Weber Carburator Manual
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The Haynes
Weber
Carburetor
Manual
by A K Legg LAE MIMI, Don Peers,
Robert Maddox and
John H Haynes
Member of the Guild of Motoring Writers
Models covered:
Weber carburetor types: DAF, DCD, DFA, DFV, DFD,
DFE, DFM, DFT, DGV, DIF, IDA, IDF, IDS, IDT, DCNF,
DCOE, DFAV, DFTA, DGAS, DGAV, IDAP and IDTP
Zenith Stromberg carburetor types: CD, CDS,
CD-2S, CDSE, CD-2S E, CDST and CDSET
SU carburetor types: H, HD, HS, HIF
(includi ng electron ic) and auxiliary starting devices
ABCDE
,
FGHU
Haynes Publishing Group
Sparkford Nr Yeovi l
Somerset BA22 7JJ England
Haynes North America, Inc
861 Lawrence Drive
Newbury Park
California 91320 USA
Acknowledgments
We are indebted to Martin Goodall of Weber Carburettors (UK)
Limited, Sunbury-on-Thames, Middlesex, for supplying technical
material and for being helpful with advice and the supply of carburretors used during the compilation of this Manual. We are also
indebted to the Zenith Carburretter Company Limited of Honeypot
Lane, Stanmore, Middlesex HAl 1EG, the manufacturer of Stromberg
carburettors. for publishing their technical material. Thanks are due to
Hobourn SU Limited of Wood Lane, Erdington, Birmingham, and to
Burien Fuel Systems Limited of Spitfire House, Castle Road, Salisbury,
for the supply of technical data. Special thanks go to Plowman Motors
of Yeovil, for supplying one of the project vehicles. Sykes-Pickavant
supplied some of the workshop tools.
We also wish to thank a number of people who where kind
enough to lend us vehicles, carburetors and supply us with technical
information and assistance, they are: Garry Pollard of Long Beach,
California; Josh Sadler of Autofarm, Amersham, Bucks; Terry
Batchelor of the Crewkerne Tyre Company, Crewkerne, Somerset;
Pete Wareham of Corville Auto Engineers, Babylon Hill, Sherborne,
Dorset; Graham Briginshaw of Western Services, Bristol; Jonathon
Evans of IIminster Motor Company, IIminster Somerset; Tony Bishop of
Autoconti Limited, Southwick, Trowbridge, Wiltshire; Ford Motor
Company (BG) Limited; Messers Derringtons of Kingston, Surrey;
Wincanton Garages (Yeovil) Limited of Addlewell Lane, Yeovil,
Somerset; 'Steptoe' of Market Place, Wincanton, Somerset; Alelc
Rollo, (Vauxhall Chevette); Martin Penny, (Saab 99); Hot VW Magazine;
Bill Hart of Bill Hart's Street Rods, Ventura California; Martin Hudson;
John Haynes, our chairman; Jay Storer, Newbury Park; all the people
at Sparkford: Brian Horsfall, Les Brazzier, Terry Davey, Tim Parker
Chris Rogers and Stanley Rudolph
© Haynes North America, Inc. 1995
With permission from J.H. Haynes & Co. Ltd.
A book in the Haynes Automotive Repair Manual Series
Printed in the U.S.A.
AI! rights reserved. No part of this book may be reproduced or
transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording or by any information storage or
retrieval system, without permission in writing from the copyright
holder.
ISBN 1 56392 157 X
Library of Congress Catalog Card Number 95-077793
While every attempt is made to ensure that the information in this
manual is correct, no liability can be accepted by the authors or
publishers for loss, damage or injury caused by any errors in, or
omissions from, the information given.
95-352
Contents
Introductory pages
About this manual
Conversion factors
Safety first!
Part 1 Introduction
Chapter
Chapter
Chapter
Chapter
Chapter
Part 2
1
2
3
4
5
Basic carburetion
Carburetor fitting
Maintenance and servicing
Overhaul
Converting to Weber carburetors
Weber Carburetors
Chapter 6 Type 28/36 DCD
Chapter 7 Type 32 DFD, 32 DFE, 32 DFM, 32 DIF, 32 DAF,
32 DGV, 32/36 DFV, 32/36 DGV, 32/36 DFAV, 32/36 DGAV
Chapter 8 Type 46 IDA, 48 IDA, 40 IDA 3C, 40 IDS 3C,
40 IDT 3C,46 IDA 3C, 40 IDAP 3C, 40 IDTP 3C, 40 IDTP 13C
Chapter 9 Type 40 DFA, 40 DFAV, 34 DGAS, 38 DGAS
Chapter 10 Type 32 DFT, 32 DFTA, 32 DFTA 1
Chapter 11 Type 38 to 48 DCOE
Chapter 12 Type 40 IDF, 44 IDF, 48 IDF
Chapter 13 Type 36 DCNF, 40 DCNF, 42 DCNF, 44 DCNF
Part 3
Zenith Stromberg carburetors
Chapter 14 Series CD, CDS and CD-2S
Chapter 15 Series CDSE and CD-2SE
Chapter 16 Series CDST and COSET
Part 4
SU carburetors
Chapter 17 Type H
Chapter
Chapter
Chapter
Chapter
18
19
20
21
0-4
0-5
0-6
1
2
3
4
Type HD
Type HS
Type HIF
Auxiliary starting devices
Part 5 Appendix
Appendix 1 Original equipment jet setting list for
Weber carburetors
Appendix 2 Conversion equipment jet setting list for
Weber carburetors
Appendix 3 Applications list for Zenith Stromberg carburetors
Appendix 4 Metering needles charts for
Zen ith Stromberg carburetors
Appendix 5 Metering needles cross-reference chart for Zenith
Stromberg carburetors
Appendix 6 Applications list for SU carburetors
Appendix 7 Needle charts for SU carburetors
Appendix 8 Needle cross-reference chart for SU carburetors
Appendix 9 Jet identification information for SU carburetors
5
0-4
About this manual
This is a manual written for the do-it-yourself car owner whose
vehicle is fitted with a Weber, Zenith Stromberg or SU carburetor. Because the carburetor is a fine precision instrument, the book has to assume the reader has a basic familiarity of carburetors. For example it
assumes that the owner has a basic understanding of the mechanical
systems of a vehicle, where the carburetor is fitted and how to adjust
the ignition timing (if the owner does not possess this knowledge, it
can easily be obtained from the Haynes Automotive Repair Manual for
the particular vehicle in question). This manual discusses the operation
of the carburetor, isolating it from the remainder of the automobile, explaining its function in detail and relating it to other systems when necessary. This is a comprehensive manual for the indicated types of Weber, Zenith Stromberg and SU carburetors.
A great deal of mystique surrounds the carburetor, its function
and tuning. This manual explodes that mystique and guides the owner
through theory, maintenance, overhaul and tuning, using only the necessary tools any reasonably equipped home workshop will possess. It
does not over-complicate the issue by giving superfluous information
which is of no practical use. By definition it is not possible to dictate to
you when to service your carburetor, nor whether the law allows you to
alter any settings (in some locations environmental agencies specifically forbid it). This manual simply provides a guide and the needed information should servicing the carburetor become necessary.
Every effort has been made to ensure that this manual is up-todate. However, it should be noted that modifications in design and
production are often an on-going process and differences in your carburetor may exist. While extreme care is taken to ensure that the technical information in this manual is correct, no liability can be accepted
by the authors or publishers for loss, damage or injury caused by any
errors in, or omissions from, the information given.
0-5
Conversion factors
Length (distance)
Inches On}
Feet (tt)
Miles
X 25.4
X 0.305
X 1.609
= Millimetres (mm)
= Me tres (m)
X
X
X
X
X
X
X
X
= Cubic centim etres (co; em s)
Litres (I)
Kilom etres (km)
X 0.0394
X 3 .281
X 0 .621
Inc hes (in)
Feet (ft)
Miles
Volume (cap acity)
16.387
0.568
1.137
1.201
0.9 46
4 .546
1.201
3.785
0 .06 1
1.76
0.8 8
0.833
1.0 57
0.2 2
0.833
0.264
= C ubic inch es (eu in; in3)
Litres (I)
US qua rts (US qt)
Litr es (I)
Litres (I)
US ga llons (US gal)
= Litres (I)
X
X
X
X
X
X
X
X
X 28 .35
X 0.454
= Grams (g)
= Kilograms (kg)
X 0.035
X 2.205
= O unces (oz)
X 0.278
X 4.448
X 0.1
= Newtons (N)
= Newt o ns (N)
= Kilog rams- force (kgf; kg)
X 3.6
X 0.225
X 9 .8 1
= Ounces-force (ozf; az)
X 0.070
= Kilog rams- force per square
X 14.223
= Poun ds-fo rce per sq uare inch
inch
X 0.068
centim etre (kgflc m2; kg/cm2)
= At mospheres (atm)
X 14.696
= Pounds -fo rce per square inch
inch
X 0.0 69
Bars
X 14.5
inc h
X 6.8 95
Kilo pascals (kPa)
X 0.145
X O.D1
Kilog rams-force per sq uare
ce ntim etre (kgf/cm2; kg/cm 2)
Pasca ls (Pa)
Pounds-force per sq uare inc h
(psi ; Ibf/i n2; lb/in2)
Mil limetres of me rcury (mm Hg)
Inches of water VnHzO}
X 98 .1
Cubic inc hes (eu in; in3)
Impe rial p int s (Imp pt)
Imperial q uarts (Imp qt)
Imperial qu arts (Imp qt)
US quarts (US qt)
Impe rial gallons (Imp gal)
Imp erial ga llons (Imp gal)
US gallons (US gal)
Imperia l pints (Imp pt)
Imperial qu arts (Im p qt)
Imperial quarts (Im p qt)
US quarts (US qt)
Imperial gallon s (Imp gal)
Imperial gallons {Imp gal)
US gallons (US gal)
M ass (w eig ht)
Ounces (oz)
Po unds (lb)
= Pound s (lb)
Force
Ounces-f orce (ozf; oz)
Pounds-force (lbf; Ib)
Newtons (N)
Pounds -force (lbf; Ib)
Newton s (N)
Pressure
Pounds - force per square
(psi; lbf/inz; Ibo n2)
Pound s-fo rce per sq uare
(ps i; lbf/in z: Ib/i n2)
Pounds-for ce pe r squar e
(psi; Ibf/in2; Ib/ inZ)
Pounds-force per squa re
(psi ; Ibf/i n2; Iblin2)
Kilo pas cals (kPa)
inch
Millibar (mbar)
Milli ba r (mbar)
X 100
X 0.0145
=
=
Milli bar (mbar)
Millibar (m bar)
X
X
X
X
=
=
= Inches of water (inH 2O)
= Po und s-fo rce pe r squ are inch
M illimetres of m ercury (mmHg)
Inc hes of wate r (inH2O)
0.7 5
0.401
0 .535
0.036
(ps i; Ibflin2; lb/in2)
X 0.01
X 68 .94 7
X
X
X
X
1.333
2 .49 1
1.868
27 .68
(psi; lbf/inz: lb/ina)
Pounds-fo rce pe r sq uare inch
(psi; Ibf/in2; Ib/ ln 2)
Pou nds -f orce per SQ uare inch
(psi ; lbf/ in2; Ib/in2)
= Kilo pas ca ls (kPa)
Millibar (mba r)
Millibar (mbar)
= Milli bar (mbar)
Milli bar (mbar)
= M illim etres of m ercu ry (mm Hg)
= Inches of water ~ n H20)
(ps i; Ibflin2; Ib/i n 2)
Torque (momen t of force)
Poun ds-force inc hes
(lbf in; Ib in)
Pounds-force inch es
(Ibf in; Ib in)
Pounds-fo rce inches
(Ibf in; Ib in)
Pou nds-f orce f eet (lbt It ; Ib tt)
X 1.152
Pound s-force feet (lbl ft; lb tt)
New ton metres (Nm)
X 1.356
X 0 .102
X 0.113
X 0.OB3
X 0. 138
=
Kilograms-f orc e centim etre
(kgt em ; kg em)
Newton metres (Nm)
X 0 .868
Pounds-fo rce feet (Ibf ft; lb tt)
X 12
Kilog ram s-f orce metres
(kgf m ; kg m)
Newton metr es (Nm)
Kilograms -torce me tr es
(kgf m; kg m)
X 7.233
X 8 .85
X 0.738
Pounds-force
(Ibt in; Ib in)
Pounds-force
(Ibf in; Ib in)
Po unds-force
(Ibf in; Ib in)
= Pounds-force
inches
inch es
inches
feet (lbf 11; lb ft)
X 9.804
Pound s-fo rce teet (Ibf ft; Ib ftl
Newt on metres (Nm)
X 0.0013
Horsepower (hp)
Power
X 745 .7
Horsepower (hpj
= Watts CN>
Velocity (speed)
Miles per hou r (mileslhr; mph)
X 1.609
Kilometres pe r hou r (kmlhr; kph)
X 0.6 21
Mi les p er ho ur (mileslhr; mph)
X 0 .354
Kilometres per litr e (km/l)
Kilo metr es per litre (km/l)
X 2 .825
X 2.3 52
Miles per gallo n, Imperial (mpg)
Miles per gallon , US (mpg)
Fuel consumption '
Miles per ga llon, Imperial (mpg )
Miles per gallon , US (mpg)
X 0 .425
Temperature
Deg rees Fahrenheit = (~ C
x 1.8) + 32
Deg rees Cels ius (Degrees Centigrade; "C) = (OF ~ 32)
• It is common practice to convert from miles per gallon (mpg) to Iitresl1 00 kilometres (1/100km),
whe re mp g (Imp erial) x 11100 km = 282 an d mpg (US) x 1/100 km = 23 5
x 0.56
0-6
Safety first
Regardless of how enthusiastic you may be about getting on w ith
the job at hand , take the time to ensure that your safety is not
jeopardized. A mo ment 's lack of attent ion can result in an acc ident, as
can fail ure to obse rve certain simple safety preca utions . The
possibility of an acc ident will always exist , and the followi ng points
sho uld not be co nsidered a comprehensive list of all dang ers. Rather.
they are intended to make you awa re of the risks and to encourag e a
safety conscious app roach to all work you carry out on your vehicle.
Essential DOs and DON'Ts
DON 'T rely on a jac k w hen wo rking un der t he vehic le . Alwa ys use
app roved jac kstands to suppo rt t he weight of the veh icle and pl ace
them under the recomm ended lift or support point s.
DON 'T att empt to loosen extremely ti ght fasteners (i.e. w heel lug nuts)
whi le the vehicle is on a jack - it may fall.
DON 'T start the eng ine w itho ut first making sure that the transmission
is in Neutral (or Park w here applicable) and the parking brake is set.
DON 'T remove the rad iator cap from a hot cooli ng system - let it coo t
or co ver it wit h a c loth and release the pressure gradually.
DON 'T attempt to drain the engine oil until you are sure it has coo led
to the point that it w ill not burn you.
DON 'T t ou ch any pa rt of the engi ne or exh aust sy stem until it has
cool ed sufficiently to avoid burns.
DON 'T siphon tox ic liquids such as gasoline, antifreeze and brake fluid
by mouth , or allow them to remain on your skin .
DON 'T inhale brake lining dust - it is potenti ally haz ardous (see
Asbe stos below)
DON 'T allow spilled oil or grease to rema in on the floor - w ipe it up
before so meone slips on it.
DON 'T use loose fitt ing w renc hes or ot her to ols whi ch may slip and
cause injury .
DON'T push on wrenc hes when loosening or tightening nuts or bolts.
Alwa ys try to pull the w renc h t oward y ou. If the si tuation ca lls for
pushing the wrench away, push with an open hand to avoid scr aped
knuc kles if the wren ch should slip.
DON 'T att empt to lift a heavy co mponent alone - get someone to help
you.
DON 'T rush or take unsafe shortc uts to finish a job.
DON 'T allow chi ldren or animals in or around the vehicle wh ile you are
wo rking on it.
DO w ear eye pr ot ecti on when usin g po wer tools su ch as a dr ill .
sander, bench grind er, etc. and when work ing under a vehicle .
00 keep loose clothing and long hair well out of the way of m oving
parts.
DO mak e su re th at any hoist used has a safe wo rk ing load rat ing
adequ ate for the job.
DO get someone to check en you periodica lly wh en wo rking alone on
a vehicle.
DO carry out wo rk in a logical sequence and make sure that everyth ing
is co rrectly assembled and t ightened .
DO keep c hemica ls and fluids tightly capped and out of the reach of
children and pets.
DO reme mber that your vehic le's safety affects that o f yourself and
others. If in doubt on any po int, get profess ional adv ice.
Fire
Remembe r at all tim es that gasoline is highly flamm abl e. Never
smoke or have any kind of o p en flam e aroun d when work ing on a
vehicle. But the risk doe s no t end there. A spark c aused by an
elect rica l short circuit , by two met al surfaces contacti ng each oth er, or
even by stati c elect rlc fty built up in your bod y under certain con ditions,
c an ignite gasolin e v apo rs, wh ich in a co nfi ned spac e are high ly
exp losive. Do not, under any circ umstances, use gasoline for cleaning
part s. Use an approved safety solvent.
Alw ays d isc onnect th e batte ry ground H ca ble at the b att ery
before w ork ing on any part of the fuel system or elec trical syste m.
Never risk spilling fu el on a ho t engin e or exhaust co mpo nent. It is
stron gly reco mmended that a fire extinguisher suitable for use on fuel
and electrica l fir es be kept handy in th e garage or w orks hop at all
times. Never try to extinguish a fuel or electrical fire with water.
Fumes
Ce rt ain fumes are highly toxic and can qu ic kly c ause
unconsci ousn ess and even death if inhaled to any ext ent. Gaso line
vapo r falls int o th is cat egory, as do th e vapors from so me cleaning
solvents. Any draining or pourin g of such volatile fluid s should be don e
in a well ventil ated area.
When using cleaning fluids and solvents, read t he instructions on
the container carefully. Never use materials from unmarked containers.
Never run the engin e in an enclo sed space , such as a garage.
Exhaust fu mes contai n ca rb on monoxid e, w hic h is ext remely
poisonous. If you need to run the engine, always do so in the open air,
or at least have the rear of the vehicle outside the w ork area.
If you are fortunate enough to have the use of an inspection pit,
never drain or pour gasoline and never run the engine while the vehicle
is over the pit . The fumes. being heavier than air, w ill co ncentrate in the
pit with possibly lethal results.
The battery
Never create a spark or allo w a bare light bulb near a battery .
They norm ally give off a certain amount of hydrogen gas, wh ich is
highly explosive.
Alwa ys di sc onnec t th e ba tt ery grou nd (-) cable at th e ba tt ery
before working on the fuel or electrica l systems .
If possibl e, loosen the filler c aps or c over wh en chargi ng th e
batt ery from an extern al sourc e (this do es not apply to sealed or
m ain te nan c e-free batteries). Do not charge at an excessive rat e or
the battery may burst.
Take care w hen add ing wat er to a non maintenance-free batt ery
and when carrying a battery. The electrolyt e, even when diluted , is very
co rros ive and should not be allowed to co ntac t cloth ing or skin.
Always wear eye protecti on wh en cleaning the batt ery to prevent
the caust ic deposits from entering your eyes.
Household current
When using an elect ric power too', inspec ti on light. etc.• wh ich
ope rates on household cu rrent, alw ays ma ke sure th at the tool is
co rrect ly con nected to its plug and that. where necessary, it is property
grounded . Do not use such items In dam p conditions and. again , do
not create a spark or app ly excess ive heat in the vicinity of fuel or fuel
vapor.
Asbestos
Secondary ignition system voltage
Certain frict ion, insulating, sealing, and other produ cts - such as
brake linings. brake bands, clutch linings, torque converters, gaskets ,
et c. - c ont ain asbes to s. Extreme care mu st be taken to avoid
inhalati on of dust from suc h pro ducts, since it is hazardous to health. If
in doubt, assume that they do co ntain asbestos.
A severe elect ric shock can result from touching certain part s of
the ignition system (such as the spark plug w ires) when the engine is
running or being crank ed, particul arly If co mpo nents are dam p or the
insulation is defective. In the case of an elect ronic igniti on system, the
secondary system voltag e is much higher and could pro ve fatal.
1·1
Part 1 Introduction
Chapter 1 Basic carburation
1
Co ntents
Section
Air/fue l ratio variati on •..••.........
.__.•.••••...•••........_.__ .__....••••..••...•.__
2
Function of a carburetor •......................•....•••......
......••••............
1
T amperproof carburetors ..
..
9
The simp le carbureto r
.
", ......
3
The SU carburetor
"
" "
" .......
6
1
Func t ion of a ca rb uret or
The m odern int ernal combu stio n engi ne ha s b een de veloped
co nsiderably from its original concept in a number of ways. including
increased power outpu t . greater flexibility and mor e efficient
combustion of fuel. As a direc t result of this , the role of the carbu retor
has bec ome an increasingly important factor, requiring freq uent
modific ation an d the Introductio n of m any previ ou sly unh eard of
devices to improve its funct ion.
Carburetor techn ology is, of cour se, a vast subject , and to cover
all aspect s would require a volume of books : howe ver, it will be helpful
for the rea der to be acq uainted with the ba sic fac tors con ce rning
ca rburatio n. It will then be easier to understand the functi on of th e
various co mpo nents w hich make up the Weber carburetor .
The prime objective of any carbu retor is to meter a mixt ure of fuel
and air to th e engin e in a form th at ca n be bu rn t quic kly and
completely. In prac tice thi s is rarely ac hieved , although the mo dern
carbur etor is much imp roved on its original counterpart and there is
every indicat ion of fur ther ad vancement . Ide ally, for complete
combustion, the air/fu el mixt ure must be supplied to the engi ne in
vapor form. This leads us to the secondary objective of the carburetor,
wh ic h is to break up or ato mize th e fuel and disp erse It into the air
passing into the engi ne. The effi c iency with wh ic h the c arbu retor
carries cut this pro cess largely det ermines the eff ic ienc y o f
combustion withi n the engine.
The third objective of the carburetor in the aut om ot ive field is
neces sary . owi ng to the c onstant cha nge of engine sp eed resulti ng
from the vehicle ac celerating and de celerating. The carburetor must be
able to vary the am ount at fuel supplied to the engine in ord er to cope
with the differen t speed and po wer requirements encountered . This
also requi res that the quantity of air be varied. alone w ith the fuel, to
pro vide a combustible mixture.
Section
The Weber carburetor _.._............................................. ...................
The Zenith Strombe rg carbu retor
_._.._
Thermostatica lly controlled air cleaner
USA carbureto rs.......
.
Weber By-Pass idle carbureto rs
2
4
5
8
10
7
Air/fuel ratio vari ation
The theoretic al air/ fuel ratio for complete comb ustion is c alled the
stoichiometric AIF ratio and under labo ratory co nditions is in the region
of 15:1 by weight . Whe n the fuel is fUlly vaporized, the ratio by volume
is bet ween 50:1 and 60: 1 because fuel vapor is de nser than air.
Howev er, fuel will tolerate a wid e range of mixtu re ratios varying from
about 8:1 to 22:1 by weight.
The st oichiometric AJF rat io doe s not give maximu m power or
m inimum fuel co nsumption. thes e two requirements bei ng ob tained
w ith AJF rati os of 12.5:1 and 16:1 respectively, as shown in Fig. 1.1.
The curve s of the graph are important with regard to the tuni ng of a
I
I
--
N
I
I
S PECI F"l C
FUE L
CON SU MPTION
H P·h
i-
~L
----~
I
I
r-..I
!
'0
--.,
'<
I
I
ra
_
-
0 ptim .. m
P OWE R
HP
Poor
,~
-of'\~
I
I
ra
,g
eor re ct
Fig. 1.1 Curves show ing the effect of th e variat ion 01 the air/fuel
ratio on power output and fuel consumption
1-2
Part 1 Introduction Chapter 1
Fig . 1.3 The principle of fuel flow into a venturi. Large arrows
indicate air flow, small arrows indicate fuel flow
Fig. 1.2 The principle of the venturi
ca rb ure to r, as they enable t he operator to tu ne the engine for
maxi mum power or maxim um economy wit hin defined limits.
It should be obse rved that an engine w ill run w it h AJF rat ios
out side the 12.5:1 and 16:1 limits, such as when sta rting (1:1 N F ratio
weakeni ng to 4: 1 N F rati o. but unde r nor mal co ndit ions th e rati o
should be w ithin the limits In order to obtain optimum power or fuel
consumptio n. There are additional ad verse effec ts w hich occur as a
result of AlF ratios outside the limits.
A weak mixtu re bum s considerably slower within the combustion
chamber and as a result may still be burning when the piston reaches
the end of its power stroke . This leads to overheating and . in extre me
cases. burnt valves and piston crow ns.
A ric h mi xt ure w ill cause c arbo n to form rapidly on the
combustion chamber and piston crown surfaces. This w ill necessitate
a prema ture de- car bonizing pr ocedure on t he pis to ns an d valves.
Spark plug perform ance will be impaired and exce ss fuel will
con taminate the engin e lubricating oil and cause rapid wear of the
cylinder walls .
