K8606 1971-1978 Mazda B 1600 1.6, 96.8 K8605 1971-1978 Mazda B1800 1.8, 109. 6 K8605 1979-1984 Mazda B2000 2.0, 120.2 K8606

This report describes the evaluation of the Redline Carburetor

Conversion Kits and the findings.

II. CONCLUSION

Comparative exhaust emission data and other information submitted by the

applicant demonstrated that the Redline Kits No. K8605 and No. K8606 using one

(1) 32/34 DFT9 A Weber carburetor meet the Air Resources Board (ARB)

requirements for exemption from the prohibitions of Vehicle Code Section 27156.

III. RECOMMENDATION

Based on the submitted information and the emissions test data on the

Redline Carburetor Conversion Kits, the staff recommends that Redline, Inc. be

granted exemption from the prohibitions of Vehicle Code Section 27156 for the

Redline Carburetor Conversion Kits No. K8605 and No. K8606 for use on the

vehicles described above and that Executive Order No. D-133-7 be issued.

IV. DEVICE DESCRIPTION

The Redline Carburetor Conversion Kits No. K8605 and No. K8606 are

similar in design. Each kit uses one (1) model 32/34 DFT9 A Weber carburetor

as an economical replacement for the OEM carburetors found on the 1971-1984

Ford Courier and Mazda pick-up trucks described previously.

These vehicles are equipped with a Zenith-Stromberg, Nikki-Stromberg,

Nikki or Hitachi carburetor depending on the make and model-year. All these

OEM carburetors are of the progressive two-barrel design (See Appendix 1).

The Weber 32/34 DFT9 A is a progressive two-barrel carburetor which is

similar in basic design to the OEM carburetors (See Appendix 2). The Weber

32/34 DFT9 A is a slightly different version of the weber DFT (Ford 740)

carburetors used as original equipment on some Ford imports orignally sold in

California. It has provisions for vacuum operated emission control systems,

including distributor vacuum advance/retard units, EGR and air injection

control systems.

A variety of emission control devices are used on these vehicles. Some

are integral to the OEM carburetor and others are external devices which

either control specific functions of the OEM carburetor or are activated by

movement of the throttle. The installation of the Weber carburetor retains

2

most of these devices or duplicates the functions of the devices in a

different manner, however, some devices cannot be retained. These devices and

their disposition after the installation of the Weber carburetor are:

1) The throttle positioner (dashpot), on vehicles so equipped, is

removed.

2) The throttle opener control system, on vehicles so equipped, is

disconnected and removed.

3 ) The deceleration control valve (Coasting Richer Valve ) and

accelerator switch, on vehicles so equipped, are disconnected and

removed.

The Redline Kits No. K8605 and No. K8606 come complete with a Weber

OFT9 A carburetor, an air cleaner adaptor and all the hoses, gaskets and

hardware necessary to install the Weber carburetor on the Ford Courier or

Mazda pick-ups. Installation instructions, which are included in every kit,

show the kit installer how to properly install the Weber carburetor. Vacuum

hose routing diagrams, contained in the instructions, show the proper vacuum

hose connections to the Weber carburetor ( see Appendix 3). An underhood

label, included in the kit, is to be affixed to the vehicle near the OEM

vacuum hose routing diagram which states that the vehicle is equipped with a

Redline Kit and that appropriate vacuum hose routing diagrams may be found in

the applicable Redline Kit installation instructions. For persons who may

have technical questions or need a copy of a vacuum hose routing diagram, the

Redline technical information phone numbers (Tech Lines ) are included on this

label (see Appendix 4). The carburetor calibrations for the kits No. K8605

and No. K8606 are shown in Appendix 5. Facsimilies of the identification

labels are shown in Appendix 6.

V . DEVICE EVALUATION

The applicant performed comparative cold-start CVS-75 exhaust emission

tests at Import Certification Laboratories in Anaheim, California. A 1984

Mazda 82000 pick-up truck with a 2.0 liter engine and a 5-speed manual

transmission was used as the test vehicle. The 1984 model-year vehicle was

used for testing since vehicles of 1984 model-year were required to meet more

stringent emission standards than vehicles of the previous model-years.

would be expected that vehicles of previous model-years would have the same

degree of performance/emissions impact as the vehicle tested when using the

same Redline Kit.

