Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on September 8, 1986.
As of Monday, October 7th, 2024 this Executive Order has not been overturned or superceeded.

Approved Parts

Part NumberModelsModification
32/34 DFT9 A 32/34 DFT11A1977-1980 Ford Courier 2.3LThe throttle positioner or dashpot, deceleration control valve (coasting richer valve), and accelerator microswitch may be disconnected or removed.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-133-12
  • Executive Order 133-12 / D133-12
  • ARB # D-133-12
  • Executive Order No: D-133-12
  • C.A.R.B. No. D-133-12
  • Resolution D-133-12
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-133-12 PDF

D-133-12 Document:

CARB_D-133-12

(Page 1 of 3) State of California AIR RESOURCES BOARD EXECUTIVE ORDER 0—133—12 Relating to Exemptions under Section 27156 of the Yehicle Code vREDLINE, INC., A SUBSIDIARY OF IMPAC _ REDLINE CARBURETOR CONVERSION KITS #k8607 AND #k8608 USING ONE (1) WEBER MODEL 32/34 DFT9 A or 32/39 DFTiI A Pursuant to the authority vested in the Air.Resources Board by Section 27156 of the Vehicle Code; and Pursuant to the authority vested in the undersigned by Sections 39515 and 39516 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 #K8607 and #K86508 using one (1) Weber 32/34 DFT9 A or 32/34 DFTII 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 Veh1c1e Code for the vehicles listed betow: Year Make — Model Engine (liter, CID) Redline Kit No. 1977—1978 Ford. Courier > 2.3, 140 . K8607 1979—1980 Ford Courier 2.3, 140 K8608 , The fol]ow1ng mod1f1cat1ons to the exhaust emission control system are permitt“d — 1) The throttle positioner (dashpot), on veh1c1es so equipped, may be removed. 2) The deceleration control vaive (Coasting Richer valve} and acceletator microswitch, on vehicles so equipped, may be disconnected and removed. 3) The vacuum hose routing may be changed as spec1f1ed in the installation instructions. All other original equipment emission control devices must be retained. | The vehicle must be tuned to the vehicle manufacturer‘s specifications. Lczgnmmens

REDLINE, INC. — * EXECUTIVE ORDER D—133—12 . (Page 2 of 3) This Executive Order is valid provided that installation instructfons 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 exempted by the Air Resources Board, that adversely affect the performance of a {s ‘~ vehicle‘s pollution control system shall invalidate this Executive Order. Marketing of this device using an ifdentification 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. Exeription of a kit shall not be construed as an exemption to sell, offer for sale, or advertise any component of 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 #K8607 AND #ks6e08. 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 or written communication. Section 17500 of the Business and Professions Code makes untrue om misleading advertising unlawful, and Sectwon 17534 makes v1olat1on punishable. as— a misdemeanor . : ~ Section 43644 of the Health and Safety Code providgs'as follows: "43644. (a) No person shall instali, sell, offer for sale, or advertise, __— or, except in an applicatfon to the state board for certification of a . .device, represent, any device as a motor vehicle pollution control. device for use on any used motor vehicle unless that device has been certified by the state board. No .person shall sell, offer for sale, advertise, or represent 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." a

REDLINE, INC. EXECdTIVE ORDER D—133—12 i ‘ (Page 3 of 3) Any apparent violation of the conditions of th1s Executive Order will be submitted to the Attorney General of California for such action as he deems advisable. Executed at El Monte, Ca11forn1a, this 2 _ 8 day ofSeptember, 1986. /W/zm & D. Drachand, Chief Mobile Source D1v1sxon

State of California AIR RESOURCES BOARD EVALUATION OF THE REDLINE CARBURETOR CONVERSION KITS NO. K8607 AND NO. K8608 USING ONE (1) 32/34 DFT9 A OR 32/34 DFTI1 A WEBER CARBURETOR FOR EXEMPTION FROM THE PROXHIBITIONS OF VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13 OF THE CALIFORNIA ADMINISTRATIVE CODE SEPTEMBER, 1986