Exc essively ri ch or lean mixt ures also inc rease the am ount of
toxic emissions in the exhaust gases. In some countri es this has led to
th e des ig n and intr odu c tion of emission contro l systems. It wi ll
theref ore be appre ciated that mixture control is extremely critical over
th e comp let e range o f engine speed s and lo ads. and the correct
func tioning of the carburetor is therefore an important if not essential
factor.
The mixture co ntent of a particular engine can be tested by using
an exhaust gas analyzer to determine the amount of ca rbon monoxid e
(CO) present. The instrumen t is partlcularty helpful wh en adjust ing idle
Cutaway view of a typical eCOE
Weber carburetor
mixture sc rews in order to supply the correct AJF mixture necessary for
good co mbustion. Exh aust gas ana lyzers are ava ilab le from special
tool companies and their use may very well become compulsory in t he
fut ure in view of the tre nd tow ards tigh ter regulations regardi ng air
pollution.
3
The simple carburetor
All mod em carburetors are designed around one basic princ iple.
This is illust rated in Fig. 1.2 which is a cross -sectlon of a tube havlnq a
curved restricti on within it. The restrict ion In a ca rburetor is termed a
venturi . If air is drawn throug h the co mpo nent it w ill increase in speed
in proportion to the cross-s ectional dia meter of the venturi. Since the
air dens ity de creases progressively to a poi nt w here its velocity is
greatest, the air pressure at the smallest section o f the venturi will be
co nsiderably less than atmospher ic.
In the carburetor, this pheno meno n is expl oited by Inserting a fuel
out let or nozzle into t he vent uri, this being suppli ed by a reservoir or
float chamber (Fig. 1.3). Note that under static conditions, the fuel level
in the float chamber is jus t below the nozzle outlet in order to prevent
fu el fro m leaking into the noz zle ; also th e air pr essure in the f loat
chamber is identic al to that at the nozzle, i.e. atm osph eric. When air is
drawn through the venturi arrangement it w ill be observed that. due to
the difference in air pressure at the float chambe r and outlet nozzle, the
fuel will flow out of the nozzle and mix with the air. On an engine, the
resu lting m ixture is drawn into th e cylind ers and c ombustion takes
place.
1-3
Part 1 Introduction Chapter 1
IIII
I
2
\5
(
5
Fig . 1.5 The Weber idli ng speed system
Fig . 1.4 The Weber air bleed c orrecti on system
1
2
3
4
Nozzle
Air bleecJ jet
Emulsion tube
Reserve wef!
5
6
7
8
Main fuel jet
Float chamber
Venwri
Throttle valve
In order to maintain the lev el of the fuel just below the nozzle
outlet, a float controlle d inlet valve is incorporated into the flo at
c hamber. As the fuel flows out of the nozzle its level drops and the float
opens the valve; when the correct level is reached the valve shuts.
To regulate the amount o f mixtu re adm itt ed to the engine. the
ca rburetor is pr o vided with a thro tt le va lve w hich. w hen c los ed ,
completely seals the engine side of th e venturi.
Unfortunately, the simple carbur etor has one fault which renders
it unsuitab le for use in the road vehicle where the engine is operated at
variable spee ds and loads. In its present form , the air/fuel mixtur e will
be cons istent provided the air flow remains at a constant speed . If the
air flow is increa sed , its density will de crease in tar great er proportion
to the liq uid fuel, with the result that the mixture becomes progressively richer. If the air flow is dec reased the mixture will progressi vely
weak en.
Anoth er fault is t hat the sim ple carbureto r makes no provision for
engine idling , accelera tion . or co ld starting. It is therefore ob vious that
additional modi ficati ons must be made in ord er to adapt the carburetor
for automotive use.
4
The Weber carburetor
Carburetor manufactu rers have overcome the defi ciencies of the
sim ple carbureto r in various ways. With the use of sophisticated test
eq uipment , Weber has develope d t heir carbu reto rs to a very hig h
st andar d and have pro ved to be leade rs in th e fi eld o f carbu retor
manufacture.
To overcome the mixture enrichening phenomenon mentioned in
Section 4, the Weber carb uretor is equipped with an air bleed system.
Reference to Fig . 1.4 shows that as the fue l flo ws from t he float
chamb er to the nozzle in the venturi, it passes a tube called the
emul sion tube), w hic h is vente d to atmospheri c pr essure and
add itionally has a num ber of hol es drilled throughout its length. The
effect of the depression act ing on the nozzle will not only draw fuel int o'
the carburetor but also air through the air bleed jet and into the fuel via
the holes in the emulsion tube . As t he engine sp eed increases, the fuel
level inside the emu lsion t ube low ers with th e result that mo re air is
released into the fuel. The fact that the fuel becomes emulsifi ed also
results in better atomization at the nozzle.
In the Weber carburetor the emulsion tube is removable and by
varying its diameter, location of holes and diameter of the air bleed jet.
the mixture strength for a parti cu lar engin e ca n be adju sted to fine
limit.
At engine idling spe ed there is insuff icient vacuum in the vent uri
5
4
5
6
1
2
3
Air jet
Fuel jet
Main fuel jet
4 . Idle spe ed mixture
ori fice
7
Progre ssion orific e
Idle mix ture adjusting
scre w
Throttle idle speed
adjusting screw
to dra w any fue l fro m the nozzle: so a separate supply o f fuel is
channelled to the engine sid e of the thrott le valve where there will be
greater vacu um, since the thro ttle is clo sed. Rg. 1.5 illustrates a typical
idl ing speed circ uit an d it will be obse rved that a fuel jet and air
corrector jet is inco rporated to pro vide a combust ible mixture; the air
jet also prevents a syphoning effect throug h the circuit. A volume of
mixture adj ust ment is also incorp orated , so that it is possible to vary
th e mixture strength as necessary in cooperation with the throttle valve
adjustment screw , which con tro ls the amo unt of air allowed pas t the
t hrott le valve at idlin g.
It should be noted that the idle circuit is supplied from the low er
regi on of the emulsion tube. This arrangement ensures that the idle
ci rcuit cease s or is in so me instances reversed w hen the main fuel
system is in operation.
Th e Weber car buretor also inc lude s w hat is termed as a
progression func ti on. When the throttle valve is open slightly atter
be ing in the idling position, there is a tendency for the mixture to leanout and t hus cause the engi ne to misfi re. To overco me this prob lem,
on e or mo re transit ion orific es are drill ed into the idling circui t on the
inlet side of the thrott le valve and in the carbu retor barrel. Reference to
Fig . 1.6 wi ll show that the vacuum on the engine side of the throttle
valve is progr essively introd uced to the tran sition orifi ces and ext ra fuel
is thus provided to cove r this stage of increasing engine speed. When
the engine reaches sufficient speed to draw fuel from the main nozzle,
t he prog ression functi on will cease.
Wh ere t he th rottle valve is ope ned fully and quickly, even th e
progression orifices are insufficient to enric hen the mixtur e enough . In
Fig . 1.6 The Weber progression syst em
Idle spee d mixtu re orifice
2
Progression orifice
1
1-4
Part 1 Introduction Chapter 1
2
-
9
I
10
11
II!
.'"'D
I
,
9
i---
8
2
I
ro·;.;,
I~ I
I
3
4
6
Fig. 1.7 Th e Weber piston type acc el erator pump
1
2
Operating rod
Spring
Control lever
Throttle valve
Intake valve
3
4
5
6
7
Pump p iston
Discharge jet
8
Ffoatcharnber
9
10
Delivery valve
Pump jet
when the throttle is closed, because this action lifts the pump
ope rat ing rod by way of a lever. When the throttl e is ope ned , the
operating rod is free to move the piston down its bore under t he action
of the accelerator pump spring . Fuel is channelled past a one-way ball
valve, thro ugh the pump jet, and thus mixes with the air being drawn
into the engi ne. The fuel is prevente d from re-enterlnq the fl oat
chamber by a ball and seat in the intake valve, but in order to calibrate
the amo unt ot tuel injected, a disch arge hole aI!ows a certain amount
of tuel to return to the float chamber. The disc harge hole also prevents
fuel being injected during slow throttle movement.
The diaphragm type pump operates in a similar manner, except
that a spring tens ioned diaphragm is used instead of a piston.
The final failure of the simp le carbu retor co ncems col d start ing. In
th is respect there are two ma in methods employ ed in the Weber
carburetor .
1-
~~~~~:; :;; -
3,
fJ
,,;,,;,
,...
~l"
Operating lever
2
3
Pump spri ng
Diaph ragm spring
Cam fever
Rolle r
ThmNle valve
4
5
7 . Discharg e je t
8
Diap hragm
9
10
11
The first method employs wh at is b est descri bed as a separate
carburetor within the main c arburetor. Fig. 1.9 shows the system in
basic for m, It w ill be observed that the system ca n be introduce d or
regulat ed by means of a manually contro lled valv e, The system is
design ed to give the necessary enrichment of mixture for starting with
the throttl e valves in the idli ng position .
The second met hod is shown in Fig . 1.1 0 and is te rmed th e
strang ler or shutter valve type. With this syst em, an offset valve is
pos itioned in the carburetor inlet and by restr ict ing the amount of air
admitted to t he ca rburetor. the quantity o f fuel emerging from the
nozzle is increased, thus enriching the mixture for starting. Once the
engine has started, the mixt ure must be weakened and this is automat ically taken car e of by the off set design of th e stra ngler valve. As soon
as the vacuum below it reaches a pred etermined level, th e larger area
of the valve w ill b e dr aw n do wn wards aga inst t he tension of a
calib rated spring and add itional air will thus be admitt ed.
The strangler valve may be ope rated manually or automatically,
bu t in either case must be returned to its fully open position as soon as
the engine reaches its norma l op erating temperature.
The range of Weber c arbureto rs includ es variations of the
fun cti on s so far desc ribed. Where necessary the re wil l be further
descriptions in detail in th e relevant Chapters of t his manual dealing
with t he individual carburetor types.
F=-::..- - -- -.?
~ "-~===~=-::
1
f'\'
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5
•
4
\
6
Fig . 1.10 Th e Web er strangler
type choke
1
2
l
7
3
4
5
Ch oke valve
Nozzle
Venturi
Throttle valve
Calibrated spring
-·-==<
,j, 1
\
11 . \ \
Fig. 1.9 The We ber je t type chok e
Starting mixture
chann e'
Starling air j et
Valve
4
5
6
7
Reserve well
Thro ttle valve
Starting fuel je t
Float chamber
-
-1 ..._1
JI I I \
J
I
2
3
Intake valve
Deli very valve
Pump jet
F-:::-__- -=-_-.::
- -- - -
-
2---
5
Fig. 1.8 The Webe r diaphragm ty pe accel er ator pump
1
6
this case an accelerator pump must be used. Figs. 1.7 and 1.8 show
the two types of accele rator pump used on Weber carburetors .
With t he piston type pump. fuel is drawn from the float cham ber
4
I \ \
!, .
I
\ \
3
1-5
Part 1 Introduction Chapter 1
On e of the most sophisti cated St romberg
CD ca rbure t ors. the COSET
ven t
Equally so phist icated b ut with o ut
the thenno static starter, th e eDSE
da mpe r assem b ly
cover
sprang
sucti o n chamber
lJ.I lde rod
diaphragm
air va lve
vent to under5kte
of diaphntgm
;:3;.!8
Fig . 1.11 Th e ba sic Stromberg
CD c arbur etor
body
m.xon, c namber
throttl e pla te
air flow
b ridge
-------
l...~ .. ~
c:i>
------t:;;:::;::;=:::;:;:::;::7."'f
-----or.
.:
~
.
1/
~ ; ....~..~:;::~
-,
»,
needle
~v~
Hcet chamber cOIltainin 9
inlet valYi! a nd float
lomined fo r claritv)
-;:.-: .: . s,
5
The Zenith Stromberg carburetor
Z enith Stromberg ca rb ureto rs are eng ineered w ith a new
ap proach t o the basic fundamenta ls of carburet or design . If the airfl ow
can be increased w ithout Increasing the depression and the fuel flow
can be co ntr olled by automaticall y varying the size of th e jet, then the
mixtu re ratio can be mai ntained con stant over a large range of airflow
ch aracteristics.
The air valve pr esents a co nstriction in the bore of the bo dy and
forms a "venturi" . It moves in a ci rcu lar hol e in the top of the bore
which is ma chined t o gi ve a very c lose fit on th e air valve wi th o ut
actu ally touchin g it. The air valve has a central extension, the guide rod
w hich slides in a sleeve in the cover . A flexible diaphragm , trapped at
its outer edge betwee n the top of the bod y and the cov er and secured
at center to the air valve. forms a suct ion chamber with the cover. The
suction chamber is in co mmunicat io n with the downstream (engine)
side of the air valve via a vent hol e in the base of th e valve. A circular
thrott le plate hinges in b earing s at each sid e of the ch o ke bore
do wn stre am of the air valve. A float chamber cont aining the inlet valve
and float mechanism below th e body , supplies fuel t o a jet fix ed in th e
bott o m of th e c ho ke bore at the ra is ed b ridge. The jet receives th e
lower end of a tapered needle fitt ed to the unde rsid e of the air valve
(refer to Fig 1.11 ). A vent pa ssage co n nect s t he area be low the
1
1-6
Part 1 Introduction Chapter 1
Rod guide
Piston rod
Su ct ion chamber
Suct ion disc
Piston
Air rectifier
Indu ction pipe flange
hOle--1~~~~W
Suct ion air entra nce
to suction cham ber
•
Taper needl e
J et
F loat cha mber
o
Fig. 1.12 The basic SU carburetor in si m plified cross-section
diaphr agm wit h atmosphere.
Airflow pas t the air valve creates a red uced pre ssure in the mixing
c ham ber (the pa rt of the choke bore between the air valve and the
throttle) wh ic h is se nsed in the suction ch ambe r. The air valve rises to a
height which is gove rned by the magnit ude o f the depression in the
suc tio n cha mb er ba lanced by the weight of the air valve (and the
expansion forc e of the spring. when fitted). These forces (upward and
downwa rd) m ust always be in balanc e. Because the air valve is free to
ris e or fall it will hunt fo r a posi tion w here the two forc es are in
equili brium. If the airflo w is increased. (by open ing the throttle), the
suct ion deve loped in the mixing chamber w ill be sensed in the suct ion
ch am ber. As thi s suction forc e is great er than the weight of th e air
valve (plus the sp ring load) the valve will lift , increasing the area of the
choke. This allows more air to pass but as the choke area is larger the
velocity remains t he s am e and th e depression is unchanged.
Movement of the air valve causes the tapered needle attac hed to it to
be withdrawn fro m the jet , thu s increasing the annu lar area around it
and permitting more fuel to pass. The rate of increase of fuel flow with
need le lift is determined by the tape r of the needle.
This description of the operation of the const ant depression (CD)
carburetor appli es for norma l running (engine co mp lete ly warm) and
running at part or full throttle
6
The SU carburetor
SU carburetor s are engineered with a new app roach to the basic
f undam ent als of ca rb ureto r design. If t he airflow c an be increased
without inc reasing the depression and the fuel flow can be con troll ed
by autom atically varying the size of the jet. then the mixture ratio can
be maintained co nsta nt over a large range of airflow charact eristics.
The practica l expres sio n of this co ncept takes the form show n in Fig.
1.12.
The piston present s a constriction in the pipe and forms a v enturi.
It slides within t he ch amber whi ch is in commun ic ati on w ith the
dow nstr eam side of the piston, throug h a port in the pist on. Airflow
past the piston creates a reduced pressure in the mixing chamber (the
part of the pipe down stream of the pisto n), w hich, is sense d in the
suction chamber. The piston rises to a height which is go verned by the
magnitude of the depress ion in the suct ion cha mber balanced by the
wei ght of the piston. These two values must always be in ba lance. As
the pisto n is free to rise or fall it will hunt for a pos ition where the two
fo rces are in equilibrium. If the airfl ow is increased , (by opening the
throttl e), the suction developed in the mixing chamber w ill be sensed in
t he sucti on cham ber. As this suction force is greater than the weig ht of
the piston. the pist on w ill rise, increasing the area of the choke. This
allow s more air to pass but as the ch ok e area is larger the velocity
remains the same and the depression is unchanged. Movement of the
piston causes the tapered needle attached to it to be withdrawn from
the jet , thus increasing the annular area around it and permitt ing more
fuel to pass. The rate of increase of fuel flow with needle lift is easily
regulated by the desig n of the taper of the need le.
This is t he principl e of operation of the SU c arburetor and it is
termed a constant depression, or variable choke , instrument.
The four ty pes of SU ca rburetors dealt w ith in this manua l - H,
HD, HS an d HIF - are all of horizontal typ e, i.e. the bor e of t he
ca rbur et or is hor izon tal, and the ax is of t he pi ston and suct io n
chamb er is therefore vertical , when mounted on the engine
Som e vehicles w hich have very restrict ed engine bay space may
have the carburetor mounted at an angle, w hen viewed from the side
of the unit, to facilitate install ation andlor servicing. The angle. normally
20° or 30°. is achieved by th e u se of an adapte r o r curved intak e
manif old, the carburetor being basically a horizontal type . (The flange
face s are still at rig ht angles to t he bore. ) This type of installation
geome try is termed 'semi- downdraft' .
Ca rburetor s may be right - or left -handed accord ing to the
po sit ion of the choke and thr ottle interconnection. The unit is righthanded if the linkag e is on the riq ht -hand side w hen looking into the
inlet, and vic e versa. Note that on type s Hand HD the float chamb er
may be on either side. and th at its position is not rele vant in t he
hand ing of the unit.
1-7
Part 1 Introduction Chapter 1
LEFT HAND INT ERCON NECT ION
\~
Plan view
engiOt' f lall{l l!
"',,
...
Series onlvl
LOO KING INTO INLET.
I
"
LOO KING INTO INLET
Fig . 1.13 Float c hamber position s on the SU carburetor s
The float ch amber is normally mo unted In front of the ca rburetor.
In this pos ition. floodi ng at the jet when go ing downhill, and starv ing
the jet wh en going uphill, is prevented (refer to Fig 1.13).
7
Weber By-Pass idle ca rburetors
A mo re recent Weber development is the bypass idl e ca rburetor
whic h has been int rod uc ed as a resu lt of leg islatio n c oncerning
atmospheric polluti on. Weber carburetors eq uipped with th is funct ion
have t wo ind epend ent idl e systems: th e first is th e basic idle system
whi ch is fitt ed to all c arbu retors an d the sec ond is t he by pass idl e
system.
Reference to Fig . 1.14 w ill show the operation of the bypass idle
system . Fuel from the float chamber is drawn through th e secondary
main jet (A) to the second ary idle jet (R) where it becomes emulsified
w ith air drawn t hro ugh t he calibrated orifice (e). The m ixture is then
drawn th roug h interr.al channels and a cal ibrated drilling and m ixes
w it h air sup p lied th rough the dri lling (0) in the pri mary c hoke . Th e
by pass idle adj ustme nt screw (E) co ntrols the amou nt of m ixture
adm itte d to the disch arge ap ert ures (F and G) w hic h t hen is draw n
th rough the inlet manifold and into the engi ne.
On some by-pass idle carburetors there is a fuel return syste m to
prevent the fue l in th e float c hamber from be ing heated excessively,
whic h co uld otherwise enrich the idle mixt ure. With this system t here is
a con tinuous flow of fuel fro m the fuel tank to the carb uretor inlet and
back to the fuel tank .
Another feature inc luded on bypass idle carburetors is the ant istall or low vac uum en richment de vice, w h ic h is normall y fitt ed to
vehlcles with automatic transm ission w here there is a tendency for the
eng ine t o stall w hen m oving th e se lector. Th e d evi ce comp rises a
sp ring tensioned dia phragm and c over, usua lly loc ated in the vicin ity of
the float c ham be r op posite the accelerato r pu mp . Und er normal
operati ng conditions, engine vacuum hold s the diaphragm against th e
sp ring pressure and fuel is drawn into the c hamber of the device . If the
engine tend s to stall , the vac uum will decrease and the spring tension
wil l c ompress the di ap hragm and eject fuel fro m th e chamber. The
de v ice is c onnected by intern al channels to the acc elerat or pump
d elivery valve and jet, and th e fuel is injected int o the primary barrel
thus pro viding mixture enrichment in or der to overcome th e stall.
8
Therm osta t ica lly controlled air cl ean er
This type of air c leaner ensures a constant tempe rature o f the
intake air so that fuel atomization in the carbureto r takes place using
air at the correct tempe rature. The air cleaner incorporates tw o inlets;
one w ith fresh air at amb ient temperature and the oth er w ith air heated
by the exhau st manifold . An internal flap determines the q uanti ty of
heated or coo l air to admit to the carburetor and is co ntro lled by a heat
sensor and vac uum assista nce .
Whe n th e engine is co ld, heated air is directed fro m t he exhaust
manifold into the air cleaner, but as the engine warms up . cold air is
progr essively mixed with this heated air. At high amb ient temperatures
the hot air intake is closed off co mpl etely.
9
Tamperproof ca rburet o rs
A further recent development as a result of atmosp heric pollution
co ntrol, is the tamperpro of ca rbu retor on whi ch va rio us adj ust ment
screw s are sealed with plastic plugs. The ty pe of tamperproo fing varies
acc ord ing to t he carburetor and in some instances spec ial tools are
required in order to remove the seals. Howe ver before removing them ,
t he owner is advised to b e awa re of any leg islat ion which may be
contraven ed by removing the seals and making adjustments. In some
temtori es a co lored seal, only availab le to gara ges , must replace the
remo ved sea l. In this instance, it is recom mend ed that the owner
ent rusts his c ar to a suitab ly equip ped te c hn ici an to c arry out any .
adjustments to the carburetor.
10 USA carburetors
Carb ure to rs used in the USA ma y have some or all o f the
following items fitt ed to them; the exact line-up will dep end on local
legal requ iremen ts :
Deceleration valve
During d ec elerati on th is va lve su pplies an ad dit ional flow o f
air/fuel mixture into the inlet manifold in order to improve combustion
w it hin the engine; this in turn lowers the hydroca rbo n emission in the
exhaust gase s. The valve is mou nted on the inlet manifold and consist s
of a spring loaded diaphragm , a co ntrol valve, and tw o po rts. Under all
dr iving conditions exce pt deceleration , the spring holds the valve shut,
bu t du ring d ece leratio n the additional vacu um open s the valve and
extra mixture is supplied to the engine. To prevent over-enric hme nt
duri ng the engi ne warm-up period whe n th e cho ke is in operation, the
cont rol valve, whi c h is temperature sensit ive to the cooling system .
on ly op erates th e d ec eleration va lve w hen no rmal op erat ing
tem perature has been reached .
Evap orative emission control
Thi s sys tem prevents unburnt hydrocarbo ns in th e form of fu el
vapor from escapi ng from the vehic le fuel syst em into t he atmosphere.
1
1·8
Part 1 Introduction Chapter 1
I
H
\
iii c:=>
OU - .
vii=:>
Fig . 1.14 The Webet" bypass id le system
(1)
AIr supply
(if)
Fuel SIJPpIy
Ai,tf wl mll(furo
Secondary main jet
S eeondafy id le je t
(iiI)
A
B
G
D
E
F
Plain air SlJppfy
Bypass idle adj ustment SCf8W
Fixed dISCharge aperture
G
H
Seco ndaty emulsion tube
Bypass dIscharge aperture
Air bJHcJ
The fuel syst em is sealed and t he carburet or is vented internally so that
th e fuel vapor cannot escape when the vehicl e is stationary. The build
up of vapor in the fu el tank and carburet or is channelled via pip es t o e
canister co nt aining act ivated car bon parti cles which absorb th e vapor,
wnen the engine is running, me activated carbo n releases the vapor
which is then draw n lnto the air cleaner from whe re it passes into the
en\1lne.
E)(haust Gas Recirculation (EGR» syst em
This sys tem eeoc ces the em is sion of nitrogen o xid es fro m the
vehicle exhaust pip e by int roducing a sma ll amoun t of inert exnauet
gas into th e inJet manifold . The eff ect at this is to red uce th e pe ak
temperat ures reac hed in th e comb ust ion cha mbe rs , whic h are
respon sibl e forthe em ission of nitrog en oodes.
The EGR valve is lJSuaity operated by vacuum from the carburetor
and sometim es uses ttl e same vac uum tax e-ctt port as that used tor
the distributor advance . althoug h no rmally a separate port is pr ovtaed ,
Ignition advan ce and retard ports
On some engi nes the ignit io n is advanc ed and retarded by
vac uum fro m the carburet or and inlet manifold. On so me car bu retors
bamtake-off port s may be incorporated into the c arburetor.
Dashpo t
This device can be fitt ed to most carbu retors as a bolt -on extra.
Its purpose is to ret ard the action of tile throttle lever" as it retcms to ree
idling posi tion after releasing th e thrott le. This prevents an ave!' we ak
mixt ure, parti cul arly d uring dec elerat io n and therefore red uce s th e
em ission of certain harmful gases from the exhaust system .