The results of the submitted data are shown in Table 1.

Table 1

Condition Exhaust Emissions gm/mi*

HC CO NOx Fuel Economy City mi/gal

Baseline 0.30 3.36 0.80 20.9

Redline Kit 0.24 3.44 0.60 20.2

*Average of three tests in each condition.

Confirmatory testing was performed at the Haagen-Smit Laboratory, on the

same vehicle and the results of these tests are shown in Table 2.

Table 2

Exhaust Emissions gm/mi* Fuel EconomyCondition HC CO NOx City mi/gal

Baseline 0.34 3.2 0.78 21.8

Redline Kit 0.35 3.2 0.68 20.1

*Average of two tests in each configuration.

VI. DISCUSSION

The results of the emission testing show no increase in NOx emissions.

The HC/CO emissions remain unchanged since the differences between the

baseline and device tests are considered to be within the limits of test

variability as determined by the Haagen-Smit Laboratory.

This demonstrates that the installation of the Redline Kit. No. K8606

and the modifications to the original exhaust emission control system required

for the installation will not have an adverse effect on emissions from the

1984 Mazda pick-up test vehicle which was selected to be representative of all

the vehicles on this exemption application. Since Redline Kits No. K8605 and

No. K8606 are similar in design, it would be expected that the conversion kit

No. K8605 would achieve the same level of emission control when installed on

the same type of vehicles to replace OEM carburetors of similar designs.

Redline has submitted all the required information and fulfilled the

requirements for an exemption.

5 -

6-256 Zenith A-1 fors

ZENITH-STROMBERG 2-BARREL ( Cont.)

Choke Shaft Components

Air Horn-Choke Plate

Spring (Calif Only)

Sight Glass Components -Emulsion Tube

Fuel

Strainer -Accelerator Pump Components

Air Bleed PumpFloot

Jet Discharge Idle jet (P)Weight

Slow Speed Fuel Cut ValveFuel Inlet & Return Fitting

Fuel Inlet Fitting & Needle Valve Air Bleed

Main Jet (P)

Secondary Throttle Diaphragm ComponentsMain Jet (S)

Deceleration Valve

Idle Mixture Screw

-Curb idle Screw

Throttle Body

(S) = Secondary

(P) = Primary

Throttle Shaft (S)

Throttle Shaft Components (P)

COURIER CARBURETOR EXPLODED VIEW 2CU02

6-259 LUMBINI GUINVICIVIS

ZENITH - STROMBERG 2-BARREL ( Cont.)

Slow Air Bleed (P) Choke Chamber

Accelerator Pump BootSlow Air

Bleed (5)

Fuel FilterChoke Shaft Components

Float Needle Valve & Housing Nut Choke Valve

Power Valve

Main Air Bleed (S)

Accelerator Pump ComponentsSlow Jet

Slow JetSolenoid Valve-

Emulsion Tube (S)

"O" Ring Slow Jet (P) Air Bleed

- Main Body -Main Jet (S)

Main Air Bleed (P -Main Jet (P)

Emulsion Tube (P)Secondary Throttle Shaft

Throttle Lever 24Throttle Adjust Screw

on sat Idle Mixture Screw

-Throttle Body

1MAP01

Primary Throttle Shaft Components

(S) = Secondary System

(P) = Primary System

MAZDA CARBURETOR EXPLODED VIEW

6-105

09

IVINAI CUIDUICIVIS

NIKKI (STROMBERG) 215282-231 2-BARREL ( Cont.)

-Choke Body

Accelerator Pump Lever

Throttle Return Spring- Accelerator Pump Connecting Rod+Fuel Inlet

Needle Valve Seat Filter

Accelerator PumpSlow Jet PumpPower Jet

WeightMain Air Bleed

Needle Valve (Primary) AirServo Main Air Bleed

Biged Sight Glass(Secondary)Diaphragm Assy. Step Jet

Air Bleed -

Main

Carburetor Body

FloatIdle Stop Solenoid

Secondary Main Jet (Primary) Throttle Link Main Jet

(Secondary)Throttle Valve Body

plugs

-Idle Mixture Screw

Curb IdleFast Idle Adjusting Screw Adjusting Screw

3MA05

NIKKI ( STROMBERG) (TYPICAL)

282 1976 Nikki Carburetors NIKKI ( STROMBERG) 2-BARREL ( Cont.)