EVALUATION OF THE REDLINE CARBURETOR CONVERSION KITS NO. K8607 AND NO. K8608 USING ONE (1) 32/34 DFT9 A OR 32/34 DFT1I1 A WEBER CARBURETOR FOR EXEMPTION FROM THE PROKIBITIONS OF VEKICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13 OF THE CALIFORNIA ADMINISTRATIVE CODE by Mobile Source Diviston 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 Resources Board 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 constitute endorsement 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. K8607 and No. K8608 using one {1) Weber model 32/34 DFT9 A or 32/34 DFTIl A carburetor. These Redline Carburetor Conversion Kits are designed to replace the Hitachi carburetors found on 1977—1980 Ford Courier pick—up trucks with 2.3 liter engines. Comparative exhaust emission tests and other information submitted demonstrate that the aftermarket Redline Carburetor Conversion Kits No. K8607 and No. K8608 using one {1) Weber model 32/34 DFT9 A or 32/34 DFTII 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 Mode] Engine (liter, CID) Redline Kit No. 1977—1978 Ford Courier 2.3, 140 K8607 1979—1980 Ford Courier 2.3, 140 K8608

CONTENTS Page Number SUMMARY CONTENTS I. INTRUODUCTION II. CONCLUSION III. RECOMMENDATION IV. DEVICE DESCRIPTION V. DEVICE_EVALUATION VI. DISCUSSION APPENDIX OEM Carburetor Diagrams Weber 32/34 DFT9 A A—2 Installation Instructions: K8607, K8608 A—3 Underhood label Carburetor Calibrations: K8607, K8608 A—5 Identification Labels: K8607, K8608 A—6 11.

EVALUATION OF THE REDLINE CARBURETOR CONVERSION KITS NO. K8607 AND NO. K8608 USING ONE (1) MODEL 32/34 DFT9 A OR 32/34 DFT11 A WEBER CARBURETOR FOR EXEMPTION FROM THE PROKIBITIONS 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 (IMPAC), 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 Converston Kits designated as Rediine Kits No. K8607 and No. K8608 using one (1) Weber mode! 32/34 DFT9 A or 32/34 DFTiI A carburetor to replace the original equipment manufacturer (OEM) Hitachi two—barrel carburetors found on the following vehicles: Year Make Model Engine (liter, C1D) Redline Kit No. 1977~—1978 Ford Courier 2.3, 140 K8607 19791980 Ford Courter 2.3, 140 K8608 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. K8607 and No. K8608 using one (1) 32/34 DFT9 A or 32/34 DFTIi 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 prokibitions of Vehicle Code Section 27156 for the Redline Carburetor Conversion Kits No. K8607 and No. K8608 for use on the vehicles described above and that Executive Order No. D—133—12 be issued. IV. DEVICE DESCRIPTION The Redline Carburetor Conversion Kits No. K8607 and No. K8608 are similar in design. Each kit uses one (1) model 32/34 DFT9 A or 32/34 DFTIl A Weber carburetor as an economical replacement for the OEM carburetors found on the 1977—1980 Ford Courier pick—up trucks described previously. These vehicles are equipped with a Hitacht carburetor. These Hitachi carburetors are of the progressive two—barrel design (See Appendix 1). The Weber 32/34 DFT is a progressive two—barrel carburetor which is similar in basic design to the OEM carburetors (See Appendix 2). The Weber 32/34 DFT is a slightly different verston 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 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 deceleration control valve (Coasting Richer Valve) and accelerator switch, on vehicles so equipped, are disconnected and removed. The Redline Kits No. K8607 and No. K8608 come complete with a Weber DFT carburetor, an air cleaner adaptor and all the hoses, gaskets and hardware necessary to install the Weber carburetor on the Ford Courter. 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. K8607 and No. K8608 are shown in Appendix 5. Facsimilies of the identification labels are shown in Appendix 6. ¥. DEVICE EVALUATION The applicant performed comparative cold—start CVS—75 exhaust emission tests at Import Certification Laboratories in Anaheim, California. A 1980 Ford Courier pick—up truck with a 2.3 liter engine and a 5—speed manual transmission was used as the test vehicle. The 1980 model—year vehicle was used for testing since vehicles of 1980 model—year were required to meet more