Idl e speed step-up valves
On vehicles tnteo w ith air cond il io ning eq uipment , a valve is
usually incorp orated into the ce rb uretcr to Incr ease th e engine Idle
speed sett ing d uting the period wh en the air cooditloning compressor
Is in operation. This is necessary because the additional load on the
oogine wouid normafly cause n to stall. The adjustment of lh ~ var.e will
de pend o n t he type at engine i1 is fitted t o and th erefore th is
Info rm at ion shou ld be obt ained from thO! vehicl e m anufact urer.
However, the overall effect of the step-up valve is to retain I he original
eng ine id le speed wh en the air condit ionin g compressor is in
operat ion.
A smner type o f st ep-up v alve i s so m eti m es fitt ed to li ehlcies
equ ipped wi th aut o mat ic: t ransmissio n. In ord er to pr event stallin g
whe n th e selector lever is moved .
Idle cut-off valve
Th is valve st ops th e f low of fuel or fu el/air m ixture in the id le
c irc uit immed iately th.. ig niti on is sw itchlKl o ff, thus elim inating any
tendency fo r the eng in e 10 run- o n or 'di esel ' . T his is pa rt icularly
imp ortant where low oc tane lead free fuel is used. because the rUl'Kln
cb eractenstce are mer e prom inent witI1 nus type at llIe! .
2-1
1
... .:.
Part 1 Introduction
Chapter 2 Carburetor installation
Co ntents
1
5
4
2
6
Introduction
Due to the mo rtt noe of application s incorporatlng We ber, Zenith
St ro m oet g and SU carbu retors , no attempt w ill be ma de in t his
Chapter to detail all the poss ible arrangements. An out line of the mo re
comm on arrangements of a particular carbu reto r is to be found in the
re levant cre pter of this manual cov ering the c arbu retor in quesuoo.
In this ch apter we will consider the g eneral installation
req uirements of W eb er carburetors, wh ich will already have been
ca tered for if t he carburetor is standard eq uipment on a particular
eng ine. Th e information Will be of speci al interest to those wishing to
install a Weber carbu retOf as a roo-etarcero component.
2
-
Introduction
,,,...
The intake manifold
Vacuum take-o ff points
-
-- - ---- --- -----
.
.
,,,,,, .
. ,." ..,
.
3
7
Consi derin g d ownd raft caronetcrs. it is im portal'lt that lt1ey are
Instal led wittl the barrels vertical, even on engines wh ich are inclined
(beca use of hood hoeight for instan ce) The flo at chamber should lace
the trent of th e ve hic le wit h the flo at fulc rum pin axis across the
vehicle; this wi ll dimin ish t he eff ect of acc elerat ion, brakin g and hili
,
I--~
,,
I
C a rbu reto r posit ioning
The ca rburet or must be positioned so that air w ill have
unim paired access to the Intake and , to prevent t urbulence aff ecting
mixt ure ratios, it is pr eferable for th e air to have as d irect a path of
entry as Is pos sible. With ecedran ca rburet ors. such as the Weber
DCOE range. it is permissible for the cartxaetc r to be inclined upwards
by 5 degrees from hor izo ntal (refer to Fig . 2.1); th e ang le being
measured from t oo engme side flange face t hrough the cem er-li ne of
th e ba rrels. Where two or more sidedraft carburetors are installed ,
rub ber fuel proof d istanc e p ieces sho uld be inst alle d between th e
fta!1gfl faces of the carburetor and intake man ifold. The out er ends of
the carb uretors should be sup ported with a support rod and bracket,
also With rubber mount ings. The support rod should be attached to the
carburetor at one end and the engine block at the other end .
,
Section
Sec tion
Accelerator and ch oke co ntrols
.
.
Air cleaners and air horns........
.
.
CarbtJretor positioning •••••••••••.•..•••.•.......•••••••••••.••...••..•....•.••••••••••••
Fuel lines and hoses
.
I
/
1-.J
I
(----.
I-..-
,
I
----- --
,
Fig. 2.1 Typ ical Webe r sidedraft carburetor
1
2
3
4
Cylinder head
Anti- vib!atIOtl flange
Support rod
Rubber mounting
5
6
AdjusUJb/e rhrott.le
conuaroa
A uxiliary shaft
and oearings
2-2
Part 1 Introduction Chapter 2
o
,,
,,
.:
Fig. 2...2 CorTect location of a single ca rb ure tor feeding fo ur
cyl inder$, showing th e position of the th ro ttle sp in d le
cl Imbing on the fuel levIurefors
\
!
e
,
,!
,
I
i
lr-- J
1
I
I
~
Downdraft carburetors
(
i
1
;
:"
I
v - '.,;
J
~
I,
Vacu um ta ke- off po int s
On w eb er cartaeetcrs no! installed wi th a vacccm take oN point
1
(J
c -
(
,
i '~ _~ __
10
r:
1/
i:
\...... _ ~_.--
Fig. 2.6 Typi cal ca bl@ and rod throttle c ontrol
?
,
,~
l
2-4
Part 1 Introduction Chapter 2
Notes
3-1
Part 1 Introduction
Chapter 3 Maintenance and servicing
1
Content s
Section
6
Sec tion
Air cl eaner
......•..•..•..•.•...
....•..•.•.••...
......•..•..•.•..•..•
....•..•.•....••
3
Engine co ndition............................................
Fuel line s and hoses.............................. .........................................
10
4
Carburetor body ..............
Cleanin g
5
8
Introduction
Maintenance and 3ervi cing proced ures for all Weber, Zenit h
Stromberg . and SU carburetors are Identical and are of a straight forward natu re. Eng ine malfu ncti ons are com paratively rare as a res un
of carburet or faults and wh en they are trac ed t o the carburet or. there is
oft en an outside fact or at w ork, ie. sedim ent in the fuel. It Is th ese
fac tors which w ill be m ainly cons idered in this c hapter; any sp ecif ic
points in connection with a particula r carbur etor being detai led in the
relevant chapte r cr.tbrs manual.
The object of th e procedures is to main tain the carbu renon
equipment in first class cond rtion, whic h wilt also result in good engine
perfo rmance .
2
Intake manifold
Intervals ........................
Introduction
Thrott le and Chok e controls
Tuning
:
.
.
.
4
7
9
Fuel lin es and hoses
f
Che ck all fuel line unions for sec urity and any signs of leaking,
which , If present, will necessitate th e fitting of new seali ng washers
(refer to Fig. 3.1 and Fig. 3.2)
Intervals
Cleaning
This is one of the major req uirements of the fue l and carb uretion
system. Befo re an ending to any other c omponent it Is essential to
clean the exterior of the air cleaner, carbu retor, inlet man ifold and . if
necessary, the engine. To do thi s, brush on a deg reasing agent such
as Gunk, but wnere an air cleaner is not inst alled, seal the carbu retor
apertures with masking tape before applying tile agent. If the eng ine is
.
.
.
being cleaned, place a polythene bag over the distributor and seal any
apert ures with mas king tape . The deg reasing agent can be washed
away With dean water, together With the dirt and oil deposlts.
Remove all mas king tape when cleaning is completed; then, on
non-air cleaner types, wipe around the air intakes with a clean lint free
cloth.
Wh er e th e carbu reto r is standard equipm ent , servicing and
ma inte nance should be ca rrie d out in acc or da nce with the
ma nufa ct ure r' s recommend ations: in th e abse nce of this, th e
proc edur es should be made every 6,000 mil es (9600 krn).
Howev er, if the engine is op erated at high speeds for long period s
or in adverse ccoomons such as dusty terrain, the procedures must be
made more frequently.
3
,
2
.
Fig. 3.1 Check ing the fuel supply hose on a SU carburetor
3-2
Part 1 Introduction Chapte r 3
Fig. 3.2 Chec king th e fuel co nnections on a Stromb erg carb uret or
Fig. 3.3 Check that the air fi ll er is cl ean and there are no leaks into the
carbu reto r (Stromberg ca rb uretor shown)
Fig. 3.4 Checking the air filter elem ent in a SU ca rbu ret or
Fig . 3.5 Check the carburetor mounting bol ts f or the correc t tor que
ob jects or cont act any hot surf aces, such as th e exhau st syste m.
4
Where fitted, the fue l pump filt er and carbu retor fuel inlet fill er
should be removed and brus hed cle an using clean fuel.
5
Air cleaner
1
W here install ed, th e air filter should be rem oved from t he air
cleaner and cleaned. The fire resistant foam type are best cle aned in a
household liq uid dete rgent and water solution and left to dry without
th e use of any additi onal heat. The paper type shou ld be shaken to
remove any accumulated dust and d in (ref er to FIg . 3.3 and Fig. 3.4).
Clean the interior of the air cleaner with a fu el mo istened doth,
2
then wi pe dry with a further lint free doth.
3
Check the security of th e air cleaner and air duct if fitted . making
sure that there is no indicatiOn of leaking gaskets.
4
Wh6i'"e a cr an kcase b reather hose com mu nic ates with the air
cleaner. it snou ld be cleaned. together with the breather valve.
FIQ. 3.6 Checking the carburetor mounting bolts on a SU carburetor
6
2
Chec k all flexib le hoses for deterioration and chafing and renew
them if necessary . Check the sec urity o f all reta ining clip s an d if any
appear to be seized, renew them.
3
Check that all fuel lines and hoses do not rub against any sharp
Intake manifold
1
Ch eck the sec urity 01 the carb uretor mou nting nuts and th e inlel
man ifold mounting nuts on the cy linder head (refer to Fig. 3.5 and Fig.
3.6).
3-3
Part 1 Introduction Chapter 3
___
.~""
Fig . 3.7 Ch eck that all carburetor contro ls are free and work through
th eir full field of travel
Fig . 3.8 On Stromberg carbu retors , check that the damper is
proper oil and tig hten the cap sec urely
Fig. 3.9 Make sure the vacuum conn ecti ons on the carburetor are
sec ure and th ere are no leaks
Fig. 3. 10 Check ing the Ignition advanc e vacuum line
on a SU ca rburetor
2
Examine the inlet manifo ld for fractures and for signs of leaking
gaskets. wh ic h w ill often show up as stains on the adjacent metallic
s urfaces. To de tect minor gaske t leaks , profess ional mechanics
sometim es use a can of are0801 carb uretor cleaner. With the eng ine
idling, a small quant ity of the c leaner is sprayed aro und inlel manifold
joints and th e carburetor throttle s pind le exterior loc atio ns: il a leak
ex ists, th e eng ine wi ll spee d -up as a result of t he mi xt ure bei ng
enrichened. Extreme care must be exercised when using this method
in the interests of fire safety and In any ca se, the procedure must be
carried out in an open space.
3
If th e inlet manifold is heated by the engine coolant, check the
ccoemcn and security of the wat er hoses, tightening the retaining clips
as necessa ry.
7
8
tun of the
C arbure t or body
Check the security of all fittings and the tig htnes s of all nut s and
screws.
2
Check the damper oil on Strom berg carb uretors. (refer to Fig. 3.8).
3
Wh ere an automatic choke is fitted, ch eck the condition and
secu rity of the water hoses and tighten the retaining clips as
necessary. Also check that there are no signs of water leakage: If there
is, the gasket must be renewed .
4
Check tI1at ignition vacuum coonections where fitted , are secur e
and tha t the rubber tube is not perished or cracked (refer to Fig. 3.9
and FIg . 3.1 0).
5
Examine the underslde of the carburetor for fuel leaks.
Throttle and cho ke controls
9
1
Check all co ntrol s for smooth and complete action and renew any
control rod s or frayed cab les as necessary (refer to Fig . 3.7).
Check all balljoims and ball-bearings for signs of deterioration or
2
seizure as well as excessive c learanc es.
3
Check the tightness of all mounting pedestal nut s and balllotnt
retaining nut s.
4
Lubricat e all bearing surfac es of the complet e throttl e and c hoke
control lin kages, inc lud ing any car bu retor accessory devices w ith
mov ing parts.
Tuning
Tuning is probably th e most talked about aspec t of ca r
maintenance, yet it so often misund erstood and misinterpreted. For
instance. carb uretors are oft en spo ken of as going 'out of tune ', but
thi s is not usually the case , as there are few moving parts which co uld
alter the funct ion of the carb uretor to warrant regular 'tuning-up' . Only
at hi gh mil eages is there sign ificant wear in a ca rb uretor and at this
time a co mplete overhaul must be made. What in fact happens is that
the mechanica l conditi on of the engine deteriorates or alters and the
1
ii
3-4
Part 1 Introdu ction Chapt er 3
carburetor, be ing a very sensitive instrument, is adversely affect ed . As
shown in Chapter 1, even a ch ange of fuel could influ ence a carburetor's
performance due to an incorrect M mixture ratio bein g del ivered.
It is not always appreciated that a d'lange of ambient t emperature
or ai r density wi ll influence the operation of the carbu ret or. For this
reason the carburetor may req uire more frequent tuning than th e 6000
mile (9600 km) interval recommended In 5ectiorl2.
Wh en tunin g a carburet or, the comp lete procedure should be
earned out as given in th e relev ant chapter of this manual and , particu !arty with multi pl e fitti ngs, it is not advisabl e to cut short th e procedure
by trying to guess the correct settings.
10 Eng ine c ondition
Carbu reto r performance dep ends to a g reat extent on the
conditio n of the engine. Carburet or adjustm ents and tuning are only
accurate if th e general condition o f the eng ine is good. However th e
average serviceable engine will resp ond w ell t o carburet or luning . as
this comp ensates for general wear of the en gine compon ents. For
example, w orn valve gu ides w ill ad mit ad di tional air to the inlet valves
and this can be com pensat ed fo r by adjust ing the carburetor sligh tly
richer . Uneven w ear in the engine cyl inders may res ult in uneven idling
ch ara cteristics an d th is ca n be cor rec t ed b y slig htly inc reasing the
id ling speed adjustment .
The eng ine components responsible for 'breath ing ' are of course
most important from the po int o f view of carburetion. These inc lude the
cyl inder head , valves and valve gu i& cleaners
Foot-operated tire pump
Ught tla mmer
Center punch
Smallfiles, flat and round
Hand drill
Flat metal scraper
Wh ere nec essa ry, the fo llowing tool s shou ld be ob ta ined from a
spec ialty tool shop;
set of jet gauges
Thread tap and tap holder
Thread die and die holder
4·2
Part 1 Int rod uction Chapter 4
H 11075
Fig. 4.1 Flat metal scrape r
Fig. 4.4 Typica l th re ad die
Fig . 4.2 Set of micron p lug jet ga uges
Fig . 4.3 Thread t ap and tap holder
Fig . 4. 5 Ty pic al Stromberg CD carburetor
FIQ. 4.6 Checking the carburetor flange with a
body
straightedge
It Is Im po rtant th at all tools are in fi rst cla ss or der to preve nt
damage t o the carburetor components. This Is particularly relevant to
screwdrivers which shou ld be ground flat and square before us e.
Always enter sc rewd rivers fully into sc rew slots and s imilar ly fully
engage wrenches before attempting to tum them.
3
Materials
Bel or e com mencing the overhau l p roced ure it is advisable to
obtain the following materials:
Degreasing fluid (paint stripper or thinners will do) \
Gasoline
Clean lint -free cloth
Eme ry clo th (fine)
Eng ine oil (SAE 1OW-30)
Uthium based grease
Fine gri nding paste
Uqu id locking agent
Metal polish
Hand cleanser
4
Spare parts
The t otal amount of spare parts required for the overhaul wi ll not
be apparent until th e carburetor has been completely dismantled . but
at the m inimum a gask.et set should be obtained prior to commencing
wO
~
zur
>
z
"
~
••
.,
"
"
MAIN FUEL JET DIAMETER
" "
-
5.1 This main jet selection chart select s the co rrect size main jet
acco rd ing to the main venturi diameter and the air correction jet
(2 .00 mm standard). Where one choke feeds two cylinders, multiply
the main jet size by 0.90. Where one c hoke feeds a single cy linder,
multi ply t he jet size by 0.75
Weber, unless. of cours e, the vehicle is going to be raced on d iff erent
track s, race events or c hassis arrangements . It is a good idea to write
down all the sizes of the main jets, emulsion tubes, air co rrect ion jets
and any other importan t ca rburetor specifications and retain t hem for
your records.
5
In s t a llin g a W e b er dual c a rbu reto r kit o n a VW engine
Installing du al Weber 44 IDF Carbure tors
The following article involves a complete step-by-step installation
of a Weber carburetor kit (44 IOF) on a 1971 Voikswagen Beetle. The
article is courtesy of Ho t VW magazine and appears in the Novem ber
and Dec ember issue s of 1995. The conversion may appear simple to
many \fIN owners , but patience during the installation , and mechanical
understanding are paramount for smooth, trouble-free operation.
Altho ugh this Weber conversion installation is spec ific to this style
and size VW eng ine , t here are many similar ities t o all Web er
conversions that can be drawn from this article. Follow the instructio ns
carefully and organize the workplace to the point where every part and
tool is acco unted for. Don't force any bo lts or nuts into or ov er an
incorrect thr ead pitc h and make sure ali gasket surfaces are clean and
free of old material.
Techn ically, installing a well-engineered dual Weber carbureto r kit
on your Volkswagen Bug is not all th at compli cated. In most cases, the
kit s hav e all th e nec essary co mpo nents and hard ware requi red to
complete the co nversion, eliminating any inconvenient extra t rips to
the auto part s stor e during th e pro cess. This mak es th e p roc edure
relatively simple due to the fact that detailed instructions are generally
included in the box, along w it h all the co mponents. Sounds like it' s a
straight forw ard and simp le op eration at th is po int . But, lik e many
things these days, there are a few surprises waiting around the co mer
for unsuspec ting VW ow ners taking this route. And , th e unexp ect ed
pro of surfaced, as it usually do es. when many of our readers decided
to send us feedback claiming it' s a lot more complex to install a dual
Weber carbureto r kit than it' s crac ked up to be. This coup led with the
fact that we'v e received word from several Weber carburetor dealers
Part 1 Introduction C hapter 5
5.2 layout of a com plete 44 IOF "PLUS" Weber duaJ ca rburetor kit
5-5
5.3 Use a brass T-sect ion in place of the plastic part
1
"-=
5.4 The project engine is a mostly stock VoN 1600 engine
with dual po rt heads
5.5 Remove the coo ling tin breast plate
c laiming th e main Weber distributo r has sub stant ially improved th e
dua l 40 and 44 IOF kit s and th at th ey now have a bette r lin kage
sys tem . This necessitated a cu rren t inst all ation feat ure in ou r
magazine, prom pt ing us to probe deeper into the subject. What we d id
next was co ntact one of Calif orni a's largest Weber deale rs, Fast
Freddy's, located at 2604 Harbor Bivd ., Santa Ana, CA 927 04; (714)
540-3801, and made arrangements to take delivery of t heir 44 IOF XE
"Plus" kits (refer to Fig. 5.2), along with an STE synchromeler carburetor flow meter, a mandatory tool needed fo r tun ing the carburetors.
This wo uld be a goo d tim e to add th at if yo u're loo king fo r a
drastic increase in horsepower by simply bolting a dual carbureto r kit
onto your stock 1600 cc VoN engine, you've got another think coming.
Keep in mind that a profess ionally-assembled perform ance engine has
a "b uilt-In" balance betw een cy linder heads, cam pro file, exhaust
system and carbu retion. In othe r words , if you're looki ng for the best
results fro m a dual Weber carburetor kit, w e' d reco mmend that t he
eng ine d isplaces at least 1700 co, has a mild profile cam and so me
degree of head work , along with an aftermarke t header system, and, of
co urse, you'l l need a mechanical advance d istr ibutor On our case we 'll
be usin g a Bosch OOg), as opposed t o a vacuu m ad vance system
that' s used on stock \fIN engines.
The best way to begin is by laying out all the parts in the kit and
take account of everything. At thi s po int, you w ill immed iately notice
that you need a few more parts , as we d id. That' s when we head ed
do wn to Kymco Motorsport s, in Costa Mesa, CA, to round up some
extra parts as well as pick their brains as to any add itional sugges tions
they had for improving the installation. At this point you will also need
to make the de c ision of whether yo u wa nt to reta in the stock fu el
pu mp, or switc h over to an elect ric pum p. If you choose to use an
elect ric pump. Facet offers an electric fuel pump rated in different fuel
flow increments. Weber carburetors require 1-1/2 to 3 PSI of delivery,
maximum. Therefore, the Facet UN 750-06 14 is the choice part , and
you will also need four 1/8-inch NPT fitt ings with 114-inch hose barbs
to complete the conversion.
An electric fuel pump should be mounted as c lose to the fuel tank
as possible, and beneath if as well, and should be mo unt ed using
some sort of rubber insulated padd ing. It just so happ ens that a pair of
\fIN Rabbit radiator mounts (part # 171 121 275E) work well and will
make the pump appea r to run much quieter from inside the car. If you
dec ide to retain the stock fuel pum p, which is perfect ly fine, you w iil
need a mech anical fuel pressu re regulator stabilized betwee n 1-1/2
and 3 PSI for optimum results. While we were at Kymco we also picked
up a brass T-f itt ing and about S feet of stock fuel line, in addition to a
see-thro ugh fuel filter, which doubles as a juncti on for the smaller 5mm f uel line and the larg er 5/ 16-inc h lin e to the ca rbureto rs. Th e
Weber kit inc ludes a plastic T-section, but after a short period of use,
they are notorious for c racking ; we all know how dangerous a fuel leak
is near the VoN engine, wh ich is why we opted fo r a brass unit (refer to
Fig.5.3).
Now that you have everyth ing you need, you can begin working
on the car (refer to Fig. 5.4). The previous mentioned order of operation
is very important, especially if you happ en to be working on your only
form of transportation and otherwise have no way of retrieving needed
parts. Begin by removing the gas cap , and disconnecting the battery
cab les as well as the t hro tt le cab le. The next orde r of b usiness is
removi ng the air filter and co oling t in breast plate (refer to Fig. 5.5).
5-6
Part 1 Introduction Chapter 5
5.6 Unbolt the heat risers from the
muffler and .
5.7 . . . remove them from the intake
manifold
5.8 Loosen the boot clamp from the end
casting sect ion of the intake manifold
5.9 Remove the distributor cap and ignition
wires from the engine compartment
5.10 Remo ve the nuts that retain the end
sections to the cylinder heads
5.11 Remove the end cast ing from
the engine
Now, depend ing upon whether you have a stock or afte rmarket intak e
man ifold (ours was a two-p iec e atterrnarket versio n), remo val of th e
intake manifo ld and carburetor assem bly will vary.
If you have a two- piece asse mbly, you can unbolt th e heat risers
from the header system (refer to Fig . 5.6) and remov e them from the
main center sect ion (refer to Fig. 5.7), allowing you to unbolt t he end
cast ings from the head s and remove them from the ma nifol d cent ersection without having to remove the generator or altemator and fan
housi ng first (refer to Fig. 5 .8 through 5.11). At this point you should
disconnect the vac uum lines and fuel line from the fuel pump, plug ging
it to keep gas from leaking out . As state d, if you have a stock intake
man ifold y ou wil l need to loosen th e side bo lts on the fan ho using ,
disconnect t he wires fro m ge nerato r, remove th e strap an d lift th e
generator and fan housing far enough to remo ve the intake manifold
5.12 Remove the intake manifold
center bolt and . . .
and carburetor as a complet e unit (refer to Fig . 5.12 and 5.13). Then,
thoroughly clean the int ake mountin g surfaces using a gasket sc raping
too l. Go ahead and re p lace th e fan shrou d and generat o r in t heir
ori ~nal position, repiacing the generator pulley, strap, nut and fan belt .
Replac e the rear coo ling t in, or br east pl at e, and then you will
need to reloc at e the co il and mount ing b rac ket so t hat it doesn 't
interfere with the dual carburetor linkage cross bar and arms. The dual
carburetor kit co mes w ith a bracket that allows you to mount it off the
base of the fuel pump, sec ured to the engine case . How ever, in our
case we decided to sec ure the brac ket to one of the fan housing sheet
metal sc rews . As per th e W eber installati on instructions , if you use
their bracket, you will need to place the coil adapte r over the rear fuel
pum p stud and reinstall the fuel pum p nut and case nut to secure the
br acket . To rq ue the case nut/bolt to 15 tt.-ro s. Reuse the original
5.13 . .. lift the carburetor/ intake m anifold
assembly from the engine
5.14 Remove the stock distributo r
from the engine
5- 7
Part 1 Introduction Chapter 5
"5.15 A mech anical advance ignition system
is preferred over the vac uum advance
system originally equipped on these engines
5.16 Insta ll custom plat es over th e heat riser
ports left on the stock mutner
5.17 Double nut t he studs for removal
a good tim e to remove your stock vacu um advanc e d istr ibutor and
install the new mechanica l advance igniti on system (refer to Fig. 5.14
and 5 .15). Then, reinstall th e dis tributor cap and ign ition wir es. If you
find th at wor king In the engine co mpa rtment is a litt le tight, it may help
to rem ove th e dec klld as this wi ll provide extra work ing space.
last but not leas t, install th e custom p lates ove r th e heat riser
port s on th e muffler (refer to Fig. 5.16), Use a sma ll amo unt of heat
applica ble silico n sealer betw een th e tw o surfaces .