Pump Lever

Air Horn Choke Plate

Choke Shaft

Emulsion Tube

Sight Glass Choke Connecting Vacuum Cable Bracket

Float Rod Hose Fuel Strainer

Accelerator Pump Assy.

Air PumpBleed VacuumDischarge Acc. Pump

BrakeWeight & C Inlet Check BallAir BleedFuel Inlet Fitting Bal

Primary Idle Jet Vacuum Brake Connecting RodFuel Inlet Needle Valve-

Fuel Cut-Off Valve Secondary Jet

Primary Main Jet

Jet Plugs

Secondary Main Jet Secondary Operating

Decel Valve (Man. Trans. Only) Diaphragm

Idle Mixture Screw

-Idle Speed Screw

Primary Throttle Shaft

Pump Rod

Fast Idle Lever

Throttle Lever

ConnectingSecondary Throttle Shaft Return Lever Lever

Throttle Spring.

4MA05

NIKKI {STROMBERG) CARBURETOR

318 1981 Nikki Carburetors NIKKI 2-BARREL - MAZDA B2000 ( Cont.)

-Choke Valve Choke Piston

Diaphragm Lever Air Horn Choke Piston Diaphragm Choke Shaft

Choke Piston SecondaryVacuum Pipe Main Air BleedDiaphragm

Connecting Rod

Body Gasket Primary Pump ArmMain Air Bleed

Choke Housing

Thermostat Fuel Primary Cover Connector Small Venturi

Thermostat StrainerSet Plate Choke Arm Floot

Accelerator Check

Level Glass

Valve alve Gasket Seat Slow Jet Plug Window

Throttle Arm PlugSlow Air Bleed

Step Jet Float Frame

Step Air Bleed-Slow JetBodyThrottle Lever Holder Check Valve

AcceleratorThrottle Lever PumpStarting Arm Rubber PlungerFast Idle Gasket

Cam Spring Strainer ClipDiaphragm -StrainerChamber Fast Idle

Cover Cam Secondary - Primary Main JetDiaphragm Main Jet

SecondarySpring Flange- Throttle

Diaphragm Gasket Main Passage Shaft

PlugSecondary

Idle AdjustingThrottle Screw Primary

Lever -Throttle ShaftDiaphragmSecondary Arm Chamber dle Adjusting

Screw Spring

Fast Idle Cam FlangeAdjusting Arm

SecondaryThrottle Link Spring Throttle Valve

Pump Link Primary

Throttle Throttle ValveAdjusting

Arm FlangePrimary Primary Set ScrewThrottle Arm Throttle

CollarThrottle Opener Throttle Adjusting Screw Throttle

Return Spring Opener Arm

Fig. 9 Exploded View of Nikki 2-Bbl. Carburetor

306 1981 Hitachi Carburetors HITACHI DCS 328 2-BARREL ( Cont.)

Choke Valve

Air Horn

Choke Piston Diaphragm lever Body GasketChoke Piston Diaphragm

Choke ShaftVacuum Pipe Choke Piston Diaphragm

Connect Rod Secondary Main Air Bleed Primary Main Air Bleed

Pump Arm

Choke Arm

Choke Thermostat Cover Fuel Connector Primary Small Venturi Window FrameStrainer

Level GlossScrew Cover Plate Float Valve Seat Accel, Check Valve Plug Gasket

OaSlow Jet Plug Float

Choke Cover Throttle Arm Slow Air Bleed

Step Jet

Step Air Bleed Body

Throttle Lever Holder Check Volve Slow Jet

Throttle Lever Starting Arm

Rubber

Gasket Fast idie Strainers

Diaphragm Chamber Cover

Com Spring

Fast idle Com Flange Gasket

a Clip200

StrainerSecondary Main Jet Primary

Accel. Pump Plunger

Diaphragm Spring

Diaphragm Main Jet Main Passage

Plug Secondary

Diaphragm Chamber Throttle Shaft

Secondary Throttle Lever Primary Throttle

Secondary Arm Shaft

Mixture Adjust Screw Shell

-600 Fieng

Throttle OpenerAdjust Screw Secondary Throttle Valve

Spring Pump Link Primary Throttle Voive

Throttle Adjust Arm

Fast Idle Com Adjust Arm Flarge Set Screw

Primary Throttle Collar

Throttle Return Spring Throttle Opener Arm

Primary Throttle Arm

Fig. 8 Exploded View of Hitachi DCS 328 2-Barrel Carburetor (Ford Courier 2000)

