Weber Carburetor Installation Instructions Samurai.pdf

READ AND UNDERSTAND ALL STEPS OF THESE INSTRUCTIONS

BEFORE BEGINNING THIS INSTALLATION.

SUZUKI SAMURAI

For kit no. K600

using (1) Weber 32 DGAV

(Legal in California ONLY for racing vehicles which may NEVER be used upon a highway.)

Tools and equipment needed:

Parts supplied with installation kit:

Combination, box or open end wrenches

1- 32 DGAV Weber Carburetor

(metric)

1- Manifold Adapter

Socket set with 12mm socket

1- Air Cleaner Adapter

Screwdriver (regular and phillips)

1- Cable Bracket

Pliers

1- Hardware Kit

Gasket scraper

Cleaning solvent and rags

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 analyzing equipment.

NOTE: late model vehicles fitted with Emission Control Systems have many vacuum lines and

electrical connections in their fuel systems. It is essential when dismantling, that disconnected lines

be identified with a corresponding number tag or label system. To establish function, locate and

identify the source of each line. Use the under hood emissions diagram, or the factory service

manual for reference when identifying hoses.

Disassembly

1. Disconnect the vehicle’s battery.

2. Remove the gas cap.

3. Drain approximately one (1) quart of engine coolant.

CAUTION: Hot water may be present.

4. Using either the map inside the vehicle’s engine compartment, or a factory service manual

for your year/make vehicle: tag each hose, vacuum line and electrical wire/connector

attached to the original carburetor and air filter assembly for proper identification during

reassembly. Disconnect all connections once they are identified.

5. Disconnect and remove the flexible connector and the sheet metal elbow between the

carburetor and the air cleaner housing.

6. Disconnect the fuel line from the original carburetor.

Plug the end of the fuel line to prevent leakage.

7. Disconnect the throttle cable from the throttle lever and the cable bracket.

8. Remove the four (4) nuts that secure the carburetor to the intake manifold. Remove the

carburetor and the spacer/gasket. Insert a clean rag into the intake ports to prevent dirt

and gasket material from entering the engine.

9. Remove the stock carburetor mounting studs from the intake manifold. NOTE: For correct

stud removal or installation, use stud removal/installation tool or the “double-nut” method.

DOUBLE-NUT METHOD: Install two nuts approximately half way down the stud. Lock the

nuts together. Turn the lower nut for removal and the upper nut for installation.

10. Clean the intake manifold flange surface thoroughly.

ASSEMBLY

11. Remove the rag from the intake manifold.

12. Apply Loc-Tite (supplied) to the 8mm end of the stud into the two holes of the manifold

closer to the passenger side fenderwell.

13. Using appropriate gasket sealer, slide the smaller of the supplied adapter gaskets over the

two studs so that the larger hole is closer to the valve cover.

14. Slide the manifold adapter over the two studs in the same manner as the gasket and using

Loc-Tite (supplied) on the tow allen bolts supplied secure it to the manifold.

Torque the bolts to 7 ft/lbs.

15. Install 8mm studs into threaded holes of the manifold adapter (apply Loc-Tite to the studs)

insuring that the studs go no further than flush with the bottom of the adapter.

16. Slide the remaining gasket over the studs (with the large hole facing the valve cover), fol-

lowed by the Weber carburetor (insuring that the linkage faces the firewall). The Anti-

Backfire Valve bracket may require bending for clearance.

17. Slide the supplied cable bracket over the two (2) adapter studs closer to the valve cover.

18. Using the nuts and washers supplied, secure the carburetor to the manifold and adapter;

and tighten, in a criss-cross fashion to 7 ft/lbs.

19. Re-route the throttle cable so that it runs from the firewall to the front of the valve cover and

back around to the installed bracket. (Run cable under and through the PCV hoses and tee.)

Install the cable on to the cable bracket and throttle lever.

20. Remove the throttle pedal stop adjustment bolt and nut from the floor of the passenger

compartment.

21. Adjust throttle cable at the cable bracket so that full throttle can be achieved, AND, the

throttle returns fully to an idle position (choke plates should be held open to bypass idle

kick-up of choke linkage).

CHECK THROTTLE OPERATION FOR FREE MOVEMENT. IF THERE IS ANY BINDING

OR STICKING, CORRECT AS NECESSARY BEFORE PROCEEDING.

22. Remove the original water choke hose from the back of the intake manifold. Using the new

hose and clamps supplied, install the hose between the fitting at the back of the manifold

and the upper fitting of the water choke housing on the Weber carburetor. Connect the

remaining original water hose to the lower fitting of the water choke housing.

23. Connect the supplied vacuum hose between the vacuum advance unit of the distributor and

vacuum fitting on the base of the Weber carburetor that faces the passenger side fenderwell.

24. Connect the original float bowl vent hose to the 90 degree fitting on the passenger side of

the Weber carburetor.

25. Remove the plug from the original fuel line and connect the line to the fitting on the driver’s

side of the Weber carburetor.

26. Cap off any exposed vacuum fittings from hose removal in step 4. (One (1) 1/4” vacuum cap

is included to cap the larger fitting on the EGR Valve.)

27. Install air cleaner adapter using supplied washers between the adapter and the 5mm allen

bolts for adapter. Torque bolts to 10 in/lbs.

28. Re-install the flexible connector and the sheet metal elbow removed in step 5. (The elbow

may require modification in order to fit flush to the air cleaner adapter.) Use the supplied

6mm bolt and the original sealing washer to secure the elbow to the adapter.

29. Reconnect the battery and replace the gas cap.

30. Depress the throttle pedal once to initiate the choke unit and start the engine. (Realize that

the float bowl is empty and it will require cranking the engine a few moments in order to fill

the bowl with enough fuel to start the engine.)

31. A. Check for leaks around the carburetor mounting base and the fuel line connection.

Correct as necessary.

B. Warm engine to operating temperature and recheck step A.

C. Set idle speed and mixture to factory specifications.

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

REDLINE WEBER

TYPICAL DGV CARB INSTALL VIEWS

These views may vary depending on application. For general assembly assistance only.

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