5.18 Each carburet or is ident ical from Weber therefo re it will be
necessary to cha nge seve ral components on one t o be ab le t o mount
it to the opposite side
sc rews to in sta ll the co il on th e adapter, lacing the w ire te rm inals
to wa rds the number 3 and num ber 4 cylinde rs . Recon nect the co il
w ires, and if you choose to do so , install new spar k pl ugs at this t ime
as it is most convenient to access them no w . And wh ile you're at it,
massage some grease or Vaso line int o the intake manifol d gaskets,
and install them on th e cylinde r heads. Do not use the stock sta mped
metal OEM gaskets.
Anot her thi ng you will need to do is be sure th at yo ur cy linder
heads do not have the locating dowel by the intakes, othe rwise thi s wil l
int erfer e wi th inst all ati on of t he Weber ma nifo lds . If the dowe l is
present, remove it with a pair of vise grips or pli ers. This would also be
5.19 Reverse the throttle stop and linkage
arms on the left carburetor
Carburetor bench assem b ly
For th e m ost part, the general instructi ons that acc ompany the kit
are fairly comp lete, but it' s at thi s point th at certai n procedures need to
take place which are not mentioned in the Weber installati on instructions. For instance, you will need to remove the air horns, or velocit y
stacks , and double nut the threaded studs (refer to Fig. 5.17), removi ng
all eig ht from the pair of carburetors as th ey are not long enough to
exte nd throu gh the lin kage bracket, vel ocity slacks and air c leaner
base. However, new hardw are is supplied w ith th e kit to hand le th e
assembly, wh ich occurs later on .
As you will notic e by looking at th e carb uretors, they are identic al,
with fuel inlets, linkage arms and etc . allan th e same side (refer to Fig.
5.18). To install them on a IfW Bug, you will need to set th em up as a
right and left side unit . Thi s is done by keepin g th e fuel inlet to t he
outsid e position. In ou r case , it was the left carbu retor that needed to
be modified. The fu el inlet and plug locations need ed to be swapped,
as do th e th rott le stop and linkage arm pieces (refer to Fig. 5.19 and
5.20). Then , inst all t he thro tt le lever spacers and loc k nuts on eac h
carb ureto r. Inst all the threaded studs into th e m anifolds us ing th e
supplied loc king compound, or l octite if you prefer (refer to Fig. 5.21),
and t ight en the stud into the manifo ld flange. Next, you ca n bolt the
carb uretors to th e m anifold s us ing th e wavy washers and nu ts
supplied in the kit (refer to Fig . 5.22).
5.20 Make sure the fu el inlet locations
face th e same d irection to ease
fu el line installation
5.2 1 Apply Loctite onto the lower threads
of the stu d before installi ng th em into the
intake m anifol ds
1
5-8
Part 1 Introducti on Chapter 5
5 .22 l1ghten the carburetor-t o-i ntake
manifo ld bolts
5.23 install the left side carburetor first
5.24 Tighten the manifolds onto the cylinder
heads using a speed wr ench and extensions
The instructions tell you to assemble the c ross bar bracket, flange
gaskets, air filter base and air horns at th is ti me, but due to lim ited
spac e in th e eng ine compartme nt we'd sugg est do ing that aft er th e
carbu retor and manifol d assemb ly are installed . Our sugg estion is in
alignment with the Weber instru cti ons, as they mention the fact that
d ue to the length required for the crossbar to seat prop erly in the
brack et , the right and left side parts can not be assemb led sim ultaneou s ly . We simp ly assemb led th em in the ca r and enc ountere d no
problem whatsoever.
Final assembl y
When it com es t ime to insta ll th e carb uret or assemb lies on t he
motor, the left , or d river's side unit, should be installed fi rst (refer to Fig.
5.23). Installation is made easy by using a ratchet wit h a 10- to 12-inch
extension and universal swivel conn ector between the extension and
socket (refer to Fig. 5.24). Secure the manifold in place, then install the
right side manifold and carb uretor in the same manner. Next , hoo k up
th e fuel lines from the fu el pum p to th e c arburetors , being sure to
tighten each hose clamp. Now, slide the center pull lever and the left
and right extens io n arms o nto the c ross-bar so there is a eo o angle
betw een the centerline of the compo nents (refer to Fig . 5.25). Install the
jam nuts onto the ball ends and thread the ball-ends into each end of
the cross- bar shaft . This is a good time to install the comp lete air hom
assemblies, as mentioned earlier and shown in the exp loded view in the
instructi ons, leaving the right side semi-loo se as to allow you to Install
the cross-bar shaft . Then, install the cross-bar self- centering spring in
the left bracket bushing, and insert the left hand ball-end into the left
bracket bushing and spring , first , then do the same for the right side,
before tightening everything down (refer to Fig. 5 .26 through 5.28).
Once the c ross-bar has seated in th e bu shings , secure the air
horn ass emb ly (refe r to Fig. 5 .29). Make sure th ere is 1/32 -inch
5.26 install the air horn assemb ly ont o the
left side carb uretor, . . .
5.25 Install the exten sion arms with a so-eeq ree angle to each oth er
c learance betw een th e bush ing flange and ball flange. Now you can
inst all th e ca rbureto r linkage rods to eac h of th e exten s io n arms ,
c hecking to be sure that they are as c lose to vert ical as possible and
that the o peration of the linkage is totally smooth and not bind ing in
any way at all (refer to Fig. 5.30 through 5.32).
Tuning
Before starting the engine to sync hronize the carburetors, be sure
th e c arb uret or linkage is movin g f reely and the ig nit io n w ires are
installed in the correct firing order. You can now replace the gas cap
5.27 . . . install the cro ss bar self-centering
spring into the left brac ket bushing and . . .
5.28 . . . finally install the right side air horn
assemb ly gasket
5-9
Part 1 Introduction Ch apter 5
5.29 Afte r the linkage has been co mpletely
installed, tighten the right side air hom
5.30 Install the link age arms to the
extension arms
5.31 Tighten ing the upp er linkage ann
adjustment nut
1
5.32 Last, tighten the extensio n arms
to the cross bar
5.33 Use a spec ial tool available from Weber
to sync hronize the ca rburetors
and hook up the batt ery c ables. Reset the ti ming o n the mechanical
distribut or using the static method to get the t iming close before initiai
sta rt up . Sta rt the engine and check for any vacuum leaks. if none
seem to be present, use a timing light to properly set the total advance.
Sy nc hronize and set the idle mix tu re using t he Weber instructi ons
(refer to Fig . 5.33). A simplified method can be perform ed by removing
the linkage rods, and synchronizing the idle speed screws . Install and
adjust the linkage rod s, and then adjust t he bac k barrel air bypass to
match flow of front barrels. If they need more fine tuning, or if problems
see m to be affec t ing performance , co nsult w ith th e Weber
5.35 Tighten the union piece to allow
maximum linkage travel
5.34 Install the thrott le cable into
the union piece
troubieshooting guide .
With the synchronizing process co mplete, tum t he engine off and
proceed with the thrott le cable installation (refer to Fig. 5.34 and 5.35).
Depending upon the type of cable yo u have, the kit co mes with tw o
different union pieces which should work for most ap plications. If you
need to c ut you r cab le, be sure the ca ble is allow ed to mov e freely
thro ugh the entire linkage travel, and tha t you have allow ed enough
cable to fit through the shorter piece and it is securely in place. Then.
co mp lete the installation of t he air clea ner elements, bott om breast
plate and top plates (refer to Fig. 5 .36 and 5.37). Have an assistant
5.36 Install the breast plate into the
engine comp artment
Tighten the mounting hardware
5-10
Part 1 Introduct ion
Cha pter 5
5.38 Using an assistant, depress the acc elerato r pedal and make sure
the carbu retor linkage reach es wide open thr ottle with out bind ing or
hesitation
5.39 The Directory pub lished by Driven by Design, lists complete
information on parts suppliers, restoration shops, upholstery
outlets, etc . co nceming Porscbe mco ets
depress th e acce lerato r and c hec k for b ind ing linkage {refer to Fig.
5.38). Also , c heck fo r ade quate hood clea rance bef or e c losi ng the
decklid. If everyth ing looks goo d, head down the road for a test drive.
Cons id ering th e di ff icu lty fin din g the co rrect parts , labor and
inf orm ation for yo ur resto rati on , Driven by Des ig n Pub lic at ion s in
Carmel, Califo rnia has created a co mp lete list of all the W eber
spec ialty shops on the west coast. This book lists anyt hing from Weber
c arburetor suppliers to restorati on ex perts. The titl e, Th e Directory
(refer to Fig. 5.39), lists specialty shops , distributors, expe rts etc. for
the resto rat ion of Por sc he modeis. This co mp lete listing direct ory is
available th rough Driven by Design 1-4 08-625-9342 .
6
Weber carburet or tips
The do-it -y ourselfer wi ll always hav e q uestions c oncerning
his/ her Weber carb uretor installation and it is best to know a shop and
tec hnician that is knowl edgeable conc ern ing your partic ular ty pe of
vehicl e. Refer to the list at the end of this Section for a co mplete list of
t he W eber repr esent atives in your area. For examp le, Alfa Rom eo
racing enthusiast s should discuss their carburetor id iosyncra sies with
a tr ained Alfa Rom eo tec hnician who has mu ltipl e hou rs experienc e
with installation and tunin g Weber conversions. These spec ialty shops
have knowledge and access to many of the carburetor and manifold
parts that are necessary for the complete job .
M any of th e early model Pors ch e 911s ca me with origina l
eq uip me nt W eber ca r buretors and a large perc entage of t he CIS
mechanical injection mo dels are converted to Weber carburetion. PMO
in Santa Mon ica , Californ ia has tech nica l expert ise co ncern ing
Porsc helWeber in stall at ion s . Ques tions arise suc h as "w hy do the
spark plugs foul quickly wit h my particular size idle j ets r . ~What typ e
of fuel additive is best for the Weber conversion on my Porsche 91 1?".
"What are the b est main je t, air jet, idle j et , emulsion tub e, choke
com binations for my size engine using the Weber 40 IDA 3C(1) setup ?" All these questions require a trained expert who has come across
the problems and solved them many ti mes before. Don't be afraid to
learn as much as possible about your c arburetor set-up espec ially if
you plan to race the vehicle or drive it for performance.
Weber Carburetor company has moved its aftermarket carburetor
operations to Spain and is now co nc entrating on produc ing fuel
inject ion syste ms. Alth ough the Weber co mp any conti nues to build
quality carb uretors, the bulk of the producti on is being shifted into fuel
inject ion. Eventually many of the three barrel Porsche carburetors w ill
be p hased out. As a res uit of t his c hange in po lic y, PMO in Santa
Monica will soon start pro duction of its own three barrel carbu retor for
Porsche 911 engines . Co ntact PMO (1-310-393-5423) for co mpl et e
details.
W eber carburetor c onvers io ns have gathered its own gro up of
speciaity shops and organizations tha t handle anything dealing with
this perio rmance equipment. These businesses range from V8 hotrod
shops to rac ing and speed testing facil ities for Ferrari and Porsch e. It is
a good id ea to iocate many of th ese spe c ialty sho ps by loo king
through magazines and advertisements to gather as much information
possible about your "cu stom or Classic automobile".
Weber carburetor sup pliers and in stallers
AL FA RICA MB I
6644 San Fernando Road
Glendale, Ca. 91201
1-81 8-956-7 933
Weber ca rburetors for Alfa Romeo
DRIVEN BY DESIGN
8440 Carmel Valley Road
Carmel, California 93923
1-408-62 5-1393
Publishers of directory information on Pors che and Weber suppliers
OTTO'S
41 Venice Beach Blvd .
Venice Beach, Ca.
1-310- 399- 3221
Weber perform ance installations and testing
FAST FREDDY'S
2604 South Harbor Blvd .
Santa Ana, Ca. 92704
1 ~714-540-3 801
Weber kits for foreign and domestic engine con versions
WORLDPACK (REDLINE)
303 West Art esia Blvd .
Compton, Ca. 90224
1-3 10-604-8200
Fact ory d istributors for Weber carburetors
A DVANCED ENGINE MANAGEM ENT
15606 South Broadway Center
Gard ena, Ca. 90248
1-310-327- 9336
Performance dyno testing, conversions and installation
P.M.O.
135 17th street
Santa Monica, Ca 90402
1-310-393-5423
Porsche Weber and custo m carburetor specialists
Part 1 Introduction Chapter 5
PRECISION M OTORWORKS
930 East Orangethorp Avenue
Anaheim, ce. 92801
1· 714·879-9072
Porsche Weber carbu retor performance special ists
PERFOR MANCE PARTS
150WlI"eIess Blvd .
Hauppauge. N.Y. 11788
1- 801).654--2778
Weber kits and parts supplier
GREENFIELD IMPORTED CAR PARTS
335 High Street
Greenfield , Mass. 0 1301
1· 413·774- 2819
Weber kits and parts supplier . Expert technicians available
INTERCO
150 Wireless Blvd.
Hauppauge, N.Y. 11788
1· 516· 434-1 818
1-800 -64 5-74 88
Weber kits and parts supplier
M OTORSPORT AUT O
1139 West Col lins Avenue
Orange , Ca. 92667
, -800-633-6331
1-714-639-2620
Weber DGV kits for Z cars
EU ROPEAN RACI NG
2899 West 190th Street
Redondo Beach ,
90278
1·31().37().-3815
Weber kits and parts suppHer specialiZIng in VW and Porsche
ce.
5 ·11
JA M ENGINEERING
886 Abrego Str eet
Monterey, Ca. 93942
1-408-372-1787
1-800-431-3533 (outside C8Jifom ia)
Weber kits for BMW and Mercedes Benz
PIERCE MANIFOLDS
Mike Pierce owner
8901 M urray Avenue
Gilroy , Ca 95020
1· 408-84 2--{j667
Largest distributor of Weber carburetors and manifolds. Spec ialiZing in
overseas and Canad ian production models
NA R.W.
7355 Canby Road
Reseda , Ca.
1-81 8-8 81-1 222
Web er installations and perform ance tuning on Porsches
CENTERLI NE PRODUCTS
4715 Nort h Broadway
Boulder, Co. 80302
1·303-447-0 239
Weber kits for Alta Romeo
MOTORSPORT AUT O
1139 West Collins Avenue
Orang e. Ca. 9266 7
1-800-633-6331
Weber con version kits for teseen Z cars
1
6-0
Part 2 Weber Carburetors
Chapter 6 Type 28/36 DCD
Co nte nts
Section
Assem bly
.
Con struct io n
7
2
Disassembly
Fault di agnosis
5
Introdu ct ion
t
9
Ope ratio n
Removal and refittin g
Special overha ul procedur es ..... .. ... .... •. .
Tunin g
.
Adjustment data
Float le vel setting dim en sion s
in (m m)
Closed po sition
0 . 197 15.0)
0 ,53 1 (13. 5)
Ope n pos ition
S troke
.
0 ,3 3 5 (8 .5 )
Section
3
4
6
B
Part 2 Weber carburetors Chapter 6
6-1
I ntToduetlon
The Webe r 28/3 6 carburettor is of the down draught type
and has two bar rels 10 supply the primary and secon dary funclions; Ih e primary barre l i s of 28 .0 m m dia meter at the th rollie
valve Iocalion and l he secon dary barre l is of 3.60 mm dia me te r.
Eaen throttle valve is mounted on separate shahs and Ih e
valves are of the differentiel Of progressive choke type . The
linka ge bet w een the I WO t hrottle valv es is arranged so th aI t he
secon dary thrott le valve does net com mence to op en unlil the
primary I hrottle valve Is open.
The carbu renor is normally fined 10 t he engin e as a single
unit with both barrels feeding a common inlet manifold . th e
most oommon arr angem ents being as follows:
t
1 One unit on II four-cyfinder in ...Jine eng ine
2 On, unit on II $ix -cyli nder in-fine engine
0 000
-
Fi g. 6.1 Single cerburettor fittod to a fo ur--cylinder in-line
eng ine (Sec 1)
The carbu retlOf iden tifi cat ion marl<. is Iocaled on the lower
frange oute r surfac e.
The main body ar'\d cover of the W eber 28/36 OCO ce rbure nor are made of die-ca st aluminiu m or zinc alloy (M al akl .
the mou nting nange being machined n at for fining on the inlet
manifold . The upper face of th e cov er is also machin ed flat and
inco rpo rates fou r th readed ho les fo r the fining of an air cleaner
(pho lol.
The hrottle valv es and shah s are of brass and th e shahs ron
directly In the carburenor body. All fu el and air jet s and emulsion l ubes are of bras s construct ion and are screw fittings into
the mai n body .
Internal channels of the mai n bo dy and cover are mostly
drilled and are sealed wit h lead plugs w here necessary.
The fu el float assembly compri ses two sem i-floats which
are each of two halves soldered toget her: th ey are made of thi n
brass sheet .
3
cco- cco
Fi g. 6.2 Single carburettor f itted to a six-cyl inder in-lin .
engine [S ec 11
Operation
Cold starting
The ta rt!ng device titted to Iy pe OCO carburetto rs opera tes
Independ ent ly of the main circuit and may be cons idered as a
separate carb lJrellor w it hi n the main carburettor.
W hen the cho ke cable is pulled. th e sta rting dev ice op arat lng lever turns the cont rol shah wh ich lifts the start ing valve off
of Its seat . Reference to Fig. 6.3 wi ll show th at fu el from the
float Chamber (7) Is driven t hrough th e channel (53) to arrive at
the starter fuel Jel (52) . Air ent ering th rou gh t he air correcti on
Jet (5 1) and the bypass channe l emu lsifie s th e fu el as it i drawn
th rough the staning jet ernutsrcn ho les and th e byp ass channe l.
The mixture is the n drawn through the channel (4 8) and pest
the starter valve (501 where add it iona l air from the channel (4 9 1
weakens the mix ture. The fi nal mixture i s drawn t hroug h the
channel 154 1 and into bot h the pri mary and secondary carburettor ba rrels al t he en gine side of the throttl e valves.
Once the engine starts. the vacuum in the channels (54 )
and (571 inc reases t o such an ext ent that the starter plunger
(56) is pulled against spring pressure from the seat (5 5!.
Addi tional air is t hl,ls adm itted to th e mix ture to allow the
engine to continue running.
The starting device has a prog ressive act ion made possible
by the tapered shape of th e valve head. Low erin g th e valv e w ill
reduce the amou nt of mixtl,l re admitted to th e engine. The
sl,lpply w i g cease when th e valve is complet ely shut.
Idling and progression
Refer to Fig. 6.4 and note th at wh en the eng ine is idling th e
SO!l cond ary th rottle valve (37) is complete ly shut . but th e primary
2 .0 Typical air clean er with th e cover removed
th rottle 1131 is slightly open . accordi ng to th e throttle idli ng
adjl,lstment screw setting. Fuel is drawn from t he floa t chamber
hrough an internal chan nel to l he fu el jet in th e id ling jet (34!.
On passin g th rough the fu el jet. air is introd uced to th e fu el from
t he calibrated bush 13 51 and the ho les in the idling jet tube . The
fuel then becomes emu lsifi ed.
The mixture then Pl SSlS through the channel (321. past the
id ling mixture adjust ment screw (201. thrtllJgh th e id ling feed
ho le 13 1) and into th e pri mary carbu rett or th roat at the eng in e
side of the th rottle valve. The idl ing adjustment screw (201 has a
tapered end and can th erefore be adju sted to adm it more or less
fu eVa'r mixtl,lre as necessary.
2
6-2
Part 2 Weber carburetors Chapter 6
B
I
I
' ''~r'~~ '
[
i
4~
49
51
~'=d-""'50
52
7
54
"n..
55
56
Tr';'!-!- 57
Fig . 6 .3 Co ld sta rting de vice ope ratio n 15 K 3 1
7 Float chtlmbef
48 Channel
5' A lrc orrectionjer
52 Stt/rtlng jet
49 Air channel
53 Fuel channel
50 Starter valve
54 Emu lsion channel
Wh en t he primary throttle valve (13) Is ope ned slig ht ly to
inc rease th e engine speed, the prog ressiOfl t ore (3 6) is bro ught
into action to pro vide add itional fuel. Th is is nec essary 10
prevent a fl at spot occu rri ng before the m ain prima ry fu el supp ly
s yst em co mes intOopera tion .
When the pri mary throttle valve (13 1 is 8pp rol(ima te ly i
open , th e secondary thro ttl e valv e (3 71 w in commence to open.
This actio n causes the secondary progression hole (3 8) to be
blougtl t under engine vacuu m. Fuel is the n drawn from th e float
chambe r to t he seconda ry idling ;e tI2 71. where air is introduced
from th e calibra te d bush (26 ). The m ilrture passes th roug h the
chann el (29 ) and thus em erges from the progression hol e (3 8).
With either thrOltl e valve fully open, the prog ression system
for th e part icular carbuee tt c r barrel ceases.
Norm al running
Under full throttle and high speed cruising cond itions. th e
throttl e pl ate s w ill be suffici ently fer fro m the id ling and
progression hol es to prevent them fro m adm itting fu el and the
ma in fue l supply c ircuit s w ill be bro ught into acti on.
Refer to Fig. 6 .5 and not e that fu el from the flo at chambe r
171 passes throu gh the main jets (8) and Channe ls (9) to the
5 5 S tarter ~ir v~/ve seat
56 Starte r air valve
57 Transfe r channal
A Cold s tarting pos ition
B W arming up p osition
C Closad p osition
em ulsion tub e w ell s (11). At the same ti me. air is drawn
throu gh th e air corrector jets 0 1. throug h the centre of the
emu lsion tubes (12) and via th e emulsion tube holes to the fue l.
The fu el the n becomes emulsified and Is dra wn t hrough the
no zzles (17 j ll nd aultili ary ventu ria (161and thu s mixes with the
main air supply as it i s drawn throu gh t he chokes {l SI and into
the engine.
Under static cond it ions t he level of fue l in the float chamber
and emu lsion tube wi ll be identical: however. as the engine
speed increases and t he fu el fl ow is faster, the fu el level in the
emu lsion tube dro ps. 8y providing addi tional holes in the lower
part of the emu l sion tube. th e necessary air correction is made
possible at t he higher engine speeds.
The main fu el suppl y circuit s of t he pr imary and secondary
carburatt or barrels operate progr essively and there is a certain
amou nt of overlapp ing as each circuit is brought into action.
Acceleration
To provide the engine with a rich mixture w hen accelerating . the cerbarertcr is equipped with an accelerati on pump
which is operated bv the prim ary throttle of th e carbu rettor and
injects only jnto th e pri mary venturi. Reference to Fig. 6.6 will
6-3
Part 2 Weber carburetors Chapter 6
31
30
13
2
Fi g. 8 .4 Carburettor id li ng and progressi on phase
I Sec 3)
12 Prim ary emu lsion wbe
13 Prim llry throttle villve
20 I dling msaare control screw
26 Secondary air j et
2 7 Secondary idling j et
28 Secondary emulsion tu be
29 Secondary progression chltnne l
29
30 Primary barrel
3 1 I dle feed orifice
32
34
35
36
37
38
Pri mll ry idlin g and progression channel
Primll ry idling jet
Prim ary air j er
Prlm ll r y progression hoie
Seco ndary throttle valv e
Secondary progression hole
slww that whe n th e primary thro ttle valve is closed. the lever
(4 51 lift s the operating rod (441 und er the act ion of the coil
spring. The piston (42 1 is pu lled up th e pi st on bore against th e
pressure of t he spring (4 1) and fuel is drawn from lhe float
chamber (71through th e int ake valve (4 7).
Whe n th e primary thrott le valve is opened . the lever (4 5)
moves away from th e opera ti ng rod (44) and allows the piston
(42 ) to mov e down the bo re unde r the act ion of the spr ing (4 1I.
The ball In th e int ake valve (47) preven t s fuel retu rning to the
float cha mber {7) and the fuel is fo rced along the Intern al
chann el (43 ), past th e delivery valve (4), through the pump jet
(39) and Into the primary ventu ri. The inlet valve (4 71 mayo r
may not inc orporate a disch arge orifi ce accor ding to th e
app licat io n. but wh ere th ere Is one . II cert ain amount of fue l is
di scharged back int o th e float chamber during th e ecceleration
pump pIston stroke. By fi ne calibrati on of th e discharge orifice .
it is po ssibl e to det erm ine t he exact Quantity of fue l injected by
the acceleration pump.
4
Rem oVlil and refitting
No te : Thll foff owing prOClldurll gives II generlll (lither thlln a
specific me thod of removing and refirting the carbure tt or. as
milch will depend on the 'ocation within the vehiclil.
Unscrew and remo ve the reta ining nut s and w ithdraw th e
air cleaner cov er and filter gauze. Unscrew the air Cleaner
retaining screws, being very careful not to drop them int o the
cerburen c r barrels.