stringent emission standards than vehicles of the previous model—years. It 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 Test Procedure: CVS—75 Exhaust Emissions gm/mi Fuel Economy Condition HC CO NOx City mi/gal Baseline 1.54 25.77 0.71 19. 30 1.72 30.31 0.75 18.76 Average 1.63 28.04 0.73 19.03 Redline Kit 1.28 15.98 0.69 17.51 1.32 15.51 0.72 17.65 Average 1. 30 15.75 0.71 17.58 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 Test Procedure: CVS—75 Exhaust Emissions gm/mi Fuel Economy Condition HC cCO NOx City mi/gal Baseline 1.658 23.07 0.94 17.7 1.56 23.94 0.84 17.6 Average 1.62 23.51 0.89 17.6 Redline Kit 1.36 17.95 0.76 15.3 1.33 13.66 0.70 15.6 Average 1.35 15.81 0.73 15.5

VI. BISCUSSION The results of the emission testing show no increase in emissions. This demonstrates that the installation of the Redline Kit. No. K8608 and the modifications to the original exhaust emission control system required for the installation will not have an adverse effect on emissions from the 1980 Ford Courier pick—up test vehicle which was selected to be representative of all the vehicles on this exemption application. Since Redline Kits No. K8607 and No. K8608 are similar in design, it would be expected that the conversion kit No. K8607 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.

1980 Hif A—1 uvretors 327 ~© HITACHI DC5 328 2—BARREL (Cont.) 10) Mark the primary throttle plate location in reference to its other objects which might damage calibrated orifices, Discard bore and to its relative position on throtfle shaft. Remove throt— old gaskets and use new gaskets for assembly. tle plate and shaft from lower body. REASSEMBLY INSPECTION & CLEANING Reassemble carburetor in reverse order of disassembly. Make sure that primary and secondary components are installed in their correct locations. When installing throttle valve or choke Clean all parts thoroughly in solvent and check all passages valve, make sure to eliminate gap between valve and wall of * and parts for wear or damage. Make sure that all jets are carburetor. When assembling float, ensure float collar is clear and clean. Do not attempt to clean jets by using wire or installed. Choke Vaive Choke Shaft & \ Choke Piston Diaphragm Lever » Pump Lever 9 Bi—Metal /::m (Thermostat) Air Horn . Cover Float Collar s Choke . Emulsion Tube a Housing Retaining Fuel Strainer 3 . . Choke Arm Plate a €> fl\*fl Venturi Pump & Discharge fl 83 Accelerator " @& Weight & | Pump " B Ball g Assy. hi B|,'erd g VacuumPull Down ? Acc. Pump Vacuum Bight Glass Inlet Check Ball Hose Fuel Inlet Fitting Primary Idle Jet Choke Piston Fuel Inlet Needie Yaive Diaphragm Fuel Cut—Off Valve Connecting Rod Secondary Jet $ & Primary Main Jet C faph : Jet Plugs 4f' @/Dmp ragm Cover D Secondary Main Jet & gr—-muphrcgm Spring Coosting Richer Screw & © (Deceleration) Valve ne"~~——Diaphragm Gasket e Fast Idle tever Return Lever 1Pz Connecting 6 Throtfle Lever Secondary Throttle Shaft Levw ~*~~—— Throttle Spring Fig. 7 Exploded View of Hitachi DCS 328 2—Barrel Carburetor (Ford Courier 2300)