runu FIESTA 1600Tipo 32 DFTA 1/A

USA '79 - CALIFORNIA A-2NUMERO CARBURATORE

WERES FORD

18670.410 791F-9510-MA

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Melle ordinationi indicare: numero di matricola del particolars richiesto, is eventuale taratura e if numero . tipo di carburators.

Numero diDENOMINAZIONE DENOMINAZIONEordinarione

Coperchle cartuirators . . . . 31716.737 Ports getto del minimo . .Rosetta per scatola awviamonto automatico . 65510.107 Getto del minimo primano . Vite fissaggio disposlilvo awviamento 64700.004 Getto dol minimo socondario Dispositive awlamento complete dl: 67004.505 Getto principale primerto

Membrane . . . 47407.169 Getto principale secondario - Molla per membrane 47600.225 Rosella forma plasirina

- Coperchio per membrane 32384.041 Guamicione tenuta albertal - Vite registro membrane 64505.022 Boccole ritegno guamizione Vite flesaggio coperchio membran 64500.084 Albarino principale escondario

- Molla avrlamento 47805.042 Plastrina supporto alberint Guamizione par dispositive aviamento autom. 41565.008 Vite faplatro fartails secondaria

Ecatois con spirale terrostatics 67804.333 Rosetta di rasamento albering primano Guamizione tenuta calore . 41040.059 Lava comando ferfalle completa di: Tappo pat coperchio membrane . $1075.011 - Vite registro minimo veloce Quamizione per coparchlo carburatore 41705.057 - Dedo per vite di registro

#1030.012 Rosetta di sicurezza Gutto aria cl thing Hamario 77501.195 . Dado fissaggio alberino primastoMatix ti di freno seconderio 77501,250 * Bocools per leve ellentalawhy Ha arulsinnabare armada

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Numero all ardinazione

62570.004 74403.080 "

74403,060 73406.107 . 73405.100 *

56510.087

41575.010 12750.085

30015.285

62130.010 64865.012

65836.019 46041.105

$4715.016 $5620.002

$4715.014 3775.653

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THIS VEHICLE IS EQUIPPED WITH A REDLINE/WEBER CARBURETOR CONVERSION KIT. (See carburetor identification tag for kit number) PLEASE REFER TO THE APPROPRIATE VACUUM DIAGRAM SUPPLIED WITH THE KIT FOR PROPER VACUUM HOSE ROUTING. IF NEEDED, COPIES OF THE APPLICABLE VACUUM MAP ARE AVAILABLE THROUGH REDLINE, INC.

TECH LINES

California 1-800 932-3722 U.S. 1-800 932-3787

K 8605 A-5

Stage of Development Date: 4-27-84

Prototype # 1006 Location of #DAShROT BOSS

Carburetor Model 32/84 2 67 24 Part # 1006 PROTO # BAse Unit #22670. 045

Application: Model COURIER Year 72- 78 MonthofG mod year

Engine Size / 8 2 Air Cond. - Y

Transmission: ML AT

Calibrated parts Adjustments

Value

Main venturi 24/ 25 Float levelling:

Auxiliary venturi 40 / 460 with gasket (brass) mm

Main jet 110 / 10 with gasket (plastic) 7 frim

ir corrector jet 155 / 160 without gasket (brass) mm

Emulsion tube E21 / E30 without gasket (plastic) mm

Full power fuel bush 1:00 from face to carburetor bowl mm

Full power air bush N.A. Maximum float stroke 19 mm

Power valve spring 4/7600 13/ P.n.