2 Loosen the fuel supp ly hos e cl ip and pu ll th e hose fro m the
inlet pip e.
3 Slacken th e choke cable retaining screws on the startin g
devi ce and pull th e cable clear .
4
Disconnect the throttle control rod from th e th rott le lever.
5 Pull the ignition advan ce tube from th e vacu um pipe on th e
side of the carbur ettor.
6-4
Part 2 Weber carburetors Chapter 6
18 19 20
-r-r "'' "
,.+-'
,
12
,
2
3
•5
6
7
Fig . 6. 5 Cllrborenor norma l ph ase (S ec 31
A ir co"~cror jet
Needle valve seet
Needle valve
Spring hook
Fulcrum pin
Floa t
Float cfl amber
8 Main jet
9 Chen nel
' 0 Thro ttle shaft
15
16
17
18
19
Throttl e valve
14 Throt tle lever
20 Idling mixture adjustm ent
screw
"'3'2 Emulsion tube
Em ulsion tube well
Choke
A u"cifiafy venturi
D ischtlrge rou te
Thro ttle sect or
I dling IIdJustm ent screw
2'
22
23
2.
25
S lot
S ector lug
Unk s ector
Secondary fever
Secondary throttle shaft
4',1++~
42
47
10 46 45
44 25
Fig. 8.6 Carburettor acceleration phue (Sec J l
7
Float ch ambe r
10 Prim ary th ro tt le shaft
25 Secon dary thro ttle sh aft
4 0 De llI/Sty !FaN e
4 7 A ccelerator pum p s pring
42 Pump piston
43 Fuel channel
44 Ope ratin g rod
4 5 Le ver
4 6 OparlJting cam
4 7 IntlJ/(aand discharge
,.he
39 Pum p /et
6 Whe re fitt ed , disconne ct t he a utomat ;c tra ns miss io n controls fro m the cerburettcr.
7 Unscrew and remove tha carburettcr mounling nuts I hen
withdraw the unit over the mounling studs.
8
Remov e the inlet m ,'
Part 2 Weber carburetors Chapter 6
6
Sp ec ial overhaul procedure s
After carrying out the gene ral overhaul procedures given in
O1apter 4. th e follo w ing special procedures should be made :
1 Using a hand chuck and W eber tool no 98005 900. reform
th e id ling jet seatings In t he carbu rett or body by carefu lly rotating th e tool in alte rnate dir ecti ons. Finish the seatings by Inserting W eber too l 98 0 10 500 and gently tapp ing the cent re pin
whi lst rotati ng it.
2 U sing th e same procedu re as described in parag raph 1,
reform th e starter valve seat and bush. using W eber too ls nos
98004100 and 98002 6 50.
3 Using the same procedure as described in paragraph 1.
refor m th e starting jet seal. using W eber too l nos 98006 300
and 980 10 600.
4 If th e emulsion tube bores are disco loured and show signs
of sedimen t bui ld up, ream them clear again using W eber tool
no 98005 300 . Rotate t he tool slowly w ith a hand chuck unt il it '
mov es quite free ly, th en remo ve it wh ilst still rotating It.
5 If. on disassembly, the th rott le shaft s (4 9 and 54 ) are a
t ight fit in the cerbu rettor body (77) and they are of or ig inal
diameter (8.0 rnml, use Webe r tool no 9 8003 600 to ream the
shaft bores cl ear wi th the aid of a hand chuck. Should the shaft
bores be excessively worn, oversize shafts of 8. 5 mm di amete r
mu st be fitt ed and the bores should be reamed using Webe r
tool no 98 00 3 500. Note that norm ally the shaft itself will wear
quicker tha n it s bore. in which ease it w ill on ly be necessary to
renew the shaft .
6 Using a small file. remove any burr s th at have formed at the
end of the shaft bores as a result of reaming.
7 Check th e intem al channel s of t he carburettor bo~t- -
21
•
.~ ,
21
,
\
18
Fig. 8 .4 Id ling
,"" prog ression
12 We /Is
14 A ...compen sation jet
,.
'5
Progr ession hofes
Adjustment scr ew
17 Channel
18 Throttle valve
phas. (tri ple choke typesl
(5 "c 31
"
20
21
22
23
24
I dling feed hol es
Idling mixture screw
Channel
Chertnel
FIg . 8 .5 Normal phase 14& I DA end 48 IDAI {Sec 5 1
1
2
3
4
Float
Fulcrum pin
N eedle valve
5
Jdlingje l s
e
Needle valve seat
A ir corrector jet
C"librated bush
7
Auxiliary venturi
the ai r corrector [et s (5) and is then d rawn th rough the nozzle s
(61and chok es (9 1and into the engine.
Tr ipl e cho ke types
Refer 10 Fig. 8.6 and note that unde r full thrott le and cru ise
Noule
8
s
'0
Em ulsion tube
Choke
w. n
11 Main i et
' 2 C/ulnne l
13 Flo af ch am ber
condi tions. fuel is drawn from t he float chamb ers (5} through
the main jets (10) and channels (1 1) to the emu lsion tu be we lls
(12). The fu el becomes emulsified with air dra wn in through th e
air cor rector jet s (3 ) and, aft er leaving th e emul sion tubes (4 1. is
drawn th rough the nozzles (2 ) and cho kes (t 3) into t he eng ine.
8-3
Part 2 Weber carburetors Chapter 8
,,
,/ /
,
-,,
-_ . ~- - - - -~
'.:'
,;,
I
1l
10
Fig. 8 .6 No rmal phase (t rip le choke types) (Sec 3 1
1
2
3
4
Auxiliary ve nturi
Nozzle
A ir corrector jet
Em ulsion tube
5
6
7
Float
Float ch am be r
Needle valve se /If
21 n
Needle valve
Fulcrum pin
10 Main jet
8
9
1 1 Channel
12 W elf
13 Choke
2
22
/
26
l~l~W2728
.~.
_u--
:,.':.:-: ' ,
...:,"
.... ...
.
' . . .. .
'
'
/
23 24
25
Fig. 8 .7 Acceleration phasa f46 IDA and 48 IDAI ISIfC 3 )
13 Float chamber
Delivery valve
22 Pump jet
21
23 Inle t and discharge valw
24 Chan nel
25 Channel
Accelera tion
48 IDA and 48 IDA types
Refer to Fig. 8. 7 and note that when the throttl e velv ea are
clo sed, th e lever (29) under the action of it s spring. lift s the
accelerat or pump operating rod (2 6 ). Fuel Is th en drawn from
26 Ope rating rod
2 7 Sp ring
28 Piston
29 Lever
30 Cam
th e f loat chamber 11 3 } throu gh th e inlet valve (23) Int o the
pum p chamber. Wh en th e throttle valves are opened. the cam
(30) moves the lever (29) aw ay from the bottom of the operat ing rod (2 6) and the pisto n (28) mov es down the pum p bore
under th e action of t he spr ing (2 7). The inlet valve ball the n
8-4
Part 2 Weber carburetors Chapter 8
vehir:!e. On some applications for instance, the retaining nots
m ay no t be ,ccessib/, without removing surrounding com pon ents.
16
"
1 Disconnect all hoses from the air cleaner, if fitted. Remove
the air cleaner cover and edract the air cleaner ele ment .
2 Detach the air cleaner base from the carbu rett or. if fitted.
3 Disconnect the th rcttte linkage from t he th rottl e lever.
4 Disconnect the fue l in let hose or pipe (w ithdraw the fil ter on
triple choke type s).
5 Unscrew and remo ve the Carbur eltor retainin g nuts and
spring wash ers and withdraw the earburettor com pl ete over th e
mounting stuos .
6 Remove Ihe gaskets from Ihe inlet manifo ld and clean all
traces of gasket from th e contact face s of the manifold and carburertor .
7 Protect th e inlet man ifold from ingress of for eign matter
whilst the cerbcrettor is removed by sealing it wi th maskin g
tape.
8 Refining is a reversal of remov al bu t the follow ing
addit ional points should be noted :
f.} A lw a ys fit new gaslt:ers and tight en the ret aining nurs
I1Vl1nly in di.gonal sequl1nce
fb} The idling I1djustm ent scre ws should be set as
dl1scribed in S Ktlons 8 .nd 9. and finally tun ed as
described in S ection TO
.,
is )4
5
D i sassem bl y (46 I DA and 48 IDA types}
Fi g. 8 .8 Ac ce lenl1ion ltriple choke types } ts ec 3 J
e
25
2.
27
2.
2.
F/(u l( Chamber
Pump jer
De livery vtJfva
Rtlltn' se plate
D iaphragm
Spring
30 Di/,phragm
31
32
33
34
35
3.
37
Op erating fe ver
Cern
Lin k8ge
l e ver
Channel
Inler and discharge valve
Channel
closes and fuel is forced t hro ugh t he ch ann e ls (2 4 and 25),
through the deli very valves (2 1/ end pump jets (22) into the
barrel s in the vicinity of the tHIXi liary venturis. The i nlet val ve
(23) may Incorpo rate a calibrat ed disch arge ho le wh ereby some
fue l ret urns 10 the float chamber; by varyi ng the size of the
disc harge hole accord ing to th e applicat ion, the amount of fu el
injected by the purnpiets 122) can be varied.
Tri p le c ho k e ty pes
Refer 10 Fig. 8 .8 and note th at w hen the th rottle valves are
clo sed, l he sprint! (29) pushes the diaphragm (3 0) outwards
and fuel is drawn from the float wa shers 16t through the inlet
valves (36), alont! the channels (35 ) and int o the pump
chamb er. Wh en th e throttle valves are opened, th e lever (34 )
pul ls the li nkage (33) and the cam (3 2) causes th e leve r (3 1) to
depre ss the diaphragm (30) against the tension of the spring
(2 9). Fuel is forc ed past the release diaphragm 128 ) w hen th e
plate (2 7) moves against the reacti on sprin g and th en travels
through the channe ls (37) to the delivery valves (26). It is then
inject ecl tIl rough the pump jets (2 51 into th e carburettcr barre ls
in the vicinit y of the au~ iria rv venturis. The in let valve{s) (23)
may incor porate a cali brated di scharge hole w hereby some fue l
ret urns to the float chambers; the size of the hole clepend ing on
the partiCular appl ication .
IDS type carburett crs are equipped w itll boo ster jets
located at th e mouth of each auxiliary ventu ri. Their purpose is
to provide mi)(1ure enrich ment during high speed conditions.
4
Rem ova l ancl ref itting
No te :\ The following !Noce dure give s a general rather th8n a
spedfic m e thod of rem oving ,nd refitting the carburettor, as
milch Wl71 depend on the location of the carburettor with in the
Thoroughly clean the caeberertcr elrterior and wi pe dry.
2 Referring to Fig. 8.9. unscrew and remove the retaining
nuts (6 1) and w it hdraw the fitter gaUl e (64 ) (phot o).
3 Unscrew and remove th e ret ainin g nut s (60). remove t he
plat es (59l and withd raw the air Intake horns (58) .
4
U nscrew and remove the fi lter inspect ion plug {571. remove
the w asher (56l and extract th e fuel filter (5 5) and reta in ing
bush (6 3) (phOto).
5 U nscrew and remove the ca rbu retto r cover retai ning nuts
(62) and carefully 11ft the cover from the carburettor bod y (6 5).
making sure that the gasket (14 ) is not brok en (photo).
6 Lift the gasket (14) from the carburettor body ( 6 5~. If it is
necessary to retain tha gasket for any reason and it has become
shrunk . it is recom mended that the em ulsion tube hold ers (4 8)
and idling jet holders (50 ) are removed before removing t he
gasket .
7 Invert the carbure ttcr cover (1) and unscrew the needle
valve {l 21. then remove the wa sher (13) (photo),
8 Remo ve the locking wire from the float fulcru m pi n screw
head (17), then unscre w and remo ve it toge ther w ith t he
wash er (16) (photos l.
9 Lit! the uoet (15 ) from the float chamber.
1D Unscrew and remove t he teet chamb er drain pl ug (23 ) and
w asher (22) (photo).
11 Unscrew and remove the accelerator pump in let and
discha rge valve {111 from the bott om of th e float chamber
(pho to) .
12 Unscrew the emulsion tube hol ders (4 8) from the carburettor body (65) and lit! out the em ulsion tub e assembl ies
(pho to ).
13 Separate the emu lsion tubes (4 61from the holders (4 81and
then pull the main Jets (4 5) and air correcto r jets (4 7 ) from the
em ulsion tubes (4 6 1. Take care not to damage th e jets whe n
removing them and if pliers are used , interpose a piece of paper
or card to prevenllhe brass being scratched (phol o).
14 U nscrew the idli ng jet holders and air cor rector jets (50 )
from the ca rbcrertor bod y (6 5) and th en separate th e idlin g jets
(49) (photos).
15 Unscrew and re move the accelerator pum p delive ry valv es
(8) together w ith th e pump jet s (lO l and washers (9) . the n
separ,te the washers and jets from th e valves (photos).
16 lift th e accelerator pump operating rod (4) against the
tension of th e spring (6 ) until the retainer (51 is released from
the earburettor body (65 ), th en w ithdra w the com plet e
5.2 Removing the filter Qill.lze (twin
choke type )
5.4 Removing the rue! fi lter (tw in choke
rvpel
5.5 Removing the carbu rettor cover
(twin cho ke type)
~
·
'"-"· f "" ' ':~iM-, ' '
.t ~":!it;}!:,:)
~~('::
-"':;;.~ . I ;
L. :
...>' / ~
»
1/1) .~
>
5.7 Remo ving the needle valve Itwin
cho ke type )
5.8b Removing the float fu lcrum pin
(twi n choke type )
_.
5.10 Removing th e fl oat chamber dre in
pll.lg (twin choke type )
5.11 Location of the pump Inlet lmd
di scharge val ve (twin choke type)
5.12 Remov ing sn ernulslon tube (twin
chok e type )
5.13 Em l.llsion tube compo nent s (twin
choke typel
5.14a Removing t he Idling Jets (twin
cho ke type)
5.14 b The Idling Jetand holder (twin
choke type)
2
8-6----------------
1
5~r- 6 2
63
'iiit"
~ 55 '5
- --"---:"''''
(?£c
5
6,'-_ ,
t:t-'66
lllA
L
.
-----.--- - -~" --' . ' ",
65
3e'A
8- 7
Part 2 Weber carburetors Chapter 8
5.15. l ocati on of the a c cele rato r pum p
delivery valvehw in cho ke type l
5.15 b Pump delivery valve and Jet
compon ents Itw in choke ty pe l
5.17 Accelerator pump compon ents
l twin choke type )
2
5.19 Removing the auxili ary ventu ris
(twin choke t ype)
Fig . 8 .10 Auxiliary venturi removal
tool I sec 51
accelerato r py mp "sembly.
17 Lift the acceler ator pump piston 17) against the spring (5)
and di sconn ect it from the operating rod by turning it thro ugh
90 ° . Remove the pi ston (7). spring (5) and retain er (5 1from the
operatin g rod (4) (photol .
18 On 46 IDA types , remove the accelerator pump operating
rod bush (B81.
19 Note the location of the auxllia rv vent uria (18) and mark
them , If necessary, with a pencil to ensure correct refitting, then
withdraw them from the carburet tor body (6 51 (photo). If
necessary, use a wood en or plasti c dow el rod insert ed from the
throttle valve end of the barr el. to tap the auxil iary ventuns free.
If they are excessively tight, it will be necessary to obtain Weber
too l no 95 10 150 0035 ,
20 Remove the chokes (1 9). noting th at the end with the
5.20a Removing the chokes [twin choke
type l
sma ller intern al diame ter is uppermost (photos). If th ese are
excessively tight it wi ll be necessary to obta in Weber tool no
96 101 500034.
21 Uns crew and remo ve the id ling mix ture adjusting screws
(20) and springs (2 1) from the carbu rettor body (65) (photo) .
22 Unscrew and remo ve the idling adju sting screw (3 9 or 39 A)
and spring (38 or 38A) from the cerbur ettcr body (65 ).
23 Bend back the tccktabs (26) on each end of the t hrot tle
spindle (32) and unscrew the nuts (2 5) Iphotol. If the nuts are
tight, use Weber too l no 98023 70 0 to hold th e spindle wh ile
the nut is loosened; if this precauti on is not take n, the spin dle
(32 ) may become buckled. Note: Under no circumstances
should the nvts be loosen ed or tighten ed with the throttle
v/I!v~s bBing forced aglJinst the barrel walls.
24 Remove the nuts (2 5). tab w ashers (2 6). spacer (27 or 2 7A )
Fig. 8 .9 Exp loded view of th e 46 1DA and 48 10 A cerburettor ISec 5)
18
19
20
21
22
23
24
8
Cover
S tud
Stud
Pump roa
Retainer
Spring
Piston
De livery valve
9
W.tSh~rs
25 N u<
/
2
3
4
5
,
e
/ 0 Pump jet
/I Inlet and disc/Illrge valvt!
/ 2 Needle valve
/3 W asher
/.
/ 4 Gasket
/ 5 J:loat
Wllsner
17 J:utcrum pin
Auxiliary venturi
Choke
Mixfllre adjus tment scr~w
Sp ring
Washer
Pilig
Progression hole
inspe ction plu g
2 6 Tab washer
27 and 27A S paur
28 Spring
29 Lever
30 Clip
3 1 Rollpin
32 Throttle $pind/~
33 S crew
34 Throttle valve
35 Sprin g
36 Cam
371lnd37A L~v~r
38 Ilnd 38A S pring
39 and 39A Idling Ildjus tment
scre w
40 Retainer
4 / Spring
42 Dust seal
43 8 atlring
44 Stud
45
M/I!n j~t
46
47
48
49
Emulsion tll~
A ir correcror jet
Holder
Idling j~ t
50 Holder
8,"
5/
52 Washer
53 Union
54 Washer
55 Fuel filter
5' Washer
5 7 Plug
58 A ir intake hom
59 Plate
60 Nut
6 1 Nut
62 Nut
63 8 l1sh
64 Filter ga uze
65 Car!xJrettor body
66 8 l1sh
Fig . 8 .11 Choke remova l tooll Sec 51
5.20b Cho ke diame ter s ize loca tion ltwi n
cho k.e type )
5.21 Idling mixt ure s cre w lo catio n ltwin
choke type)
5.23 Thro tt le spi ndle stop leve r location
5.25 Thronle va lve retainin g sc rew
lo cation Itwin cho ke type )
[twin cho ke ty pe )
5.27 Rem oving a thrott le va lve {tw in
5.28 Accel er at or pump leve r loca tion
cho ke ty pe )
(twin cho ke type)
5.3 0 Re mov ing the 5p4"ing reta ine rs
(twi n cho ke type )
5.3 1 Re movi n g the th rottle shaft
springs Itwi n cho ke type )
Part 2 Weber carburetors Chapter 8
and lever (3 7 or 37 A) from th e thr ottle spindle (32) .
25 Un sc rew a nd re move th e throttle va lve reta ining s cre ws
(3 3 ). be ing carefu l not 10 e xert e xcess ive press ure o n th e
spind le (3 2) (photo).
2 6 Note t h e po sition of the thrott le va lves in rel at ion to th e
barr els. and if ne ce ssa ry mark them wit h a pe nc il.
2 7 Turn th e sp ind le to the fully open position a nd w ithdraw th e
two t hrottle valve s (3 4 1fr o m t he i r lo cat io n slots (phot o} .
28 Usin g a small screwdriver, pr ise the C-ellp (30) from th e
acce lerator pump lev er pivo t then w it hdraw t he lev er (2 9 1 and
spring (2 8 ) Ip ho to },
2 9 Using a suitable pin punch . drive the roll pin (31) thro ugh
th e ca m (3 6 ) and spi nd le (3 2) . To ensure co rrect refitting, m ark
the cam and sp ind le i n relation to eac h other.
3 0 Rem ove the spring retai ne rs (40 ) from ea ch end of t he
th rott le s pind le by inse rt ing two seif-ta pp ing scr ew s into t he
ho les and pu ll ing t he m w ith p lier s (pho to).
3 1 Remove th e spri ngs (41 ) and dust sea ls (4 2) (pho to).
32 U sing a pl astic o r woo den ma llet, tap one end of the sp ind le
(3 2 ) until t he be aring (4 3 1eme rges from t he o pposite end of the
c arb uretto r body (6 5~ .
3 3 Continue t o drive the spi ndl e out with a leng t h of dowel rod ,
at th e sa me time reco ver th e cam (36 ) a nd spr in g (3 5 1.
3 4 Mount the sp ind le loo sel y in a so ft jaw vice. th en ta p th e
spin d le (3 2f t hro ug h th e bearing (4 3).
35 T empora rily reinse rt the sp ind le (3 2) into t he c arb uretto r
body and remove th e remaining bearing ( 43~ using th e metho d
d escribed i n paragraph s 32. 3 3. and 34.
3 6 If th e bear ings are exce ssiv ely w orn , it is po ssib le for the
inner race t o separate f rom th e outer race leav ing the latt e r in
th e ca rburettor body. If thi s h appens, gently heat the bo dy with
a gas blow lam p until the race ca n be removed . On no acco unt
use exce ssive h eat. oth erwi se the main body may be per m anent ly di stort ed. It i s not po ssible to obtain this component
as a spa re.
6
8-9
D isassembly (tri p le choke ty pe s)
Thorough ly cl ean th e carbu rettor exte rio r and wi pe dry.
2
Ref err ing to Fig. 8 .12 , un hook the thrott le le ve r return
spri ng (w here f itt ed). then unscrew and remove the c arbu rett or
cover ret ai n ing nut s (4 A ) and spring plate (w h ere f it ted ) (photo ).
Lift the cover ( 1) from th e c arbu reltor body, being ca ref u l
3
not to br eak the gas ket (11 ) Iphc t cl.
4
On 46 IDA 3 C ty pes, remove the screw s (77 ) and lift off t he
gauz e fi lters (7 6 ).
5
Un screw and remove th e ret ainin g nu t s (4) and withd raw
the three air intake horns (3 ) and gasket (w here fitted) (photo).
6
Carefu lly lif t the ga sket (11) from th e ca rburettcr body.
7
Un screw both fu el in let uni on bo lt s (1 4 ) and w ithdraw th e
unions (9 and 10) f rom t he co ver (1) . Sepa rate th e sealing
w ash er s (8 and 13 ) from t he unions and bo lts and with draw t he
f ue l fi lt er gauz es (12) .
8
Pull th e inte rmediate ho se fr om th e i n let uni on s (9 and 10 ).
9
Un screw and remove t he needl e va lv e hou sing plugs (7 )
and washe rs (6) (p hot o).
10 Unscrew and remove the needle v alv es (5 ). no ting t he
quantity of w a shers (7 5) f itte d to th em (p hot o).
1 1 Remove th e locking wi re f rom th e f lo at fu lcrum pin scre w
h ead s (1 8). th en remove th e f ulcrum pin s to gether w ith th e
w ash er s ( 17) [photo ).
12 Lift th e two f lo at s (1 iI) from th e f loat c ham b ers.
13 Un screw and remove th e drain p lug s (6 4) and wa sh ers (6 3)
{pho to).
14 Un screw and remove the main je t ho ld ers (6 1) and w ashers
(5 9 ), th en un screw the m ain jet s (6 0) from th e ho ld ers (61)
(pho to s).
15 U n screw and remove th e id ling jet ho lde rs (6 6). th en pull
out th e id lin g jets 165 ) (ph ot o s).