—\ N. 13 ols& Kay vant name Relerence pumber Kay nr. > 18 PART Name Ratessoc merber . i 1 ToP tove® AsBY $1718.710 18 1 Sacondary emulsion tube §1400.27 2 1 Auto choke "O" ring seal 41665.008 19 2 Idte Jet holdar g1370.00 3 3 Auto—choke fixing scrow ca885.001 20 / 1 Primary idio jot Tai04.08 £ i AUTO—CHOKE ASAY including: B7004.220 20 1 Secondary idie fet Ternace B 1 =Choke diaphragm 47407.160 21 1 Primary main Jet TredRiD 6 1 = Diephregm loading spring 47800.226 21 1 Secondary mein let Taatoto 7 3| ~ Drapniegm cover — 32304.041 22 4 Weshar Ensionn & 1 = Diaphragm edjusting ecrow 84598.022 23 4 Shatt sseling bush e1870.E1 9 3 = Diaphregm cover (Izing scrow ©4800,004 24 1 Spacer 127 00. 10 3| Plate haing scraw 64815,008 25 1 Secondary enafi Topt£.32 11 1 Thermontat housing lock ring 82138.020 28 4 Shafl bearing plate 6218007 +2 + Thermoatat houelng 87004.220 27 1 Socandary thealtls adjvating acrew 13 t Hoat asaiing paskal 41c4c.0s4 ~ 28 2 Washar D + Screw plug #1073.011 29 1 Throtile raire contrl leror inckrFng ie 1 Carbusetor caver gesket 41705.037 30 1 — Faal ids adjusting scrow 18 i Ront $1030,012 31 1 ~ Atocting ecrave fixing rut 17 1| Primary ut correction Jet T7o01.2b0° 32| 2 Lock wnther 17 1 Becandary eir corection Jet F7T801,230 33 2 Pormary shail Aring nat i 16 t Prmary emittion who #1c50.202° 34 t Bush for trea lever

5/13/86 _ e 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 SsUPPLIED WITH THE KIT FOR PROPER VACUUM HOSE ROUTING. IF NEEDED, COPIES OF THE APPLICABLE VACUUM MAP ARE AVAILABLE THROUGH REDLINE, INC. TECH LINES 233 604 — 0273 California 1—800 #932—3722— U.S. 1—800 932—3787

m A—5 3 F Stage of Development Proto Date: 9/16/86 Prototype # K—8608 Location of # Carburetor Model 32/34 DFT Part # 22570,045& NA =Not Applicable Application: _rord Mode!l Courier Year go_ Month AF = As Factory Engine Size 2.3 Air Cond. - No Transmission: (::) AT Calibrated Parts Adjustments VaTue rMain venturi 32/34 Float lavelling: Auxiliary venturi 4.0/4.0 with gasket (brass) mm Main jet "117" / 115 _ with gasket (plastic) 7 mm Air corrector jet 155 / 160 without gasket (brass) mm Emulsion tube F—21 / FP—~30 without gasket (plastic) mm Full power fuel bush 50 from face to carburetor bow! mm full power air bush A/F Maximum float stroke 19 mm Power valve spring 47600 131 P.n. uel enrichment bush 170 Accelerating pump: ir enrichment bush 110 10 complete pump strokes ixture enrichment tube/hole 2.00 delivery cm3 , . Pump Cam Auxiliary venturi mixture enrichment bush Throttle opening pump 14850 130 Stroke adjustment .mm

1Ck.bra'ced Parts, Con‘t. Adiustments,. Gon‘t Value Main throttle plate adjustment idle jet "6or / "60" 1st throttle opening at start idle air bush 175/70 of 2nd one 7—2 mm irreversibility hole NA idle mixture adjusting hole/bush 1.20 Dash—pot idle mixture bush NA Throttle opening at dash pot Sonic idle air bush/hole NA contact NA am By—pass idle air hole By—pass idle mixture hole Manual _starter Spark Advance hole AF Mechanical pull—down mm Progression ho le AF T1 Fast idle mm AF T2 Pneumaticpull—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°/78° Starter plate clearance adj. —6 nm Needle valve 1.50 Mechanical pull—down 5 mm Fuel recycle hole 50 Fast idle on starter piston Fast idle Pump jet .50 Fast idle cam timing {({mm/step nr.) Pump discharge Pull—down lever/modular cir. mm Inlet valve w/discharge pump +45 Minimum pneumatic pu]l-dofin mm Pneumatic pump jet NA Maximum pneumatic pull—down mm r @Wimatic pump discharge NA Fixed index mark Mechanical pump diaphragm 47407.050p.n, Moving index adjustment L2