Fuel enrichment bush NA Accelerating pump

Air enrichment bush NA 10 complete pump strokes

Mixture enrichment tube/hole 2.90 delivery m3

Pump Cam # Auxiliary venturi mixture enrichment bush Throttle opening pump 14850, 130

N.A. stroke adjustment mr

-1-

Calibrated Parts , Con't. Adjustments, Con't. K 8605

Value

Main throttle plate adjustment

idle jet 47/ 60 1st throttle opening at start

idle air bush of 2nd one mm175 / 70 1. 2

irreversibility hole NA idle mixture adjusting hole/bush 1620 Dash-pot

idle mixture bush NA Throttle opening at dash pot

Sonic idle air bush/hole contactNA mm

By-pass idle air hole

By-pass idle mixture hole NA Manual starter

Spark Advance hole Mechanical pull-down mm

Progression hole Fast idle

T2 Pneumatic pull-down

T3 Minimum pneumatic pull-down

TA Max pneumatic pull-down (half

T5 choke)

Starter rod complete P.n.

Starter spring P.n.

Progression slot Automatic starter THROTTIE

Throttle plate angle Starter plate clearance adjustment . 60mm78 278 Needle valve Mechanical pull-down150 Fuel recycle hole 50 ( 1052 57 032 ) Fast idle on starter piston

Fast idle

Pump jet Free ball Ipoe Fast idle cam timing (mm/ step nr.

Pump discharge Pull-down lever/modular clear. mmN.A. Inlet valve w/discharge pump . 45 Minimum pneumatic pull-down

eumatic pump jet N.A. Maximum pneumatic pull-down mm

Pneumatic pump discharge N.A. Fixed index mark 2 MARK Rick

Mechanical pump diaphragm 47407. 050 P.n. Moving index adjustment

-2-

K 8605

alibrated Parts, Con't. Adjustments, Con't.

Value Starter jet Bimetal assembly 5 7804 4//6p.n.

Starter air jet Pull-down diaphragm spring P.n.

Gasket kit P.n. Starter spring P.n.

Tune up kit P.n. Starter spring P.n.

Master repair kit P.n.

ADDITIONAL NOTES

SEE NOTES ON PROTO SHEET toos Fee

See NOTES ON CARS 1005 FOR EGR PORT PLACEMENT

-3-

DFT MODIFACTIONS LOOKING DOWN ON CARB TOP COURIER AXMODELS

1 18 . $ 2.3

O O

EGR SPARK HOV TUBETUBE

USE THIS TUBE AS DRILL GUIDE FOR # 30 DRILL DRILL up TC . CSO BEFORE BREAKING THROUGH FIND USE THE SAME CENTER AS GUIDE FOR 1 MM (1034 ) ORILL AND ORILL THROUGH INTO

VENTURI IN CARB

KIc.U .

CAPED IDLE FIQ MIXTURE CARS

BE OKELLO OUT USING #12THIS CAN PMLIST DRILL

MUST 24 PLUGGED TOTHIS HOLE WESICE TAKE CRICINAL ESR PORT IN-OPERATIVE

A LEAD BAR . 230 FOUND X 1675 LONG IS SUGGESTED

79 2.3

- sock 5/15

-

MUST USE 2 MM WASHER ON DFT TO USE STOCK LEVER AUx- SPRING TAB 2 HOSE CLATAPS 5 MTG WASHERS 85 MM NYLOCK NUT

MOUNT

- Le Nove STOCK THROTTLE LEAF? AND

LIPSIDE Down! ON WEBER

K 8606

( 6 ) tage of Development Date: 4-26-84

Prototype # 100.3 Location of # Dash POT Boss

Carburetor Model_32-34 DET Part # Lkoto # 100 3 ( 2:26 70 045)

Application: ModelCOURIER Year 79/80 Month

Engine Size 2. O Air Cond. - Y N Transmission: (MT) AT

Calibrated parts Adjustments

Value

Main venturi 24 /25 Float levelling:

Auxiliary venturi 4.0 / 4.0 with gasket (brass)

Main jet 112 / 115 with gasket (plastic)

ir corrector jet 15 5 /160 without gasket (brass) mm

Emulsion tube F21 /F30 without gasket (plastic) mm

Full power fuel bush 1.00 from face to carburetor bowl

Full power air bush N.A. Maximum float stroke 19 mm

Power valve spring 47600 . 13/ P.n.