16 Un screw and re m ove the air co rrec to r je t s (74), th en in vert
6 .2 Throttl e lever ret urn spr i ng lo cat ion
(t rip le choke t ype )
6 .3 Removing the c arbu rettc r co ver
(t ri p le choke type)
6.5 Removin g the air intake horn s (t rip le
c ho ke ty pe)
6.9 Removing the ne edie va lv e hou sing
p lug (trip le cho ke type)
6. 10 Removi n g th e n eed le valve s (t ripl e
choke type )
6 . 11 Removi ng th e float fulc rum pin
(trip le cho ke type )
2
8-10 - - --
-
- - --
-
-
- - --
-
-
-
-
-
-
-...,
45 IDA 3C
Fig . 8 .12 Exploded vie w of the 4 6 IDA 3 C catburettor (S e c 6)
1
2
Co ver
S tud
3 A ir horn
4 and4AN ut
5 Needle valve
30 Co ver
3 1 Cover
32 Spring w asher
6
Washer
33 Nut
7
8
9
10
11
Plug
34 S crew
Washer
Union
Union
Gasket
35 Linkag e
12
13
14
15
File /filter
Washer
Bolt
FloBt
16 S tud
17 Washer
18 FuJcrum pin
19 Spring
2 8 S pring
29 Diaphragm
36 Washer
3 7 Nut
38 Thro ttle sp indle
39 Clip
40 Ph-or
4 1 A rm
42 Cam
43 Un k/!!ge
44 Roff pin
4 5 Thro ttk valve
20 Thro ttle sp indle
21 Thro ttle sp indle
22 and 23 S tud
24 S pring
25 Plate
46
47
48
49
50
51
26 Diaphr agm
52 Spring
2 7 Accelerator p um p housing
S crew
Nut
Tab wash~
l.ever
Lever
Space,
53 and 53A Spr ing
54 Idling adjustment screw
55 Progression hole in spe ction plug
56 Locknut
57 A ir compensating adju stment screw
58 Choke felilining screw
59 Washer
60 Mainlef
61 Holder
62 Mixll/fe lIdlu$tment screw
63 Washer
54 Dr8in plug
65 IIdinglet
66 Holder
6 7 Choke
68 Auxiliary venturi
69 Washer
70 Pump l et
7 1 Delivery vellf e
72 I nlet and discharge Ifalve
73 Emu/sion tube
74 A ir coracu»:jet
75 Washer
76 Filt er gauze
77 Screw
8-11
Part 2 Weber carburetors Chapter 8
I::A .. j
6. 13 Remo ving the dr ain plug s Itriple
choke type )
6. 14a Removing a main jet (triple cno ke
",,,,, )
6 .14b A ma in je t an d ho lder (tr iple
cho ke type)
2
6.158 Re mo ving a n idling jet {triple
cho ke type l
6.15b An idlin g jet a nd ho lde r (triple
choke type l
6. 16 a Re mo ving th e a ir corrector je ts
(triple choke type )
6 .16b Rem oving an emu lsion tube
(triple cho ke type l
6. 17 Locat io n of an a cce le ra tor pump
inlet and discharge val ve !triple c ho ke
type )
6.18 location of a n a cce lerator pump
d elive ry va lve (triple choke rvce l
li~;::
the carburettor body a nd extract the emu ls ion tubes (7 31. If the y
a re a lig h l fit du e 10 overt ightening of the air jets. careful use of
a se lftapp ing s crew ma y be ne cessa ry to extract the e mu lsion
tu bes (photos).
17 Unscrew a nd remove the acce lerator pu mp inlet valves 172 1
from the bonom of the flo at c hambers (p hot o).
18 Unscre w the ecceleretoe p ump delivery valves (7 1) a nd
re mo ve them together with t he w ashe rs (6 91 (Pho tol.
19 Withdrew th e wa shers (6 9 1 and p ump je ts (70 1. th en , on
lOS types, re mo ve the re ta ining screws a nd withdra w the
booster jet asse mblies.
2 0 Un screw t he accelera tor p ump reta ining n uts 13 31 an d
remove Ihem together .....ith the s pring washers (3 2) (p ho to ).
2 1 Withdre w th e eccereretc- pum p cover (3 01 a nd body (2 7)
over the location studs; at th e sa me time recove r the rea ct ion
sp ring f2 4l e nd plate (2 5 ) (pho to).
__
22 Caref ully remov e the re lease d iaphrag m (2 6) from th e body
(2 7l.
2 3 Separate the co ver (301 from the body 127) and re mo ve the
return s pring (281.
24 Carefully pe el the pu mp diap hra g m (2 91 from th e cov er
{3 0 1.
25 Re mo ve th e locking .....ire from th e c ho ke re ta ining screws
(S8l then unscre..... and remove t hem.
2 6 Note the location of the a uxiliary ve nt uria (6 81 a nd marie
them with a pencil it nece ssary to e nsure correct refin ing; th en
.....ithdraw them from the ca rbur ettor body Ipho to al. If necessary _
us e a wood en or plastic do .....e l rod inserted from the thrott le
valve end of the barr el to tap th e aux iliary ve nturi s fre e but. it
they are excessively t ight, it will be ne ce ssary to obtain Weber
tool no 9 6 10 15 0 003 5 .
27 Remove th e cho kes (6 7), notin g th at th e e nd w ith th e
8-12
Fig . 8.13 Location of the booster je t s on lOS types (S e c 51
6.20 Acce ler ator pum p cove r lo ca tion
6. 2.1 Remov ing t he pum p react ion plate
(tri pl e choke type )
and spring (t ripl e c hoke tvpe }
6.26a Removing an a uxilia ry vent uri
(t ri pl e choke ty pe)
6.26b Auxilia ry vent uri and size
id e ntificatio n (triple choke type l
6.27a Re moving a ch o ke (triple choke
type l
6 .27b Choke and size ide nt ifica tio n
(tri ple cho ke t ype ]
Part 2 Weber ca rburetors Chapter 8
sma ller intemal diameter is uppe rmost (p hot o s). If t hese are
excessivel y tigh t it w i ll be necessary to obta in W eber t ool no
96 10 150 0034.
28 Un screw and remove th e t hro t tle valve ret aini ng screws
(4 6), be ing carefu l not to exert excess ive pressu re on th e
spind les (20 and 381 (phot o).
29 Turn th e spind les to t he fu liy op en posi t io n and w it hdraw
th e t hree t hro ttl e val ves (4 5) fr om their loc at ion slots (pho to s).
30 Slac ken t he int ermediat e li nkage screws (34) and wi thdraw
th e sho rt spindle (2m from th e carbu rettor body (photo). No te
t hat on some types t he li nka ge in corporates grub screws
inst ead o f nuts.
31 Remove t he ret urn spri ng (1 9) from th e sp ind le (201.
32 Remove the linkage (3 5) from th e lon g sp ind le (3 8).
33 Extra ct t h e spring cli p (3 9) f rom th e lin kage (43) th en
detac h t he lin kage f rom th e lever (41)l wh ere appli cabl e).
8-1 3
3 4 Extract the spri ng clip (3 9} and unscrew the pivot (4 01 then
withdraw t he acce lerator pu m p cam 142l (phot o).
35 Usi ng a suitab le p in p unc h, driv e t he roll pin (4 4) through
th e sp indle (3 8), at t he same ti me mark th e lever (41 ) and
spindle (3 8) in relation to e ach ot her to fa cil itate refi tt ing.
36 W ith a su itable leng th of dow el rod , careful ly t ap t he
sp ind le (3 8l out of th e carb urettor bo dy and throu gh t h e lever
(41).
37 Be nd bac k t he lockt ab (4 8) and un screw th e nut (4 7). If
necessary, mount th e spi ndle in a soft jaw vi ce during th is
operat ion.
38 Remo ve th e nut (47). tab w asher 14 81. lever (49), spacer
(5 1) and sp ring (5 2) f rom th e spi ndle (3 8), noting th e relat ive
pos ition of th e lever.
39 On some ty pes th e locati on of t he sho rt and lon g th rottle
spind les is reversed and it is t herefore im por t ant to not e th e
2
6.28 Th rottle va lve ret ainin g screw
lo cati on Itri ple choke ty pe)
6.29 a Remo ving a thr ottl e valve (t ripl e
choke typ e)
6.29b A t hro ttle valve (t rip le chok e typ e)
6.30 Int erm e diat e lin kage (tr iple chok e
typ e)
6 .34 A ccelerat or pump cam locati on
(tri ple choke ty pe)
6 .4 0 Rem ovin g th e air co mpe nsat ion
adj ustment scre ws (tri ple chok e type)
6.4 1 Removing th e idlin g m ixture screws
[t riple choke ty pe)
6 .4 2 Remov ing th e pro gressio n hol e
in spection plu gs (tri ple cho ke type )
8-14
Part 2 Weber carburetors
Chapter 8
correct fitted position of these ite ms.
40 l oo sen th e lo ckn uts (56 ) th e n unscrew and remove th e air
compe nsa t ion ad justment screws (57 ) (ph oto ).
4 1 Uns crew and re mo ve t he idling mixtu re ad just men t s c rews
(6 2l and spr ings (53 A ); on so me mod els a p lain w asher and
seal are f itt ed to t he screws (photo).
42 Un screw and re mo ve t he pro g ress ion ho le inspect io n pl ug s
(5 5 ) (photo ).
43 U nscr ew and re mo ve th e id ling adjust me nt scre w (5 4 ) and
sp rin g (5 3).
7
S pe ci a l o verhaul procedures
Afte r ca rry ing out th e ge neral ove rha u l procedu res gi ve n in
Chapter 4 , th e fo llow ing spec ial proced u res s ho uld be fo llow ed :
46 IDA and 48 IDA types
1
U sing a hand chu c k an d th e spe c ial W eber too l, reform t he
main jet seatin gs at th e bo tto m of t he em ulsio n t ube hou sin g
w ell s by ca refu ll y rotat ing t he t oo l in a lterna te direction s. Fin ish
th e seati ngs by in sertin g t he furt her W eb er tool and gently
tappi ng t he to p of th e tool w hilst rotat in g it.
Using t he same procedu re as describe d in parag raph 1
2
reform t he i dlin g je t seats.
Triple choke t ypes
3
U sin g a hand ch uck and W e ber t ool no 9 6 00 32 5 0 7 67 .
refo rm th e id lin g jet seats b y ca ref u lly rota ti ng th e too l in a lte rnate direc tio ns. Fini sh t he seat ings by insert ing Webe r to o t no
96 10 3 15 08 16 and gentl y t app in g t he to p o f the too l w hi lst
rota t ing it .
4
If th e em u lsio n tub e we l ls are discolo ure d and co nsid erabl e
sed iment has accu mu lated, th e bo res m u st b e ream ed usin g
We be r t oo l no 960 0 325 0 7 6 2 an d a hand Chuc k , Turn t he too l
ca refu lly un til it m ov es fr eely t he n co ntin ue t urn ing it whi lst
remo vin g it .
5
If o n d isasse m bly. t he t hrottle spi nd les are a tig ht fi t in the
ca rburett o r bo d y and th ey are of or i9 ina l di am et e r (8.0 mml. use
W eber t oo l no 9600 0 3 5 0542 to ream the sp in d le bo res cl ear
wi th the aid of a hand ch uck. Sho uld th e spi nd le bores be
exce ssively w o rn , o vers ize sp in d les of 8.5 mm d ia meter m ust be
f itt ed . Th e bo res shou ld be ream ed using W eb er to ol no 9600
0350556.
6
U sin g a sma ll fil e. re move any burr s w hic h hav e been
formed as a resu lt of rea min g as described in p arag rap hs 4 and
Fig. 8.14 Overhauling the id li n g jet seats (t ri p le cho k e typ es)
(Sec7 )
5
A ll t ype s
7
Chec k th e int e rn al channels for b loc kage by inj ectin g f ue l
f ro m a syri nge and obse rving w he the r it e me rges f reely fr om th e
pa rti cu lar ch ann el bei ng teste d , If any are bloc ked , it w ill be
necessary to dri ll ou t th e lead pl ugs as shown in Fig . 8. 15 . 8 . 16
Fig. 8.15 Lead plug lo c a ti o n points (S ec 7 )
e-ca.tz.
8 Th e c han ne ls are of t h e dia me ters vi z 1.0 mm, 1,5 m m and
2 .0 m m . Th e W eber t ool no s 962 0 1 75 18 4 6. 9 6 2 0 17 5 18 4 7
and 9620 175 18 4 8 shou ld be used to check that the ch anne ls
are cl ear fro m th eir fu ll le ngth s.
9 Th e carburettor bo dy sho u ld be t horoug h ly c leane d afte r
ov erh au l t o re mov e any swa rt an d dirt. prefe rab ly using cle an
fu el and air p ress u re. The lead plu g s shou ld be renew ed and
ret aine d in po siti on by u sin g th e W eber too! no 96 10 3 15 0823
as a punc h untit t he plu gs are exp ande d int o th eir bores.
10 Che ck t he t hrottle spind les fo r h igh spots wh ich co u ld
ca use t hem to seize and if necessary. clean th e sp in dl es with
fin e emery t ape .
8
A sse m b ly {4 6 IDA and 48 IDA type s!
N ot e : AI! componen ts sroota be clean and dry be fore s tarting
th e assembl y p roce dure.
1
U sing a sui ta b le di am et e r lengt h of tubin g, drive o ne
Fig. 8 . 16 A c c el erat o r pu m p ch ann e l lead p lug lo c at i on
poinu (Se c 7 )
Part 2 Weber carburetors Chapter 8
Fig. 8.17 800ster jet c ha n ne l lead plug locat ion points (IDS
types) (Sec 7)
Fig. 8.18 Method of retaining the lead plugs (Sec 7)
be a ring ( 43~ fully into th e c a rbure tt o r body ( 6 5~ (Fig. 8 .9 ).
2
Mount th e sp ind le (3 2) in a soft ja w vice an d d rive the
re ma in in g bea ring (43) onto th e s pind le (3 2) w ith tubi ng
lo cate d on the inne r diamete r. Make s ure th at it is fitted to t he
correct en d so tha t the roll pin hole is towa rds the ie ve r (2 9) en d
of th e carbureno r.
3
If a new cam (3 6) o r s pind le (3 2) is being fitt e d , re a m t he
ca m as necessary so th at it is a firm s liding fit on the s pind le.
8.4 Fitt ing th e thro tt le s haft (twin choke
type )
8-15
4 light ly lubr ica te the s pind le (3 2) and bearings (4 3) with
engi ne 011. t he n ins e rt the s pind le into t he carb urettor body (6 5)
a nd th rou gh the spri ng (3 5) and cam (3 6). Ma ke s ure that t he
sp ring and cam are lo ca te d corr e ctly so t hat they will o pe rat e
t he le ve r (2 9) (pho to) .
5 Drive th e bea ring 143) into th e carburetto r body us ing
tub in g lo c at e d o n t he o ute r d iame te r; if nec ess a ry support t he
o ppo s ite bea ring during th is ope rat ion to e ns ure tha t bo th bea rin gs a re fully ente red (ph oto).
6 Fit th e dust seals 14 2} a nd sp rings (41) ove r eac h e nd of t he
s pind le (32), the n tap th e s pring ret aine rs into the ca rbure tto r
bod y (6 5).
7 If the o riginal sp ind le (3 2) and cam (3 6) a re bei ng refitt ed ,
a lign t he previous ly ma de mark s a nd dr ive the roll pin (31) into
th e s pindle unt il it is in a ce ntral po sitio n. then locate the s pring
(3 51 (phot o).
8 Tu rn the sp ind le (3 2). against the te ns io n of th e spring (3 5)
if a lrea d y fitted, unt il the th rott le va lve s lots c an be seen fro m
th e flan ge end of th e carburetto r; th en ins e rt the thro tt le va lves
(3 41. e nt e ring t he ind e nte d ends first . a nd c lose the sp ind le.
Ma ke sure th at the t hrott le va lves a re fitt e d the correc t w ay
ro und so th a t th e a ng led pe rime ters s ea t in the bo res an d the
ind e nta tio ns a re ad jacent to th e ba rrei p rog res sio n holes.
9 Sna p the va lves s hut s e ve ra l t ime s in order to ce ntra lise
th e m. th e n insert a nd t ighten the va lve reta in ing s cre ws (3 3)
wit hout e xe rting exc essive press ure on the sp ind le. It is re co mme nded t ha t ne w sc rews a re a lwa ys fitte d, as it is qui te easy to
cross-threa d pre viou sly peened sc rews , Lock the sc re ws (3 3) by
pe enin g wit h Webe r to o l no 980 10 900 w h ilst support ing th e
s pindle with a le n gth of wood. Alte rnat ively, coat the th re ad s
wit h a liqui d lo cking a ge nt (f uel res istant ) prior to ins e rting
them .
10 If a ne w s pindle (3 2) o r ca m (3 6) is be ing fitt ed , bot h mus t
be drilled wit h a 0. 078 in (2.0 mm ) dri ll to a ccommodate th e
roll pin (31). To do th is it is esse nt ia l to obtain th e specia lW eb e r
fixture. Drive in th e roll pin when comp leted until it is in a
ce ntral position , th en lo cate t he s p ring (3 5).
11 Fit th e sp ring (28) to the acce lerato r pu m p le ver pivot.
followed by th e le ver (29) wit h th e lug uppe rmost. Press the Cc lip onto the pivot a nd then c heck tha t the le ver move s free ly
w he n th e th rott le spind le is tu rne d.
12 Fit the thro tt le leve r (3 7 or 37Al, s pa ce r (2 7 or 27Al. ta b
w as he rs (2 6 1 an d n ut s (2 5) to th e ir res pe ctive en ds of the
s pind le (3 2). Tig hten th e nu ts a nd loc k th e m by ben d ing the
lo ckt a bs (2 6 ) Ioh oto ). Do not overt ighten t he nut s a nd und er no
circ ums ta nces for ce th e thrott le va lves a ga inst the ba rre l wal ls.
13 Fit t he spring 13 8 or 38A) to the id ling adjustmen t s c rew
(3 9 o r 39A) an d fit it to the ca rb urettor bo dy.
14 Fit t he s pring s (21) to t he id ling m ixture ad justment screws
l20) and fit t hem to the carburettor bo dy.
15 Ins e rt t he choke s 0 9) into the barrels w ith th e smaller
d iameters an d cho ke re fe ren ce nu mb er s uppermo st .
16 Fit th e a uxiliary ventu ris (18 ), ma king s ure th at t he loca tio n
sp ring s e ngage w ith t he groo ves in the barre ls a nd that th e
8.5 Fitt ing the throttl e shaft be a ring
(tw in choke typ e)
8.7 Correct lo ca tio n of the acce lerator
pum p ca m (twin choke type I
-2
8-16
8. '~2~F~;~U~;"·9-'~'~h'·O~U~'.~'.·,-er~twin choke
type l
Part 2 Weber carburetors ChapterS
Fig . 8. 19 Fitt ing t he accelerat or pump
(twin cho ke type )
8.20 Fitting th e acceler a tor pu mp delive ry
va lves (tw in choke type)
.---'
8.26 Fitting t he f loat (tw in choke type )
8.27a Usi ng a rub be r w e d ge to set th e
float (twin choke type)
supp ly cha nnels are in alignment with those in the ca rburettor
body (6 5). The extended vent uris must also be uppermost .
17 On 46 IDA types. fit the accelerator pump operat ing rod
bush (6 6).
18 Fit the spring (6) to the operating rod (4 ) fo llow e d by Ihe
piston (7 }; engage the piston with the rod by t urni ng it th rou gh
90°.
19 Fit the reta iner (5) ove r the sp ring (6) with the tab facin g
the operating rod, then low er t he assemb ly into the carburetto r
body (65) and press the retainer into its locat ion with the fl at
side of a screw driver (phot o). If t he retainer refuses to hold. it
shou ld be gently prised apart to give it th e oeceeserv tension .
20 Fit a w asher (9) to the accelerator pump delivel)' valves (8)
fo llowed by the pump jets (10) and a furt her w asher (9) , t hen fit
and tig hten t he assemb lies in to the carbure ttor body (65)
(photo).
21 Press t he idling jets (4 9) int o the holders (50) and tighten
the holders into the carburetlor bod y (6 5).
22 Press the main jets (4 5) and air corrector jets (47 ) into each
end of the emu lsion tubes (4 6) , then press the emu lsion tubes
(46) into the holders (4 8 1.
23 Insert the emu lsion tube assembl ies into the carburet tcr
body (6 5) and tighten them.
24 f it and tighte n the accele rator pump inle t and discharge
va lve (11 ) to the bottom of the float cham ber.
25 fit t he washer (2 2 ) to the drain plug (23) and tig hten the
plug into the carburettor bod y (6 5).
26 Lower the float (15) into the float chamber with the opera ting tube faci ng upwards. then fit and tighte n the ful crum pin
(17) together wit h the was her (16) (photo) . l ock th e pin w ith
locking w ire threade d th rough the adjacen t ho les in th e body.
27 The float level adjustment must now be checked in th e
follow ing manner : Ob tain a rub ber or p last ic w edg e
approximately 0 .25 in (6.4 m m) thick (t ubing is ideal for the
8.27b Checking t he float level (twin
choke type )
procedure). Insert th e wed ge betw een the fl oat and t he outer
carburettor body , th en ntt th e fl oat unti l t he di stance from t he
carburet tcr uppe r face to t he fl oat tab is 0 .953 in (24.2 m m )
(photo). If a depth gauge is not available. use verni er cali pers
and a feeler gauge as sho wn in photo 9.33b but ma ke
allowance for th e th ickness of t he feeler. With th e float held in
t his posit ion by the we dge. check th at th e di stance from th e
carb urettor upper face to t he top of t he flo at is between 0 .21 6
in and 0. 23 6 in (5.5 mm and 6.0 mrnj. M ake th e check at th e
highest point of the fl oat perim eter but not on th e annular seam
(phot o). If th e dim ension obta ined is incorr ect. caref ully band
the flo at tab as necessary and remo ve the wed ge when th e
checki ng is complete .
28 Screw th e needle valve (12 ) Into th e carburetto r cover (1)
w ith out any washers. Check the di stance from th e cover face to
th e needle ball apex w it h the needle valve in th e closed position
and w ithout the needle ball being depressed . M ake the check
w it h vernier calipers and deduct th e result from 0 .984 in (2 5.0
mm) to give the thi ckness of was hers requi red.
29 Fit the wash er fs] (13) to the needle valve (12) and ti ghten it
into t he carburettor cover {1). Check th at the dimension
described in paragr aph 28 is sti ll 0 .984 in {2 5.0 m rn).
30 Place the gasket ( 14 ) onto the top face of the carburettor
bod y (6 5).
31 Lower th e carbu rettor cover (1) onto the main body and
over th e studs. th en fit the retaining nu ts (62) and ti ght en them
a litt le at a time in diagonal sequence .
32 Insert th e fu el fi lter (5 5) into the carburettor cover (1),
followed by th e ret ain ing bush (63), washer (56) and f ilt er inspecti on plug (57); ti ghten the plug into th e cover.
33 Fit th e air int ake horns (58) to th e cover (1). Fit the plates
(59) and tig ht en th e reta ining nuts (60 ).
34 Locate t he fi lt er gauze (54 ) over th e cover studs (2) and fit
and t ighten th e ret aining nuts (61).
8-17
Part 2 Weber carburetors Chapter 8
5
3
.1
!l
.J
.;
s
~
4
Fi g. 8 .19 Float level adjustment dim ensions on 46 I DA and 48 ID A types (Sec 8 1
1
Nee dle valve
2
Cover
3
4
Needle bafl
Flo at
35 Wi th th e carbure tto r co mpletely assem bled. t he idling
adjustme nt screws should be turn ed to their prelim inary sett in gs. To do this. fi rst screw in th e throttle id ling adjustment
sc rew until it just tou ches th e th rott le lev er . th en co ntinue
t urn i ng fo r a further 2 turn s. W o rking o n th e idling m ixtu re
volume sc rews in turn, fully sc rew t he m in until th ey are in firm
contact w it h th e ir se ats, t he n ba ck them off 2 co mp lete t urn s.
Final adjustments will be necessary wh en th e cerburet tor is
fitted on th e engine (refer to Section 10l.
9
Ass e m bly (tr iple cho ke t ypes )
No te : A ff comp onents sr outa be clean and dry before st arting
t he assembl y procedure.
1 Fit th e s pr ing (53) (Fig. 8 .1 2) to th e idling ad justme nt scre w
(54) a nd fit the s c re w to th e ca rburetto r body, turning it on two
o r t hre e thr e ad s o nly.
2
Fit and tight en th e prog ression hol e ins pe c tio n plu g s (5 5).
3 Fit th e sp rings (5 3A) to the idling mixtur e a djus tme nt
scre ws (62) togeth e r with th e pla in wa sh e rs a nd seals wh ere
fitte d , t he n fit t he sc re ws into the carburettor body.
4
Fit th e a ir com pe ns at ing adjustme nts s c rews (57) fully.
th e n fit an d tighte n the locknuts (56) .
5 Fit th e s pring (52) to the sp ind le (3 8) fo llo we d by th e
spacer (51), lever (49 ). t ab wa sh er (48) a nd nut (47). Make s ure
th at the lev e r is in it s corre ct po sition as p revio us ly noted a nd
tig ht en t he nut with the s pind le mounted in a so ft jaw vice. Lock
the nut by bendi ng th e tab w as her.
6 If a new lev er (41) o r s pind le (3 8) is bein g fitt ed. re am the
le ve r as ne cessary so t hat it is a firm s liding fit on th e s pind ie.
9 .7a Fitt ing the (ong throttle s pind le
(triple cho ke type)
5
Gauge
6
Tab
7 li ghtly lubrica te th e throttl e sp ind le (3 8) wit h en g ine o il,
th en insert it into th e c arburettor body, a t th e same t ime locating th e lever (411 be twe e n t he two ba rre ls. If the ori ginal leve r
(41) is bein g refitted. mak e s ure that it is t he co rrect w ay round
as previou sly noted, the n inse rt th e roll pin (4 4) and d rive it
t hro ugh th e leve r and spi nd le until it is in a ce nt ral positi o n
(photo s).
8
Fit th e a c cele rator p um p c am (4 2) to th e pivot (40). Fit t he
pivot a nd ins ert th e sp ring clip (3 9J. On IDAP a nd IDTP types, it
wil l first be necessa ry to e ngage th e linka ge to th e leve r (41)
but, if a new leve r (41} o r s pind le (3 8} is being fitt ed , del ay
fitting th e cam (42) until th e roll pin hole has be en dr illed .