librated Parts, Con‘t. Adjustments, Con‘t. Value Starter jet Bimetal assembly 57804 416 P .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 ATTACHMENT

Stage of Development Proto Date: 9/16/86 Prototype # K—8608 Location of # Carburetor Model 32/34 DFT Part # 22670.045c NA =Not Applicable Application: _Ford Model Courier Year so_ Month AF = As Factory Engine Size 2.3 Air Cond. — No Transmissfon: (::) AT Calibrated Parts Adjustments VaTue Main venturi 32/34 Float levelling: Auxiliary venturi 4.0/4.0 with gasket (brass) mm Main®jet "117" / 115 _ with gasket (plastic) 7 mm Air corrector jet 155 / 160 without gasket (brass) mm Emulsion tube F—21 / F—30 without gasket (plastic) mm Full power fuel bush .50 from face to carburetor bowl mm full power air bush A/F Maximum float stroke 19 mm Power valve spring 47600 131 P.n. uel enrichment bush 170 Accelerating pump: Air enrichment bush 110 10 complete pump strokes wixture enrichment tube/hole 2.00 delivery cm3 . Pump Cam Auxiliary venturi mixture enrichment bush Throttle opening pump 14850 130 Stroke adjustment .mm

C.brated Parts, Con‘t. Adiustments,. Con‘t Main throttle plate adjustment Value idle jet "6o" / "60" 1st throttle opening at start idle air_bush 175/70 of 2nd one 7+2 mm irreversibility hole NA idle mixture adjusting hole/bush __1.20 Dash—pot idle mixture bush NA Throttle opening at dash pot Sonic idle air bush/hole NA contact NA mm By—pass idle air hole By—pass idle mixture hole Manual starter Spark Advance hole AF Mechanical pull—down mm Progression hole AF T1 Fast idle mm AF T2 Pneumatic pull—down mm _‘ T3 Minimum pneumatic pull—down — mm 14 Max prneumatic pull—down (half T5 choke) mm Starter rod complete P .n. Starter spring P.n. Progression slot NA Automatic starter Throttle plate angle 78°/78° Starter plate clearance adj. +6 mm Needle valve 1.50 Mechanical pull—down 5 mm Fuel recycle hole .50 Fast idle on starter piston Fast idle Pump jet 50 Fast idle cam timing (mm/step nr.) Pump discharge Pull—down lever/modular clir. mm Inlet valve w/discharge pump 45 Minimum preumatic pull—down mm P matic pump jet NA Maximum pneumatic pull—down mm t fumatic pump discharge NA Fixed index mark Mechanical pump diaphragm 47407.050pp. Moving index adjustment —z3.

librated Parts, Con‘t. Adjustments, Con‘t. Value Starter jet Bimetal assembly 57804 416 P .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 ATTACHMENT