Fuel enrichment bush NIA. Accelerating pump

Air enrichment bush N.A 10 complete pump strokes

Mixture enrichment tube/hole 2.00 X delivery cm3

Pump CAM Auxiliary venturi mixture enrichment bush Throttle opening pump 14850 130

N.A. stroke adjustment

-1-

K 8606Calibrated Parts , Con't. Adjustments, Con't.

Value

Main throttle plate adjustment

idle jet 55 / 60 1st throttle opening at start

idle air bush 175 / 70 of 2nd one 2 2 mm

irreversibility hole NA

idle mixture adjusting hole/bush 1 120 mm Dash-pot

idle mixture bush NA Throttle opening at dash pot

Sonic idle air bush/hole contact mmNA By-pass idle air hole

By-pass idle mixture hole N.A. Manual starter

mmSpark Advance hole STD DFT Mechanical pull-down

Progression hole Fast idle mm

T2 Pneumatic pull-down mm

T3 Minimum pneumatic pull-down mm

T4 Max pneumatic pull-down (half

T5 choke) mm

Starter rod complete P.n.

Starter spring P.n.

Progression slot NA Automatic starter

Throttle plate angle 78 / 280 Starter plate clearance adjustment mm

Needle valve 150 MM Mechanical pull-down

Fuel recycle hole . 50MM STOCK Fuel Red) Fast idle on starter piston

Fast idle

Pump jet Fast idle cam timing (mm/ step nr . )( Free ball type ) 50 Pump discharge NA Pull-down lever/modular clear.

Inlet valve w/discharge pump .5 Minimum pneumatic pull-down 5 mm

neumatic pump jet N.A Max imum pneumatic pull-down mm

Pneumatic pump discharge NA Fixed index mark

Mechanical pump diaphragm 47407. 050 P.n . Moving index adjustment

K 8606

calibrated Parts, Con't. Adjustments, Con't.

Value

Starter jet N.A. Bimetal assembly S9504 4/4 P.n.

Starter air jet N.. Pull-down diaphragm spring P.n.

Gasket kit P.n. Starter spring P.n.

Tune up kit P.n. Starter spring P.n.

Master repair kit P.n.

ADDITIONAL NOTES

EGR PORT NOTES

STANDARD EGR PORT AS ON 32 / 34 DET 9

( 1976 spec EQ. ) is left IN TACT

ANY Additional EGR Port is Added and is Termed As Venturi Vacuum EGR " This

PORT IS 1. 785 " from the base of the CARburetor And 1.0 mm in diameter . The port

is drilled through to the Primary Venturi Andis located directly above the VAL. Advance port . we use the 444-280-06 Fitting For

Venturi Vacuum .

Better Refrence is Throttle plate Port is 1. 2 11 From

bottom of throttle plate to itR. ofwort while plate is in closed position

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A - 3

INSTALLATION INSTRUCTIONS WEBER

CARBURETORS

READ & UNDERSTAND ALL STEPS OF THESE INSTRUCTIONS BEFORE BEGINNING THIS INSTALLATION. AFTER UNPACKING, EXAMINE THE CARBURETOR AND OTHER COMPONENTS FOR SHIPPING DAMAGE.

FORD COURIER & MAZDA PICKUP 1972 TO 1980

Kit Nos. K8605 and 52-50701 ('72-'78 Courier 1.8 and Mazda B1600, B1800) K8606 and 52-50703 ('79-'80 Courier, 2.0 and Mazda B2000)

K8607 and 52-50704 ('77-'78 Courier, 2.3) K8608 and 52-50705 (;79-'80 Courier, 2.3)

TOOLS AND EQUIPMENT NEEDED PARTS SUPPLIED WITH INSTALLATION KIT:

Combination, box or open-end wrenches 1 - 32/34 DFT Weber Carb.(metric) Socket Set (metric) 1 - Air Filter Adaptor Screwdrivers (regular and Phillips) Pliers Gasket Scraper 1 - Wire Assembly Wiping Rags Cleaning Solvent Knife Gasket Sealer 1 - Hardware Kit

TUNE-UP SPECIFICATIONS

All tune-up specifications for the Weber Carburetor remain the same as those specified by the Factory for the original unit. Emissions tune-up should be carried out by a suit-ably qualified Dealer or Independent garage, using infrared gas analyzing equipment.