9 Fit the lin kage {3 5} to the lon g sp ind le (3 8) but do not
tighten th e sc re ws at this stage.
10 Fit th e return s pring (1 9) to the s ho rt s pindle (20) a nd
lu brica te th e s pin dle with a little e ngine all.
11 Ins ert the s ho rt s pindle (20) into th e carb urettor bod y and
locate it into t he lin kag e (3 5}.
12 Make sure tha t the retu rn spri ngs (19 and 52 ) are co rrec t ly
loca ted (pho to). th en turn each sp ind le in turn to t heir fully op en
po sition s and insert th e t hrottle va lves (4 5) into the ir loca tion
s lots. Close th e t hrottl e va lve s a nd a llow them to ce nt ra lise
within the barre ls; mak e s ure th a t th ey a re fitt ed the co rrec t way
round s o tha t th e a ng led perimeter s se at in th e bores.
13 Inse rt and tighte n t he valve ret ainin g s crews (39) without
exe rting excessive pressure on th e s pind les. It is re comme nd e d
that new sc rews ar e always fitt ed as it is quite easy to c ross thr ead previou sly pe en ed sc rews. Lo ck th e scre ws (3 9) by
pe ening with W eb e r tool no 98 0 10 9 00 whilst s uppor ting th e
s pind le with a length of wo od . Alte rnatively. co at th e thre ad s
with a liquid loc king age nt (fuel res ista nt ) prior to ins ertin g
them.
9.7 b Co rrec t lo cation of th e throttle leve r
(triple cho ke typ e)
9.7c Ins erti ng th e roll pin Int o th e spi nd le
(triple ch oke type)
8-18
Part 2 Weber carburwtors Chapter 8
9 .12 Correct lo ca tio n of th e s ho rt throttl e spind le return spr ing
(t ri p le c ho ke ty pe )
9 . 14 Fitting th e intermediate linkage (t rip le c ho ke type )
Fig. 8.20 Drilling the throttle spindle (t riple cho ke types )
A Gauge
(Sec 9 )
B Driff
C Ann
14 With th e t hrott le va lves (4 5 ) fully c losed, tighten t he inte rm ediat e link age screws (34) (photo}.
15 If a new le ver (41 ) or sp ind le (3 8) is being fi tted , t he sp in d le
mu st be drilled with a 0 .079 in (2 .0 mm ) d rill to accom moda te
th e roll pin (44 ). To d o thi s it is ess ential to obtain t he W e ber
ga uge no 9620 17 5 2949. Fit the gau ge to the cent ral barrel
flange wit h t he lever (41 ) atta c he d to th e lo ca tio n peg . then dri ll
t hro ugh the leve r an d sp ind le w hilst hold ing the thrott le va lves
fully shut.
16 Ins e rt the roll pin (44) and d rive it through the le ve r and
sp ind le un til it is in a cent ral po sition.
17 On \DAP and IDT P ty pe s, e nga ge t he c a m and linka ge to
th e lever (41) , fit th e cam to t he pivot (40~, t ighten th e pivot and
fit th e retaini ng spri ng clip (3 9 ). On a ll o the r types , engage the
lin kage {43} to th e lev e r (4 1) then connect the re maining end to
th e ca m (4 2 ) a nd fit th e ret ainin g spring c lip (3 9).
18 Ins e rt th e c hokes (6 7) int o th e ba rre ls with t he s ma ller
inside diamete rs an d c hoke referen ce numbers uppe rmost.
Make s ure th at the lo ca t io n drilling s coincide with the re tai ning
sc rew (5 8) hole s (pho to) .
19 Inse rt an d tigh te n th e cho ke re ta ining s crews (5 8L then
lo ck the m wit h loc king w ire th readed throug h the ho les in the
carbu retlor bo dy (photo) .
2 0 Fit t he aux ilia ry ventu ris (6 8L making s ure that the s up ply
cha nnels a re in a lignment w ith tho se in th e carbu rettor bod y
a nd a lso th at th e c ut a wa y sections of th e nozzles face the
throttle valves.
21 W ith the carburettor body on its sid e , lo ca te the reac tio n
spri ng (2 4) into t he ac ce lerator pump chamber and lo ca te the
pla te (2 5) on to the sp ring, concave s id e towards th e body
(pho to) .
22 Place the release d iaph ra g m (2 6 ! onto the plate and the
ac cele rat o r pum p bod y (27) onto the d iaphragm wit h t he s p ring
lo cating pegs fac ing o utw a rds as s ho w n in Fig. 8.1 2 (pho to s) .
23 Fit th e retu rn sp ring (2 8) over th e pegs, followed by the
d ia phragm (2 9) a nd cove r (3 0) (phot o s).
2 4 Ma ke s ure th at th e acce lerator pump le ve r roller is sea te d
on th e ca m (42). then de pre ss the cov e r and fit the reta ining
nut s (3 3) an d spring washe rs (3 2) (p hoto ). Tighten the nut s (3 3)
in diag o na l se que nce t hen c heck the operation of the pump by
op e rating th e throttle leve r.
25 On IDS types, fit th e boo ste r je t ass emb lies a nd tighten the
ret ainin g sc re ws.
26 Fit t he pump jets (70) to the a ccelerato r pump delivery
valv es (71) followed by th e washe rs (6 9L then fit and tighten
t he assemblies into th e carburettor bod y.
2 7 Fit and tigh ten th e acce lerator p um p inlet vefve ts l (7 2) to
t he bottom of th e flo at c ha rnbe rts },
28 Inse rt th e em uls ion tu bes (7 3 ) into th e ca rburettor body
then fit and tighte n th e air co rrector jets (74 ).
29 Press th e idling jet s (6 5) into their ho lders {6 6! a nd t ig hten
th e holde rs into t he ca rburettor body,
30 Tighten th e main jets (BO) into the holde rs (61) and tighte n
th e holder s into th e carbu rettor bod y.
3 1 Fit th e w ash er s (6 3) to the d rain plugs (64). then tig hten
the plugs into the ca rburett c r body.
32 l ow e r t he floats (15 ) into t he float chambe rs with the
ope rating tabs fa cin g upwards. then fit an d tig hte n the fulc rum
pin s (1 8 ) to geth er with washers (17). lock th e pins with lo c king
wire t hrea ded throug h t he adjacent ho les in th e body (pho to).
33 The flo at lev e l adjustmen t mu s t now be checked in t he
follow ing ma n ne r: obta in a le ngth of rubber or a plastic wedge
approxima te ly 0 .25 in (6 .3 5 mm ) thick (t ubing is idea l for the
proce du re ). Ins ert the ru bber o r plastic between the flo at a nd
the outer carbure ttor bo dy. the n lift the float unt il the d istan ce
from th e ca rburettcr upper fa ce to th e float tab is 0 .709 in (18 .0
m m) [photo s }, If a d epth g au ge is not available, us e vern ier
ca lipe rs and a fee ler ga uge as shown in photo 9 .3 3b but m a ke
al lowance for the th ickne ss of th e feeler. With the float he ld in
this position by th e w e d ge . check that the distance from t he
ca rburetto r u ppe r fa ce to the top of the float is between 0 .492
in a nd 0 .5 12 in (12 .5 mm and 13 .0 mm ) (photo). Do not take
into co nsidera tion the float seam and make the c he ck at th e
high est point of the flo at perimeter. If th e dimension ob tai ned is
incorre ct, ca ref ully ben d th e flo a t ta b accord ingly (Fig. 8 .21).
3 4 Chack and adjus t t he flo a t level adjus tme nt s of both floats
us ing th e pro ce dur e d es cribed in pa rag raph 33.
35 Scre w the ne e d le va lves (5) into the c a rb ure tt or cov e r III
9.18 The choke and locating hole (triple
cho ke type)
9. 19 Lockinq wire att ached to the choke
retaining sc rew (triple cho ke typel
9.2 1 Correct locati o n of t he acce lerator
pump reaction spr ing (triple chok e typ e)
2
9. 22a Fitting the acc elerator pump
release dia phra gm .
9.22 b ... and body (triple choke ty pe)
9.23a Fitting th e acce lerato r pump ret urn
s pring (triple chok e type)
9.23b Fittinq th e acce lerator pump
dia phragm (triple choke ty pe )
9.24 Correct location of th e ac celer at or
pump lever and cam (triple choke type l
9.3 2 Float fulcrum pin locking w ire
location (triple cho ke typ el
9.33a Us ing a rubb er wedge to set the
float height (triple choke type )
9.33b Che cking t he float tab heig ht with
a verni er and feeler gauge (triple choke
type )
9.33c Chec king the float hei ght (triple
cho ke typ e)
8-20
Part 2 Weber carburetors Chapter 8
F ig. 8.21 Flo a t level adjustment dimensions on triple choke types (S e c 9 )
Float s
2
Tab
3
Gauge
4
Ca ver
5
Needle valve
(wh ere fitt ed). Tigh ten t he nuts a litt le a t a time in diago na l
seq ue nce.
4 3 Wh ere filled, lo cat e th e gaske t ove r th e co ve r (1I,
44 Fit th e ai r int ake hor ns (3) and t ighte n the reta in ing nut s (4).
4 5 On 4 6 IDA 3C types , fit t he gau ze filters (7 6) and tig ht en
t he retai ning s cre ws (7 7).
46 Hoo k th e thr ottle lev er return sp ring to th e th rottl e leve r a nd
spr ing plat e (wh e re fitt ed).
47 With the ca rburettc r com pletely asse mbled , t he idlin g
adjus tment scre ws s ho uld be turned to th eir prelim ina ry se ttings, To d o this, first s crew in th e throttle idling adju stm ent
sc rew until it jus t tou ches the throttle lever , th e n co nt in ue
turnin g for a furt he r 2 turn s. Working o n the idling mixture
volume sc rews in turn, fully screw th em in until t hey are in lig ht
conta ct with the ir sea ts th en ba ck th em off 2 turn s. Fina l a djus tments will be ne cessa ry w hen th e ca rbu rettor is fitt ed on th e
e ngin e (refe r to Sectio n 10) .
10 Tuning
9 .3 5 Checking th e ne e dle valve height (triple choke typ el
without an y wa s her s and chec k th e distan ce fro m the cov e r
fa ce to th e ne e dle ball a pex with the ne edl e valves in th e closed
po sition and without the needl e ball s being d ep res sed. M ak e
th e ch eck w ith verni er calipers an d d edu ct th e resul t from 0.709
in (1 8 .0 mrn] to give th e thi ckn ess of w ashers requ ired (photo).
3 6 Fit th e wa sh ers (7 5) t o th e needl e v a lv es (5) an d t igh te n
th em into t he ca rburetto r co ver (1) . Check th at t he dim e nsions
described in paragraph 35 are now 0.709 ± 0.004 in {1 8 .0 ±
0 .1 m m }.
37 Fit th e w ashe rs (6) to th e need le valve hou sin g plugs (7)
and tigh ten th em into th e carburettor cov e r (1).
38 Conn ect th e inte rmediate ho s e to t he fue l inlet un io ns (9
and 10).
39 Fit th e wash er s (13} to th e inlet union bo lts (' 4) follow e d
by t he filte r ga uzes (12), then fit the bo lt asse mblies to th e
unions (9 a nd 10) a nd fit th e sealing was he rs (8).
40 Loca te t he fuel union s to th e c a rbure tto r cove r (1} and
tighten th e u nion bolts (14}.
4 1 Ca refully lo ca te the gas ket (t t} to th e carbu rettor bod y ove r
the s tuds (16).
42 Lowe r the ca rtiurat tc r cover (1) over th e lo ca ting stud s a nd
onto th e gas ket , th en fit t he ret ain ing nuts (4 A) a nd sp ring pla te
Not e: Refer to Chapter 3 for general notes on tuning.
1 The idling a djus tment scre ws s ho uld be se t to t he ir preliminary po sition s as des c ribed in Sections 8 a nd 9 .
2 Connect a tacho meter to the e ngi ne in ac co rda nce w ith t he
m a nuf acture r's instructions.
3 The carburettors mu st be sync hro nized in orde r to de liver
e qual amo unts of air/fu el mixture to ea ch individual cylind er. To
check the a djust me nt it will be nec essary to ob ta in a length o f
tubing of app roxima te ly 1 metre in le ngt h and of ab out 5 mm to
1D m m (0.2 5 in to 0 .0 5 in} intern a l diam eter. Altern ativ ely a nd
prefer a bly, a sync hron ize r may be us ed lp hc tcl.
4 Re mo ve th e air cle an er ts l if fitt e d , th en s tart the eng ine and
run until normal o pe rati ng te mpe rat ure has be e n reac he d Ile the
th ermost at has opened ). To e ns ure tha t the e ng ine is re ally hot
eno ug h, drive it hard over a t le as t a 5 mile d ist a nce.
5 Switc h off th e e ng ine a nd disconne ct th e ac cel e rato r rod
co nn e ctio ns f rom each cerbu rsttor.
6 Sta rt the e ng ine and if ne ce ss ary, adjust ea ch idling speed
adjusting s crew by equ a l am ou nts until th e e ng ine is id ling a t
the ap proximate rec ommended idling speed (usu ally be tween
600 and 800 rpm for tou ring mod e ls a nd a pp roximately 1000
rpm for spo rts ca r mo del s).
7 On tr iple cho ke t ypes o nly, loo s e n the th re e co mpe nsa tio n
a djus tme nt scre w loc knuts an d scre w th e adjus tme nt screws in
until th ey a re in light co ntact with th eir seats, If the eng ine
fa lte rs as a result, tum t he idle speed adjus tme n t sc rew on each
carb urettor by eq ual amou nt s until th e e ng ine run s even ly
8-21
Part 2 Weber carburetors Chapter 8
METER
SYNCHROUJW
METER
CAflBtlfl ETTOfi F
10 .3 W eber caebu rettor synchronizer
again. Place one end of the synchronizing tube in the middl e of
one air intake and listen at the other end to the amo unt of hiss
present. Alternati vely, use the synchronizer to record the air
flo w of the air inta ke. Check each air int ake of the carbur ettcr to
det ermin e which one is passing th e greatest volum e of air. th en
adjust th e remaini ng carburettor barrels to give identi cal
volumes and fin ally tighten th e adjust ment lo cknut s. Carry out
thi s procedure ind ependently on each carcurettcr fitted to the
engine,
8 On al! carcurettor typ es, each carbur etto r mu st now be synchroniz ed with the remaini ng carburettors. To do thi s, allow th e
engine to idle and check th e volume of air flo w ing through one
air intake of each carburettor using t he length of tube or the
sync hronizer. Determin e the carburettor whi ch is passing the
.
..!..............
.........•.•.•..•••..
.....•••....
., ., .....
3
medium volume of air and adjust the idle speed adjustme nt
screws of the remaining carbur ettors until they also pass
identica l volumes of air. Whe re t he t hrott le linkage lserranqed
from a common shaft , t he individual throttle levers will have to
be adjusted by loo sening th e locknut s.
9 If necessary. turn each idling speed adjustment screw by
equal amounts to bring t he engine speed within the recommended idling limits.
10 The mixture screw adju stment s on each carbu rettcr must
now be set and synchronized. Since each screw wa s turned to
it s preliminary sett ing, w e must assume tha t they are
reasonably synchro nized to start with. Wi th the engine idling,
turn each screw by equal amounts (t a turn initially) and
observe wheth er the engine speed falls or increases. M ake
several adjustments in a simi lar manne r until the engine runs at
the high est speed comm ensurate with even firi ng.
11 If necessary. again turn each idling speed adjustm ent screw
by equal amounts to bring the engine speed within the recom mended idling limits.
12 The final mixture screw sy nchronization can be dete rm ined
by allow ing t he engine to idle, then to remove each spark plug
lead in turn and observe the reduction in engine rpm on th e
tachom eter. The reduction should be identical for each cylind er,
th en proving that the mixture strength is also id enti cal fo r each
cylind er. A further check can be m ade by removin g th e spark
plugs aft er the engine has been idli ng for approximately 15
minutes, th en checking tha t they are all in identical cond ition.
A ny with bl ack sooty deposits indi cate that the particular
cylind er is runni ng rich.
13 If necessary, adjust the idling speed screws on each carburettor by equal amoun ts to bring the engine speed within th e
reoomm ended limits.
14 Not e that on some applicati ons it may be advisable to fit
'hot ter' spar k plugs whil e adjus ting t he carburetto rs to prevent
mi sfirin g, but the original plug s must always be refitted after
completing the adjust ment.
15 Sw itch off the engine and reconnect the throttle link ages,
making adjustm ents as necessary to prevent the carburettor
sett ings from being affe cted.
16 Remove th e tachome ter from the engine and refit t he air
cleanerts] if fitted.
1
!~
..
II
5
2
•
{!g ,
3<£
76'
Fig. 8 .22 Typical th rottle li nkage arran gement fo r a four-ca rbu rettor f itting (Sec 10)
Adjuster
2
Rod
3
S pring
Not a: Dimensions A and lever angles must all be id entical
4
A djuster block
5
Locknuts
8-22
Part 2 Weber carburetors Chapter 8
11 hult diegnosis
S ymp t om
Ren onls
Engine will not start
Bloc ke d fue l filter or je ts
Flooded eng ine as a result of d ep~ssing acc elerato r ped al
Uneven Idling
Leaking manifo ld or carbur ettor fl ange gaskets
Loose idling je ts or a uxilia ry ve nturis
ellcessive sedimen t or w ater in ca rburettor
Th rottle spin dl e du st cov ers broken (46 1OA and 48 IDA)
Throttl e spind les w orn
In co rrect tunin g adjus t me nts
Carbu retlor flood s
W orn needle valvels l
Leaking or dam aged ftoat lal
Incorr ect float level adjus tm ents
Excessive sediment in fuel
Engine tacks performa nce
In co rrec t tun ing a dju stmen ts
In corre ct fl oat level adjustm ents
Excessive sedim ent in fuel
Thrott le va lve s not fully o pening
Ac ce ler ator pump fa ulty
Acce ler ato r pump leaking (triple choke ty pes)
r xcess ve fue l co nsu mption
Needle valv e not seating
leaking Of dam a ged floatlsl
Incorrect floa l level adjustme n ts
Choked air filte r ( if fin ed )
9- 1
2
Part 2 Weber carburetors
Chapter 9 Type 40 DFA, 40 DFAV,
34 DGAS, 38 DGAS
Cont ents
secnon
Assemb ly (40DFAand40DFA.V type s)
Assem bly (34 OGAS and 3 8 OGAS type sl
a
. • • • • • • • • ..
9
D isassembly 140 DFA and 40 DFA.V type sl .... • • •• • •.
D isassembly 134 DGAS and 38 OGAS ty pes)
Fault diagnos is •.••• .• . ••••.• ••. . . . . .•.• ••.. .
5
6
t1
Con st ruction
2
Introduction ••••• ••• . . . .•••••• .
Ope riltion .. . . . . .. . ... .. . . . . ...
Removal and refitting .... • • • • • • • ..
Speci al ove rhau l procedures . •• • •• •.
Tunin g
SectiOn
. . . . . .•.• • . . .
t
.. •. . . . • . •...
3
.... . • • • • • • . .
4
. . ....• • • • • . •
7
10
9-2
Part 2 Weber ca rb ureto rs Chapter 9
A dj ustm ent data
Fast id le t hro ttle va lve ope ni ng
lnlmm)
High cam position :
40 0 FAand40DFAVtypes •.•........ .
34 OGA.S and 38 DGAS types:
0 .02 9 to 0.031 10 .75 tc O.SOI
38 OGAS 1A
380 GA5 7A
.
.
38 OGAS 3 A. and 34 DGAS ••••••••• .
3 8 0GAS 4A
.
... ... •
.
l ow ca m position:
380GAS 4 A
0 ,026 to
0 .025 to
0 .02 7 to
0 .02 9 to
0.0 2 8 10 .6 5
0 .0 27 (0 .6 5
0.0 2 9 (0 .70
O.0 3 1 (0 .7 5
to
to
to
to
0 .70 1
0 .70 )
0 .75 )
0. 80 1
0 .08 0 to 0.100 (2 .0 5 to 2 .55 )
0 .08 0 eo. roo (2 .0 5 to 2.55)
0 .100 to 0 .120 (2 .SS to 3 .05 )
0 .100 to 0. 120 12 .55 to 3.05 )
3 8 DG A.S 7A
38 OGAS 1A
38 DGAS 3A
Choke valve pull down clea rance
In{ m m)
3S' DGAS typ es:
Minimum:
A lltypes
.
M SKim um :
38 D GA.S 4A. and 7A
38 OGAS 1A and 3A
0 ,112 to 0.124 (2 .85 to 3 .15 )
. . • • . •. •.•. . . . . . . . . • . ..
. .• •••• •.• . • • . • . .
Float lev el setting dimension
4 0 DFA and 40 DFAV type s •• •••••••••... . . . . . . . . . .
3 4 DG A.S and 3 8 DG AS types (b rass float) ...... . •. . •. • .
34 DGAS and 38 DGAS types (plasti c floa t)
.
1
0 ,177 to 0. 21 6 (4.5 to 5.5)
0 .19 6 to 0.2 3 6 (5.0 to 6.0)
Closed position
0 .2 3 6 in 16. 0 mm }
1,5 7 in (4 0 .0 mm )
1,3 5 in (3 4. 3 mm)
Open po sition
0 .55 1 inI 14,O m m)
1.9 68 in l SO.O m m)
1.744 in 144 .3 mm }
Stroke
0 .3 15 in 18. 0 mm l
0. 39 3 in 11 0_0 mm)
0 .39 3 in 110. 0 m mJ
Introd uction
The cerber ettor types covered in th is Chapt er are of dual
downdraught design. Each throttle valve is mounted on 1I
separate shaft . but th e shaft s are linked by toothed sectors and
the ir act ion is synchronised .
Semi-automatic choke controls are fitted to all carburettor
type s included in thi s Chapter.
The cerburert c r is normally fitted to the engine as a single
uni t, the most com mo n arrangement' bein g as foll ows:
,
One unit on 8 six-cylind~r in-line engine, itt each barrel
fee ds three cylinders seplIrlltely
2 One unit on a six-c ylinder V-engIne, ie each barrel feeds
on , bank of three cylin ders
0 00000
Fig. 9 ,'
-
Single cerbu rettcr fitted t o II six- cy li nder in-line
eng ine (Sec 1)
The carburett or identification mark is located on t he low er
flange outer surfa ce.
2
Co nstru ction
The main body and cover of the ce rbc rettor type s covered
in this Chapter are of die cas t alum in ium ccnstructton and t he
mou nt ing fl ange i s machined fl at for fitting purposes. The cover
incorpo rates a mounting fl ange for the air cleaner assem bly and
is equipped with lou r mounting studsThe th rottl e valves are of brass and the throttle shafts are of
ste, l. The t hrottle shafts run o n Teflon {PTFEI bearing s mou nted
In the main body. The choke valv es are cadmium plated steel
and the choke shaft is of st eel on DGAS types and brass on DFA
and DFAV types.
A U fue l and air jets are of brass constructi on and are
screwed into th e main body. The emu l,ion tubes are also constr ucte d of brass.
Internal channels of the main body and cover are mo stly
drifted and are sealed wi th lead plugs wh ere necessary.
The fue l float assemblies are of brass constru ction ; DFA
and DFAV types have a single flo at and DGAS type s have two
semi ·fl oats .
000
--
Fig , 9.2 Sin gle cereuretto r fitted to It six- cy linder V- engine
(Sec 1)
9-3
Part 2 We ber carbureto rs Chapter 9
3
the vacuum will cease li nd the cho ke valves I SS) will close.
how ever th e passage of air will open the choke valves IIgainst
the acti on of the bt-meeemc spring (511 due to the offset construction of t he choke valves (55). On OGAS typ es. th e action of
the shaft (50) is modulated by an tr ueenat spring (4 91.
As th e eng ine wa rm s up. the bi -metallic sprin g (51 )
prog ressively open s and th e choke val ves (55) , until at normal
operati ng temperatu re th ey are held fully open. The fast idli ng
screw (5 2) doe s not now rest on th e fast idlin g cam { 5 9 } since
th e latter has been rot ated b y t he bi- me tallic spring and
therefore the thronle valv es (12 1are free to return to the norm al
Idl ing posit ion.
Operation
Cold starting
Refer to Fig. 9.3 and note that wh en th e engine is col d and
t he throttl e pedal has been depressed once, t he bi -metall ic
spring (51) rotat es th e spindle (52) and closes the choke valv es
(55). At the same time the fast idle cam (59) prevents th e
t hroll ie valves (121from complete ly closing.
W hen the engin e is cranked. a rich mixture is d rawn fro m
the l'IOu le (9 ) to facilitate starting. As soon as the engi ne fi res,
vacuum from below the throttle valve is relayed through th e
channel (53) to th e diaphragm [47). The shatt lSOl then moves
and parti ally opens the cho ke valves (5 5) against the action of
the bi-metallic spring (5 1). If the thro llie is open ed at this sta ge,
Idlin g an d p r o g r e ssion
Refer to Fig. 9 .4 and note that wh en th e engine i s idl ing. th e
.