‘CARBURETOR: REDLINE—WEBER, 32/34 DFT 9A/11A _ K seor _ CARB E.0. No. D138—X

‘CARBURETOR: REDLINE—WEBER, 32/34 DFT 9A/11 A K 8608 | CARB E.0. No. D133—X

INSTALLAtrON instRUCTIONS y cansunerons .READ & UNDERSTAND ALL STEPS OF THESE INSTRUCTIONS BEFORE BEGINNING THIS INSTALLATION. AFTER UNPACKING, EXAMINE THE CARBURETOR AND OTHER COMPONENTS FOR SHIPPING DAMAGE. THESE INSTRUCTIONS SHOULD BE RETAINED WITH VEHICLE RECORDS AFTER INSTALLATION OF THIS KIT FOR SMOG INSPECTION PURPOSES. FORD COURIER & MAZDA PICKUP 1972 TO 1984 Kit Nos. K8605 and 52—50701 ('72- ‘78 Courier 1.8 and Mazda B1600, B1800) K8606 and 52—50703 (‘79 —‘82 Courier, 2.0 and ‘79—‘84 Mazda 32000) K8bo7 and s2e0704 (77—‘78 Courier, 2. 3) K8608 and 52—50705 (‘79—‘80 Courier, 2. TOOLS AND EQUIPMENT NEEDED PARTS SUPPLIED WITH INSTALLATION KIT: Combination, box or open—end wrenches 1 — 32/34 DFT Weber Carb. {metric) 1 — Air Filter Adaptor Socket Set (metric) 1 — Wire Assembly Screwdrivers (regular and Phillips) 1 — Under Hood Label Pliers Gasket Scraper 1 — Hardware Kit Wiping Rags Cleaning Solvent Knife Gasket Sealer 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 suitably qualified Dealer or independent garage, using infrared gas and analyzing equipment. NOTE: Late model vehicles fitted with Emission Control Systems have many vacuum lines and electrical connections in the fuel systems. It is essential when dismantling, that disconnected lines should be identified with a corresponding number tag or label system. To establish function, locate and identify the source of each line. Use the under hood emissions diagram or the factory service manual for reference when identifying hoses. (Modified vacuum diagrams showing the Weber installation are provided in these instructions) DISASSEMBLY 4’79-'84 VEHICLES 2023 LITRE ENG.: + Remove the two_ air filter mounting nuts, 1. Remove the vehicle‘s gas cap. {INSIDE AIR FILTER HOUSING.) Disconnect the air pump hoses and remove the filter assembly. 2. Disconnectthe battery. Retain the mounting nuts for use later. 3. 7278 VEHICLES 161.3 LITRE ENG.: 5. Remove the servo—diaphragm assembly and (if ‘77—‘78 2.3 LITRE ENG.: Loosen the air fil— equipped) the dashpot & bracket assembly. ter clamp and aftached hoses. Remove the air These devices will not be used with the Weber fiter from the carburetor. ‘ carburetor. Remove the vacuum hoses for Kit Nos, K8605, K8606, 52—50701 and 52—50708 are sold under the provisions of Califomia Air Resources Board Executive Order No. D—133—7 (CARB. E.C. No. D— 183—7) Products with C.A.R.B. E.0. numbers are exempt from the prohibitions of Section 27156 of the California Vehicle Code. Performance kits so noted are legal for use on public highwaysin California. WEBER DISTRIBUTION 1

