Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on September 8, 1986.
As of Thursday, October 17th, 2019 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:



                                                                  (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


                                 ‘79 — ‘80 COURIER 2.0 LITRE (CAL.)
                      [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOVED]
YACUUM PORT                        C
                                                      ARBURETOR
                                                                      Pev
                                                       rabg                  *
                                                      heths d                                         To DISTRIRUTOR
                                                                                                     vacuthd ApVANCE
       REMove                                                                     |                        ut
                                          L
                                                                                 @H




                                                                                            |f—     ain sv—rass valve
                                  vauve
                                                                                         __/
                                79 — ‘80 COURIER 2.3 LITRE (CAL.)
                      [ALL DEVICES CIRCLED SHOULD 8BE DISCONNECTED AND REMOVED]
                                                                                 vacuuh auPurien
                                                                  casy par              o weeen vertum
                                          To weren sPaRK              i
                                                           To astmauron
                                           ADVANCE PoRT
                                                                                                   4 x      Eon contror.
                                                                                                               valve
   no. 2 néuse
     ValvE an                                                                                                  Metk
                                                                                                             canisten
  wo. 1 neuse vaive
                                                                                                                           FIG. K


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                                                                    J                SATVA MOSHOD

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                                                            7                                   3.

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                                                                                  SATVA H2LINHS
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                          ‘79 — ‘80 MAZDA B2000 2.0 LITRE (CAL.)
                 [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOVED]




                                                                                                            no. 2 reuer
                                                                                                                valve
                                                                                                          No. 1 Reuer
                                                                                                             varve
     To                                                                                          _    vacuumortay
     fenFonr                                                                                               Valve
                                                                                                           to oist.
          yEHo                                                                                          vac. apvakice
    SOLENOID

                                  O                                                          *           to purce
                                                                                —      —              contnot, valve
                             l           |                                                             (1seo mooeLs)
                                sway *\                                 L
                            soushotp vauve                              3
                                 vacuum *
                             AupunER                                        L       [|———_ am ev.ease
                                                              wn pove                        varve
                             ecavaive


                                 swtce                                                                                FIG. N



                         ‘81 — ‘82 MAZDA B2000 2.0 LITRE (CAL)
                 [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOVED]




                                                                                    wn conthor vauve




                                                                                                 NO. 2 RELIEF VALVE

                                                                                            NO. 1 RELIEF VALVE


   WEBER                                                                              SPARK DELAY VALVE
   PORT
                                                                                                  To pistrmuToR
                                                                                    ~*~          vacuum Abyance
REMOVE
SOLENOID                                                                                    rhow carstEn
                            O                                                               To mmes
                        _———                                                          CoNTRoL VALVE

                         sway /.
                     soteNoiD vaLve
                        vacuum
                        AvPLIRER                                                     win my.pass
                      €cr                                                                  vaive
                            VALVE
                     EGR CONTROL VALVE
                      ENGINE SPEED
                        switch
                                                                                                                      FIG. 0


d ‘Dld




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 BAT¥A #3N9H 2 ‘ON




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                                       (5i¥2) Lniv sHiln o7 vazvm se.


                                                ‘84 MAZDA 2.0 LITRE A/T (CAL.)

                                 [ALL DEVICES CIRCLED SHOULD BE DISCONNECTED AND REMOVED]

                                                         cHamsen          to waten      ACV508(0
                                                                                             E
                                                                        THERMO SWITCH             vaCUUM DELAY   AIR CONTROL VALVE
                                                 GaAS ALTER
                                                                                                  / VALVE

                                   IDLE cOMPENsATOR

                              TO AC SWTICH                                                INSTALL .
                                                                                            HERE

               SWAY SOLENOID VALVE ..____...


                   VENTUBL —                                                                                                  NC. 2 RELEF VALVE


                                                                                              X
                  VACUUM
                                                                                                                          NO. 1 RELIEF VALVE

                      PORT

                                                                                                                       SPARK DELAY VALVE

                                                                                                                        ——> TO DISTHIBUTOR

                                                                                                                                     VAN


                                                                                                                           FROM C

                                                                                                                            To PURGE
                                                                                                                          CONTROL VAL




CATALYTIC CONVERTER




                                          Enoime spEED                          wo 1 sR
                                             swrtch                          contho.. vacve

                                               to papuraon rom
                                             EvAP. SHUTTER VALVE             waten THExwo SMTCH




                                                                                                                     FIG. Q




                                                                   10



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

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