NOTE: Late model vehicles fitted with Emission Control Systems have many vacuumlines and electrical connections in their fuel systems. It is essential when dismantling, that disconnected lines be identified with a corresponding number tag or label system. To establish function, locate and identify the source of each line.

- NOTE -

For installation procedures for the Mazda B2000, refer to

installation steps for Courier 2.0 liter vehicles.

This kit meets original equipment performance levels and is offered as a direct replace ment.

WEBER U.S. Page !

PREPARATION FOR KIT INSTALLATION. 12. Clean mounting face of intake man-ifold.

After unpacking examine the carburetor and other kit components for shipping 13. For 1.6 and 1.8 liter installations, damage. remove throttle lever from stock carbu-

retor and install it on the Weber as shown in figure 1-A. NOTE: On theseBefore installing the kit the vehicle vehicles, it is necessary to cut themust be prepared as follows: tab that contacted the microswitch from the stock lever. If the vehicle1. Remove the vehicle gas cap. has a 2.0 liter engine, install the throttle

2. Raise the hood and disconnect the vehicle battery.

- PORTION OF LEVER CUT OFF HERE

. On vehicles with 2.0 liter and 2.3 ('79-'80 only) liter engines, remove two air filter mounting nuts (save the nuts for reinstallation of filter). Remove the air filter.

On vehicles with 1.6, 1.8 and '77-'78 2.3 liter engines, loosen the air filter clamp securing filter to carburetor and

STOCK THROTTLE LEVERremove the air filter. INSTALLED RIGHTSIDE UP (1 .6 & 1.8 L. )

5. Remove the dashpot from the intake manifold. On vehicles with 2.3 liter engines, also remove the throttle return spring bracket.

6. If vehicle is equipped with "Coasting Richer" microswitch, unplug the wires from the microswitch on the manifold and remove switch from the bracket. This switch will NOT be used with the Weber carburetor.

7. Disconnect the fuel inlet and return lines from the carburetor.

8. Disconnect all lines and electrical wires from the stock carburetor. Use 2.0 L. &LEVER 2000 T FOR a corresponding number system to identify lines and wires during reinstallation. See figures 7 and 8 or the vacuum line map on inside of the hood for identi-fication.

9. Disconnect throttle linkage and remove the throttle return spring.

10. Remove stock carburetor.

WEBER CARB.11. Remove the stock heat spacer and gasket. STOCK LEVER INSTALLED

UPSIDE DOWN (2.3 L. )

Figure 1

Page 2

supplied in kit on the Weber carburetor CHOKE ELEMENTas shown in figure 1-B. If the vehicle

has a 2.3 liter engine, remove throttle lever from stock carburetor, turn it upside down and install on the Weber. See figure 1-C.

WEBER 14. When installing the throttle lever CARB.

on the Weber carburetor DO NOT OVER-TIGHTEN THE NUT. Proper tightness can be achieved by installing the nut just slightly more than finger-tight. After tightening, open the choke by hand and check for full throttle opera-tion from idle position to wide-open throttle. If any sticking or binding occurs, loosen the nut and retighten with reduced torque. If excessive torque CARB.

GASKEThas been applied, recentralization of the throttle plate may be necessary. Check operation as above again. When proper tightness of the nut and central-ization of throttle plate have been HEAT achieved, secure nut with the lock tab. SPACER

KIT INSTALLATION.

15. Coat manifold gasket lightly with gasket sealer and install on the intake MANIFOLD

GASKETmanifold. See figure 2.