these devices and plug the vacuum sources with 15. ALL 2.0 LITRE ENG.: The throttle lever the plugs provided in the kit. required for these applications is already instal led on the Weber carburetor. If the vehicle is equipped with a "Coasting Rich— e micro—switch, unplug the wires and remove 16. ALL 2.3 LITRE ENG.: Remove the stock the switch from the bracket. This device will not throttle lever from the original carburetor. Tumn be used with the Weber carburetor. the lever UPSIDE DOWN and install it on the Weber carburetor. (FIG. B) CAUTION: When Disconnect the fuel inlet and fuel return fines installing the throttle lever on the Weber from the original carburetor. carburetor, DO NOT OVERTIGHTEN THE NUT. Proper tightness can be acheived by in— 7275 VEHICLES: Disconnect and remove stailing the nut just slightly more than finger— the original dashpot, coasting richer valve and tight. After tightening the nut, open the choke the accelerator switch. Disconnect all vacuum by hand and check for full throttle operation from lines connected to the stock carburator. All idle to wide—open—throttle. If any sticking or bin— vacuum fines except the distributor vacuum ding occurs, loosen the nut and re—tighten with advance should be plugged with the‘rubber reduced torque. If excessive torque is applied, caps provided in the kit. > realignment of the throttle plate may be necessary. Recheck throttle operation. When ‘76—84 VEHICLES: Disconnect all vacuum proper tightness of the nut has been achieved, hoses and electifcal wires connected to the and no sticking or binding occurs during original carburetor. Use a factory service manual operation of the throttle; lock the nut in position or the underhood vacuum diagram to identify by bending the tab on the lockwasher around and tag each hose. (Note: Weber modified the nut. vacuum diagrams are found at the end of these instructions for ‘76—84 model years) 10. Disconnect the throttle linkage from the carbure— tor. Remove the throttle return spring. 1. Remove the stock carburetor hold—down nuts and washers. Carefully lift the carburetor off the intake manifoid. 12. Remove the stock heat spacer and flange gas— kets. Insert a clean rag in the intake manifold ports. 13. Thoroughly clean the carburetor mounting sur— face of the intake manifold. DOWN (2.3 Liter) 14. ALL 1.61.8 LITRE ENG.:; Remove the stock throttle lever from the original carburetor. Cut the micro—switch tab off and install the lever FIG. B on the Weber carburetor. (FIG. A) 17. Remove the stock carburetor mounting studs portion or uever from the intake manifold using either a stud tool / CUuT orF Here or the "double—nut" method, if the proper tool is not available. (DOUBLE NUT METHOD: in— stall two nuts approx. 1/3 the way down on the stud and lock them together. Using a suitable wrench on the lower nut, loosen the stud and remove.) 18. Install the new studs provided in the kit using either a stud tool or the "double—nut" method described in step #16. (FOR STUD INSTAL— LATION USE THE TOP NUT TO TIG STOCK THROTTLE LEVER INSTALLED RIGHTSIDE TEN THE STUD INTO THE INTAKE Mbb UP (1.6 & 1.8 Liter) IFOLD FLANGE.) FIG. A

INSTALLATION 8. 1. RE INSTA! 19. Remove the rags from the intake manifold parts. THROTTLE LINKAGE Lightly coat both sides of the manifold flange LOCKWASHERS gasket, provided in the kit, with a suitable gasket sealer. Install the flange gasket on the intake manifold. NOTE: The 2.0 litre eng. manifold gasket is the smaller of the two gaskets in the kit and has one oblong hole in the center. The smaller end of the hole faces toward the driver‘s THrottie side fenderwell. (FIG. C) Leven / & 20. Install the heat spacer on top of the manifold *spacens /V flange gasket. NOTE: The 2.0 Liter spacer has MOUNTING SCREWS a notch that must face the driver‘s side fender well to clear the EGR valve assembly. (FIG C) FIG. D 21. Install the carburetor flange gasket on top of heat 25. ALL 2.0 LITRE ENG.: Connect the throttle spacer. (FIG. C) linkage directly to the carburetor throttle lever, reusing the stock hardware. CARBURETOR 26. ALL 1.6, 1.8, 2.0 LITRE ENG.: Recon— nect the throttle return spring to its original position in the stock return spring bracket. (FIG. D) ALL 2.3 LITRE ENG.: Install the throttle re— turm spring bracket supplied in the kit using the original bolt on the ieft rear side of manifold. (FIG. E) rront or veHicte INTAKE MANIFOLD FIG. C 22. ALL 1.6, 1.8, 2.3 LITRE ENG.:; Install the SPRING Weber carburetor on the vehicle with the choke BRACKET element facing towards the FRONT (RADIA— TOR) of the engine. ALL 2.0 LITRE ENG.: Install the Weber FIG. E carburetor on the vehicle with the choke ele— ment facing towards the REAR (FIREWALL) of 27. Reconnect the fue! supply and fuel return lines the engine component. to the Weber carburetor as shown in FIG. F. Extra hose is provided in the kit if the return line 23. Install the carburetor washers and mounting should need to be rerouted. nuts supplied in the kit. CAUTION; DO NOT OQVER—TIGHTEN CARBURETOR MOUNT— 28. ‘72—75 VEHICLES (ALL): Connect the Dist ING NUTS. MAXIMUM TORQUE SHOULD ributor vacuum advance hose to the port on the NOT EXCEED 7 FT. LBS. Weber carburetor shown in FIG. F. Cap off the carburetor EGR port with the rubber cap pro— 24. ALL 1.6, 1.8, 2.3 LITRE ENG.: Connect vided in the kit. NOTE: ALL OTHER ORIGINAL the throttle linkage to the Weber carburetor DEVICES SHOULD HAVE BEEN REMOVED using the spacers and longer bolts from the kit. AS EXPLAINED IN STEP #8. (FIG D)

31. Install the air filter adapter on the Weber carbure~ — tor and secure it using the two Allen boits from : the kit. 32. Replace the stock air filter assembly and secur in place using the original hardware. Reconnec any hoses attached to the air filter assembly. Reconnect the battery and reinstall the gas cap. CAUTION: CHECK THROTTLE FOR C FREE OPERATION. IJF THERE IS ANY \ | INDICATION OF STICKING OR BINDING, vacuum 1800s CORRECT AS NECESSARY BEFORE ADVANCE PROCEEDING. Ear port Start the engine. Check for fue! and vacuum FIG. F leaks. 29. ©76—84 VEHICLES (ALL): Refer to the app— 36. Adjust idle speed and mixture to factory specifi— ropriate vacuum diagram for your year & engine cations. size for correct vacuum hose routing. (FIGS. G THRY Q) NOTE: ALL DEVICES CIR— 37. Affix underhood label. CLED ON THESE DIAGRAMS SHOULD BE DISCONNECTED AND REMOVED. 38. CHECK FOR ADEQUATE HOOD CLEAR— ANCE BEFORE CLOSING THE HOOD. 30. Connect the wire assembly supplied in the kit to the Weber choke element and idie cut—off if after following these instructions, you solenoid. Connect the remaining end to the ori— require further assistance, please call ginal 12V source used for the stock carburetor. the Weber Tech. Service Dept. at the CAUTION: BE SURE NO HOSES OR phone numbers listed below, during ELECTRICAL WiIRES CONTACT THE > normal business hours. EGR CONTROL VALVE. HIGH TEMPEAR— ATURES ARE PRESENT AND CAN DAM— . 1—800—WEBER US (Outside CA) AGE WIRES/HOSES CAUSING ELECTRE (992—3722) CAL SHORTS AND VACUUM LEAKS. 1—800—WEBER CA (CA Only) (932—3787) 1976 COURIER/MAZDA 1.8 & 2.3 ENGINE EGR CONTROL VALVE 3 WAY SOLENOID VALVE VACUUM AMPLIFIER IGNFTION SWITCH WEBER yAcUUM FROM MANIFOLD VACUUM EXHAUST MANIFOLD CARBURETOR EXHAUST PIPE WATER THERMOSWITCH FIG.G

‘7? — ‘78 COURIER 1.8 LITRE (CAL.) [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOVED] HOSE | fcassurcron VACUUM tnlang To DISTRIBUTOR VACUUM ADVANCE VACUUM AMPLIFIER TT CARBON CANISTER FUEL TANK afm AIR PUMP TaT o an CONTROI old um VALVE Ey s FIG. H "7? »‘78 COURIER 2.3 LITRE (CAL.) [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOYED] WEBER YACUUM urEeway vacuum AmMpuriEr soLENoid vAlve a > K m carb T< ~AfO * l EGR CONTROL . ADVANCE PCV vaLvE VEHICLE SPEED SWITCH * ~ I CARBON — CANISTER FIG. 1

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Document Created: 2005-09-01 12:39:49
Document Modified: 2005-09-01 12:39:49

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