16. Install heat spacer supplied in kit FRONT OFabove the manifold gasket. VEHICLE

17. Coat the carburetor gasket lightly with gasket sealer and install above the heat spacer.

18. Install the Weber carburetor above the carburetor gasket (Fig. 2). INTAKE

MANIFOLD

NOTE: On vehicles with 1.6, 1.8 or 2.3 liter engines install the carburetor with the choke element toward the Figure 2FRONT of the vehicle. See figure 2. On Couriers with 2.0 liter engines or the Mazda B2000 vehicles, install the 20. Connect throttle return spring. carburetor with choke element toward the REAR of the vehicle. NOTE: On 1.6, 1.8 & 2.0 liter engines, Install carburetor washers and mounting the spring is connected to the stock nuts and tighten the nuts. return spring bracket (Fig. 3). On 2.3

liter engines the return spring is connect-19. Install throttle linkage. ed to a bracket, supplied in kit, which

is secured by a bolt near the left rear NOTE: On 1.6, 1.8 and 2.3 liter vehicles of the intake manifold as shown in install the linkage with spacers supplied, figure 4. as shown in figure 3. On 2.0 liter ve-hicles, no spacers are used and linkage 21. Connect fuel supply and fuel return

lines. See figure 4.connects directly to the throttle lever.

Page 3

22. Install hoses removed in step 8 on the Weber carburetor. The spark WEBER CARB.advance line is connected to the lower fitting on the choke end of the carbure- FUEL

as shown in figure 5. The other INLET lower fitting is connected to the vacuum amplifier, which then connects to the EGR control valve. See figure 6 or FUEL RETURN7. The third fitting shown in Figure 5 is the venturi vacuum fitting, which THROTTLE

connects to the vacuum amplifier (Fig. 6 or 7). 2.3 L.

ONLY 23. Connect the wire assembly supplied SPRING in kit to choke element, idle cutoff BRACKETINTAKE MANIFOLD solenoid, and to a 12V. source (same source as on the stock carburetor). Use two 5-mm washers and Nylock nut supplied to install wire on the choke Figure 4 element.

CAUTION: Make sure no hose or elec-trical wire insulation contacts the EGR valve. High temperature is present.

24. Install the air cleaner adaptor on the Weber carburetor. The adaptor is secured to the carburetor with two Allen bolts supplied in kit to replace

VENTURIoriginal screws in the carburetor top. VACUUM

25. Install stock air cleaner on the SPARK adaptor. On 1.6, 1.8 and 77-'78 2.3 ADVANCE

liter installations the filter is secured EGR with a wing nut and clamp. On 2.0 liter and 2.3 ('79-'80 only) liter installa-tions, secure the filter with two bolts supplied in the kit. Figure 5

1.6, 1.8 & 2.3_LITER INSTALLATION 26. Reconnect the vehicle battery.

THROTTLE LINKAGE 27. Before starting the engine, check

LOCKWASHERS for proper linkage operation and correct as necessary.

28. START THE ENGINE. After warmupTHROTTLE check for air leaks around the carbure-LEVER

tor mounting base and correct as nec-essary.SPACERS

MOUNTING SCREWS 29. Check idle speed and adjust as necessary to Factory specifications. Idle mixture is preset at Weber factory. Refer to Tune-Up Specifications on

Figure 3 page 1.

Page 4

30. CHECK FOR ADEQUATE HOOD CLEARANCE BEFORE CLOSING THE HOOD.

NOTE: If difficulties arise during kit installation, WEBERU.S. will make every effort to provide needed assistance. Contact our technical liaison through your distributor for this assistance.

EGR CONTROL VALVE 3-WAY SOLENOID VALVE VACUUM AMPLIFIER

IGNITION FROM VENTURISWITCH VACUUM

CARBURETOR

BATTERY

EXHAUST MANIFOLD

EXHAUST PIPE

TO SPARK ADVANCE WATER THERMOSWITCH

Figure 6. Emission Control System Schematic (2.0 L.)

EGR CONTROL VALVE 3-WAY SOLENOID VALVE VACUUM AMPLIFIER

FROM VENTURIIGNITION VACUUMSWITCH

FROM MANIFOLD VACUUM

BATTERY

EXHAUST MANIFOLD

CARBURETOR

EXHAUST PIPE TO SPARK ADVANCE WATER THERMOSMITCH

Figure 7. Emission Control System Schematic (1.8 & 2.3 L.)

Page 5

VACUUM AMPLIFIER

AIR FILTER ADAPTOR

CHOKE ELEMENT

Figure 8. Typical Installation (1.8 L.)

Page 6 WEBER U.S. 445.8605.IN