2
Fig . 9 .3 Automatic choke oparatlon (D GA S type shown) (Sec 31
12 Thro ttle valves
50 Rod
5' 8 i-me ta llic spring
4 7 Diaphragm
48 Bush
49 M odt:/ating
52 Shaft
53 Channel
54 Lever
9
No zzle!>
32
55 Choke vaNe!>
56
57
58
59
Lever
Lever
Spring
Cam
60 Linkage
61 LeYer
62 A di usting scraw
63 Lever
64 Housing
22
"
":~
"
" "
'2 Wefls
' 4 Throttle valves
2 2 Calibrate d hole
23 Idling jet
33
Fi g. 9 .4 Carburetto r idling and progruslon ph.,. (Sec 3 )
24 Channel
25 Channel
26 M ixt ure screw
2 7 1dling fee d hotes
28
29
30
31
ClIm
Lever
Rod
Vent and air bleed con rrof
.
",
32 Channel
33 Progression feed holes
9-4
Part 2 Weber carburet ors Chapter 9
throttle VIM S (1 4) 8re sh ut. Fuel Is drawn fro m the flo at
chamber through Int em al channels to t he emulsio n tube we lls
(12) and the n passes :i1iary ventu ri, (17). The m i>:l ure
then com bines whh t he main air supply as ~ is drawn th rough
the chokes U 61and Into th e engine.
At higl'l engine speeds with the throttle valves (141 open,
the overfeed enrichm ent circuit is brought int o act ion lnot 40
DFA types ) lind additional fu el is supplied through th e calibrated
tubes III via th e calibrat ed bushes (4).
DGAS type cerbu ret tcrs are also equipped w it h a full power
valve w hic h operat es imm ediatel y the throttle valves are
opened quickly. Refer to Fig. 9.6 and not e that under th ese condit ions the vacuum thr ough the channel 171 is insuffici ent to
dr aw th e dia pilragm (4) against the spr ing (6) . The opera tintl
rod (51 therefore opens th e fu ll power valve (17). The fu el level
in th e emcrstcn tuba w ells (141 immediately rises and the
mixture dra wn from the nozzte (9) is enrichened. When the
throttle valves (12) are partialiy open, the vacuum th rough the
channel (7) overcomes th a tension of the spr ing (6) and the fu ll
powe r valve shuts.
A cceleration
To provid e the eng ine with a rich mbc ture w hen accelerating. the carburett or is provid ed with a diaphrag m type acceleration pum p which is operat ed by th e primary throttle shaft but
3.2 Location of the Idling and prog ression holes 140 DFAV type}
2 3 4
L'
~
!
,
11 -
- iSc--, 1
e
"
'.~.
'"
"
1
2
3
4
5
6
Enrichment tub e
A ir corrector !et
Channel
Calibra red bush
Ne edle valve seat ing
N eedle
I
I
I
13
12
11
Fi g. 9.5 Carburettor nor ma l phase l DFAV types) ISec 3 )
Fulcrum pin
Float
Ftoll t cham ber
10 Mainjet
11 Throttle shaft
7
8
9
12
13
14
15
Well
Emulsion tub e
Throrrle valve
Lever
Choke
I.
17
18
'9
20
21
Auxiliary ventl.lfi
No zzle
PrimiJry sector
Secondary sector
Throttle shaft
9-5
Part 2 Weber carburetors Chapter 9
:2
3
4
e
'U
,;,.'-
0 ,0
C ~ ,
!
;<7
- 1. I:IIi
~
ae
, "
"
~
-.
~
~
"
.
"
Fig . 9 .6 Ca rbu retto r no rmal phase IDQAS typesllS ec 3 1
1
2
3
4
5
6
7
Needle ve tve sea ting
N eedle
8
stoet
10
9
1I
Diephrtlgm
Rod
S pring
Chtlnnel
12
13
14
A ir corrector jet
N ozzle
Auxiiiary ven turi
Choke
Throttl e valve
Emulsion tu be
W ell
15 Meinjer
16 Cellbrtlted bu sh
T7 Full po wer valve
18 Float chamber
19 Hook
20 Fulcrum pin
2 1 Prima ry s ector
"
Fig.
22 Secondary sector
23 Throttle shaft
24 Lever
25 Throttle shaft
26 Calibrate d bu sh
27 Channe l
28 Ell£ichm ent tubtl
9 .7
Carbur ettor acce leretion
phese (Sec 3 1
18 Float cham ber
36 Cam
"
37
38
39
40
41
42
43
44
45
46
I,
,.:...-J I
,.~
"
"~- ......
"
.
Lever
Diaphragm
Cha nnel
Delivery valve
Pum p je t
Spring
Return spring
S tili
Blanking needle
DischfJrge jet
"
inj ect s into both ventu rts, Reference to Fig. 9 .7 will snow that
when the thron le valves are closed. the accelerator pump
diaphrag m (38) draws fuel fr om the float chamber (18). through
the ball valve (44) into the pump chamber. Wh en the throttle
varves are opened, the cam (36) moves the lever{3 7j and fuel is
forced along the channel (39). t hrough t he delivery valve (4 01
and out of the pump jet (4 1). The spring (42) absorbs the initial
mo vement of the lever (37) and prol ongs the tuer delivery
period. Excess fuel and any accumula ted air is discharged into
the fl oat chamb er (1B) throu gh the Channel (4 5) and calibrated
bush (4 6 ).
OGA$ typ es are fitted w ith a discharge bl anking needle
wh ich determines the amo unt of fuel return ed to the float
chamber l181.
OFAV types are equipped with an accelerato r pump lever
incorporating t wo pivot hol es whe reby the pump stroke can be
varied.
4
Removal and refi ning
Note : The following procedurtl gives a general rathe r th tm a
spe cific method of removing and refitting the cerburetto r, as
much will depe nd on the location within th e vehicle.
1 Unscrew lin d remove the retain ing nuts and w ithdrew the
air cleaner cover (screw s are fined to som e mode ls).
2 Lift out the air filter element.
3 Band back the Iockt abs and unscrew t he air cleaner body
retaining nuts.
4 Unscrew and remove the mou nting bracket bolts and
2
9-6
Part 2 Webe r carburetors Chapter 9
remove t he a ir c lea ne r together w ith the reinforcemen t pla te
and gasket .
S
Part ia lly drain the cooling s yste m and d isconnect the two
water hoses.
6 Di scon nect the fue l supp ly pipe and return pipe (w here
fitted) and release t he vent tube from the top of th e floet
chamber.
7 Relea se t he di stributo r a utom at ic adv ance pipe from the
side of the cerburettcr.
S
9
Discon nect the throttle co ntro l shaft fr om t he t hrottle lever.
Disconnect the cra n kcase ve nti lat io n pip e f ro m t he heat
insul ato r s pace r, If fitted.
10 Unscrew and remove the carburett or moun ting nuts then
with d ra w the un it over the mounting studs.
1 1 Remove the Inlet manifold gasket and spacer li f fitted) and
clean all traces of gas ket from th e in let manifold and ca rbu rettor
f lang e.
t 2 Prot ect the inlet m anifold from ing ress of forei gn matte r by
sealin g it w it h mas k-ing tape.
13 Refitting is , reversal of removal, but th e fo llowi"'g
,ddit io"' al po ints sho uld be noted:
(aJ A lwltrs fir new gaslrets and tigh ten the mOllnting no ts
in diago nal u qlle nce
(b) Note rhar on some fittings the lo wer gaslret hit s two
m etal V-no tc hes w hich must focate w ithin th e infet
m anifo fd
(c) Refifl the cooling system in eccorasnce with the
manufaCfllrer 's tnstru ctions
(d) The idlin g adj ustm ent scr ew s should be set as
described in SectIons 8 and 9 find fina lly tllned as described
in Sectio n 10
5
D isasse m bly 140 OFA and 40 D FAV ty p8S)
Tnoroughly clean the carbcre ttce exte rior and wipe dry .
2 Referring 10 Fig. 9 .8 . un screw a,.,d remove th e fu el filter inspect io n plug (41 and eetr act the filter (5 1(phot o).
3 Disco nnect the cho ke plat e operating rod (16) tra m the
laver (3 9) by removIng the split pin 115).
4 Unscrew and remove th e carberett or co ver retaining screws
f3 ) toget her with t he spring washers. th en carefully lift the cover
(11 from t he main body (pho t o).
5 Invert the carburettcr cov er (11 so that the flo at assembly Is
uppermost. then extract t he float fu lcrum pin (14) and withd raw
the fl oat assembly (1J ) togeth er wit h the need le of the needle
valve (12). If necessa ry, use a suita ble diame ter pin punch to
tap the pin from the two po sts. but on no accoun t prise the
slotted po st apart (photo) .
6 Unhook th e need le from the flo at assembly (13 ).
7 Uft the gasket (9) from th e cov er (1).
8 On 40 DFAV types only. unscrew and remo ve the vent and
power valve (92) from the cover 111(pho IO).
9 Un screw and remove th e need le valve (1 2) seating and
5.2 Remo ving t he fue l filte r (OFAV type}
remove th e gasket l 11 1(ph ot o).
10 Un screw th e tw o main j et s (1 71 and remove them fro m the
bottom of the float cham ber in the main bod y (phot os\'
11 Unscrew the idling jet ho lders (831 from each side of the
carburertcr body. then separate th e idling jet s (84) fro m their
ho lders (photos).
12 Unscrew and remove the air corr ector Jets (8S) from the
carburettor body (ph010S).
13 Inv ert the body and ext ract the emu lslon tubes (89) . If these
are ti ght due to overtightening of the air correct or jet s, use a
selft appin g screw to remove them but take care not to damege
the tubes (photcel.
14 Unscrew and remov e th e idling adj ustIng screws (8t) and
springs (82 ) from the body.
1 5 Un screw and remove th e throttle id ling adjustment screw
(28) and spring (2 7).
16 Unscrew the accelerator pump delivery valve (67 ) and
rem ove it to gethe r w it h the pump jet (861 and gasket (S5). then
separat e the ga sket and jet fro m the valve (pho to s).
17 Unscrew and remove the eccelereto- pump disch llrg e
blank.i ng plug 118 1(photo).
18 Unscr ew th e fou r screws (2 6) and w ithdraw th e accelerator
cov er (2 5) together with the di aphragm (24 ) and spring {2 J). If
necessary. peel th e di aphr agm assem bly (24) from the cove r
(2 51 (photo s).
19 W or king on th e cerbu rett or co ver ( 11, ext ract th e spli t pi"
(lSI and deta ch th e ope rating rod ( 161 1rom th e choke spind le
arm .
20 Pull th e rod { 15 1 th rou gh t he seal (' OJ. th en prise the plug
(10 1) and seal (10) from the cover (1) (photo).
2 1 Note the iocation of each choke valve (7) and if necessary,
mark th em wit h a pen cil.
22 Un scre w the retaining screw s (5} and remove the choke
valves (7 ) from the shaft (8). then remove th e shaft (8 ) from the
cover Lt ].
23 W orking on the carbu rettor body. unscrew th e automatic
choke w at er housing ret aining bolt (58) and remo ve it together
w ith the gasket l 571.
24 Remove the cover (56) and gasket (541; cut th e gasket from
th e th ermost at assembly (53) if it is stuck .
25 Unscrew and remove th e reta ining screws (59) and lift tha
aut om atic choke thermo stat assem bly (53) from th e body (4 71.
then remove th a retai ning ring (5 5) (phot o).
2 6 Remove the disc gasket (52) . th en unscrew and remove the
three ret aining screw s (511 and spring wa shers. Withdraw th e
automatic choke body (4 7) at th e same t im e dis engage the fast
id lin g control rod (6 1) from the ttvottte lever (71) by extracting
th e split pin (60) (photos).
27 Disconnect the rod (6 1) fro m the fast id le lever (29) by
extracti ng th e split pin {50L if fitted.
28 Not e the 10C8tl00 of the Individ ual com ponent s on the
automatic choke bod y (47) before di smantling th em.
29 Prise the O-ring sea! (3 5) fro m the sid e of th e carbu ret tc r
(photo).
5.4 Removin g the carbu rettor cover
(DFAV type)
5.5 Withdra w i"'g the floa t fulcrum pin
(DFAV type )
,.".,
5. 10 a location of th e main jet s I OFAV
5.8 location of the vern and air bleed
valve I DFAV typel
2
5.11 b Idl ing jet and holder (D FAV type )
5. 10 b Location of the ma in jet size I DFAV
",pel
,
ty pe )
5.12 a Remov ing 1he aIr con nector jets
(DFAVtype)
5. 12b Air corrector jet sire locat ion
(OFAV t ype)
5. 13 a Removing the emul sion tu bes
(DFAV tyoe)
5. 13 b Emul sio n tu be si ze lo cetion
(D FAVtype)
5.1 6e Removing th e acce lerator pu mp
delivery VIIiv'!!( DFAV type!
5. 11c Idllng jet sire location (DFAV
9 - 8 - - - -
I
Fig . 9 .8 ExpkJ ded view of the 40 DFAV carburetto r h ypic.1)(See 51
,
2
3
4
5
e
7
8
9
'0
tt
/2
/3
/4
/5
16
"
/8
'9
20
2/
22
23
24
25
2'
Car buretr or co ver 8ss8mb fy
Cerburett or to air detlner ' /li d
Cover screw and W 8 $he,
S trainer in spection p lug
Fuel inle t st1"iner assy
Choke plate screw
Cho ke plate
Cho ke shaft and le ver SUI'
Co ver to thro ttle bo dy gtlsket
Air clean er dust seel
Fuel int ake v81ve ga sket
Fuel inlet needle valve assy
Float assy
Floet le ver shaft
A uto- cho ke control ro d spli t pin
Auto-c ho ke operat ing rod
M8I'nje t
A cce lerator plug dis charge plug
Thrott le le ft-han d sha ft
Throttle righ t-han d shaft assy
Throt tle plate
Thrott fe pla te scre w
Acceleretor pump se ff-/oading
spring
Accelerator pump diaph rag m aS3'f
A ccelerator pump cover IISS 'f
A ccelerator pu mp co ver scre w end
washer
27
28
29
30
l ever
31
Spring
32
33
34
35
3'
37
38
Screw
39
40
4/
42
43
44
45
4'
47
48
49
60
Idling adjusting screw s prln.Q
Idfi ng adju stm ent scre w
Fast idling adju sting lever ass!'
A Ul o-choke sh aft spring
Auto-c hoke sha ft specer
A ut o-c ho ke body O-rfng seel
A ura -choke lever fixing nu t
Spring wa sher
Fast Idle le ver p ivot screw and
washer
A uto -chok e le ver
Right-han d shaft s~cer
Fast idle lever spring
Fast idle lever w asher
Auto -choke co ver screw (lnd
washe r
A utQ-choke cover
Auto -choke vacu um diapllr/Jgm
spring
AUla-cho ke vacuum diaphragm
and shaft ass y
Auto -choke bo d y assy
A uto -c hoke sha ft an d le vflr oss y
Auto -cboke sha ft adjust ing plate
S cre w
5'
52
53
54
Auto-choke bo dy to rhrott/fJ bo d y
screw an d washer
76
Geared sect ors co ver
Geared secfor (le ft -h/md)
A Ulo-choke thermost ll l ll SSy
78
79
Waf er chambe r to therm os/llt
80
A uto- cho ke bodr gtlSke/
ass y
55
56
57
58
59
60
./
62
'3
.4
65
••
.7
.8
'9
70
"7273
74
75
Throttle she f t bearing
77
Lock ing ,ing
Water Cha m ber
W ash er
Boll
S crew
Fast idle ro d split pin
Fast idle rod
Thrott le sha ft nut
Lockwasher
Throttle le ver
Geared se cto r co ver s crew
S pring washer
Geared se ctor adju sting screw
Ex ternal too th w asher
Wash er
Geared sector (right-hand!
Fast idling 1eVeT
ThroUIe sha ft bushing
Wa ve washer
Full throttle stop leve r
W (lsher
Geared sector adjus tin g lever
Thrott le conlro/ return spring
( le ft -hand)
/dle adjus tm en t needle !Jcrew
Spring
Idling jet holder
Idle je t
Nozzle bar gaske t
A ccelerato r pump jet
Accelerator pump v/lIWJ /lSSY
A ir corrector jet
Em ulsion tube
Auto -ch ok e w ave washtlr
Fast idling adju stin g lever bush
Po wer valve
Le ver fixin g s crew
Bushing
Valve co ntrol le ver
W asher
Spring
S p fit pin
Valve con trol rod
100 Return spring fright shaft)
10 1 Dus t seel plug
8'
82
83
84
85
8.
87
88
89
90
9'
92
93
94
95
9.
97
98
99
'f'
CD
I\)
5.1 6b Acceler ator pump jet size locati on
(DFAVtyp e)
5.17 Removing th e ac ce le rato r pum p
disch arge plug (DFAVtype)
5. 18 a Accel erator pump loca tion (DFAV
type)
5.18 b Rem oving the accelerator pu mp
coverlDFAVtypel
5.20 Rem ov ing the cover dust seal
(DFAVtype l
5.25 Wi thd ra w ing
hou sing (DFAVtype l
5.26 a In5Ulatio n gasket location IOFAV
,,,,,I
5.26 b Loca tio n of tile fas t Idling con trol
rod (DFAV type l
5.29 Aut o ma tic choke O-ring sea l
loc ation IOFAV type )
5.3 3 Remo ving t he au tomatic Choke
shaft (DFAV type l
5.34 Removing the stop plat e (OFAV
type l
5.3 5 Remo ving th e diaph ragm cove r
(OFAV type)
the
th ermostat
5.36 Withdraw ing the diaphragm rod
(DFAV type l
5.3 9a Removing the auxiliary vent uri
(DFAV type )
5.39 b Auxiliary vent uri size location
(DFAV type)
2
Fi g. 9.9 Tool tor ho ld in g throttle shaft
I OFA and OFAV types) !Sec 51
5.49a Removing a throttte val ve (DFAV
typel
5.46 Vent valve operating arm location
(DFAVtype)
5.48 Throttle valve retain ing
location (DFAV typ e)
5 .4 9b Thrott le valve showing the idle
bleed hole (OFAV type) farrowed)
5.50 a Removing a throttle shaft (DFAV
type)
5.50b Removing 8 Tefl on bush (OFAV
and fu el is forced along a channel and through
the delivery valve and pump jet (87) . A spring in the diap hragm
assembly {7l} absorbs the in itia l movement of the lever an d
extends the fuel de Uvery per iod. Excess fuel and any
accumulated air is discharged into the float chamber through a
channe l and calibrated bush.
A Carburetror intake
8 and C Vap our movement
with ignition on
o Valve seat p osition with
igniti on off
E Val ve seat
F
Float
G Vap our movement with
H
J
ignition off
Canister tube connec tion
Solenoid
Idle cut-off valve operation
As soon as the ignition is switched off , th is valve stops t he
flow of fuel mixt ure from t he idle circu it. Wi th the ignition
sw itched on, th e idle circuit ope rates nor mall y.
The valve elimi nates any tendency for the engine t o run on
w hen t he i gnit ion is sw itched off.
Float chamber vent valve operation (USA types
only)
The valve controls two separate vent circu its. W hen the
ignit ion is on and the engine runn ing , the fl oat chamber is
vent ed t o th e air cleaner through an int ernal channel. In this
condition the val ve sole noid is energ ised and the rubber seating
i s pu lled against the t ension of t he return spri ng. W hen the igniti on is sw itc hed off , the solenoid i s de-energised and t he spring
then pu shes the seatin g to shut t he air cl eaner vent passage and
ope n the passage to the evaporative em ission carbon caniste r.
Dashpot operation (USA types only)
W hen the throttle valve is released, the dashpot retards the
actio n of the throttle as it approaches the id ling pos ition ; this
prevents an over weak m ixt ure and therefore reduces the emission of certa in harmful gases from the exhaust system.
4
Rem oval and ref itti ng
Not e: The fo llowing procedure gives a general rather than a
specific method of fBmoving and refitting the carburettor, as the
fitting may vary with different vehicle mode ls.
10-4 - - - - - - - - - - - - - - - - - - - - - - - - -
,
3
~
10
Part 2 Weber carburetors Chapter 10
Diaeonnect the battery e' M 1.11ecessary to diseng age the
lev er (5 3) from the retu rn spring {54} (pho to].
40 Remove Ihe spring (54) and spacer ISS). then remove the
stop le llef IS S) whil st t e nsion ing it ag a inst the spring (5 7)
(ph oto).
4 1 Disengage the stop lever (56) then withdr aw the spring
(57) and space r (4 5) .
42 Mark the p rima ry throttle va lve 1591 w ith a pe nc il so that it
can be refi tted in its or iginal pos ltlOfl , th an unscrew and remove
th e ret aini ng screws (501 (pho t o),
43 Fully open the primary thrott le and remove the valve (59 )
from the shaft (58) whil st holding the shaft against the tension
of the 5prln g (7 3).
44 Check t het th e throttle shaft (6 8 ) is not d am ag ed w he re Ihe
retaining screws have been pee ned; if it is. cerefunv fi le th e
shaft w ith a fin e fi le. If th is precau tio n is not tak en, the Teflo n
bushe s (431 may be damage d w hen the shaft is removed. If t he
reta in ing screws (60) are tight due to previous peening. use a
fil e to remo w the end s of the screws complet ely; thi s w ilt also
prevent damage to th e shaft (581.
4 5 Carefully withdraw th e primary thr ottl e shaft (581 from the
main bod y, at the same ti me release the tension on t he spring
(7 3 ).
46 Remo ve the retu rn spring 1731. th en prise the out er Tef lon
seals (40) and wa shers (3 91from the main body.
47 U sing a screwd river, extract the Tef lon bushes (43) fro m
the main body; identify them for refitting.
4 8 Mount the prim ary th rott le shaft (58 ) in a shaft Jaw vice and
note th e po sition of the accelerator pump cam.
49 Bend back the tab wa sher (51) and unscrew the nut (50).
50 Remove the nut (50 ). tab washer (5 1). pump cam (74) and
spacer washer (4 5).
5 1 U nscre w Ind re move the seeondery t hrottle shaft nut f79}
and remove the spring w asher (80 1and space r /8 11Iphoto).
52 Close the secondary throt tl e and mark it wi th a pencil so
that It can be refuted in it s original position, th en unscrew and
remove the reta ining screws (60) (phot o). If they are ti ght,
remo ve the peened ends of th e screws with a fi le.
53 FuliV open th e seconda ry thro ttle and remove t he valve (59)
from the sha ft 14 2}.
54 Check the seconda ry thrott le shaft 1421 for dama ge In the
vicin ity of the retaining screw boles. Use a fin e fi le to remove
any irregularit ies.
55 Wit hdraw th e secondary throttle shaft (4 21 fr om the main
bod y, then prise out the outer Teflon seals (401 and wash ers
(3 9). Remove the spacer (41) (photo).
56 Usin g a screw driver, ext ract th e Teflon bushes 143) from
the secondary shaft bor e in the main body . Ident ify them so th at
th ey can be refitted in t heir origina l locations {photo}.
B
Specia l overhaul procedure.
Aher carryi ng out th e general cverneur procedures given in
Chapter 4. the fo llowing special procedures shou ld be made :
1 Reform th e idlin g jet seats using th e special W eber tool ,
carefully rot ating it in alternate directions. Finish the seali ngs
with the further W eber tool by gently tappin g t he tool wh ilst
mtating it.
2 Reform lh e main jet seats at the bottom of t he emulsion
tube bores using the same procedure described in paregreph 1.
3 Check the Teflon bushes and seals of the ch ok e and th rottle
valve shaft bores for det eriorati on and w ear and renew them if
necessary.
4 Check th e choke and th rottle shafts for disto rtion (as a
result of peening) in th e area around the valve retain ing screw s.
Use a small fi le to remove any irregul ariti es.
5 Check the int ernal channels of the main body and cover for
blocka ge by injecti ng fu el w it h a syrin ge
l;9- - n
I
a
"
"
Flei. 12.3 Normal phase lSec 31
1
2
3
4
Fulcru m p in
Flotl ! chll mber
F/ost
Ret llf'fl hook
7
8
9
10
5
Neild!.
, 1 AuxHisry venturis
6
N.edl. valve sesting
12 Chokes
M ixture enrichmflfll lubes
C.libr sfed ho~$
A ir correctorJets
Noules
Normsl running
Refer to FIg. 12.3 li nd MOte thet under full thro ttl, end high
$peed cruise conditions, fue l I, drawn from th e f10et chember
(21 through the main jet. I1S1to the em ulsion t ube well.1 17}
and the" pu t the nole. In the emu l.ion tub• • 11 81. The fue l
become. emu lsified with air dl1lwn t hrough the e lt corrector jets
(9) and II the n drawn t hrough the noule (101. lIuxlli. ry ve" w ris
13 Thro trfe lever
14 Thro ttle sh8ft
, 5 Thl'(Jt tle villve s
16 Emulslon rubes
17 Emulsion tu be we lls
1S
'9
20
21
22
Mainiets
CrtlnkcaSBemissiOil rube
Clllibrated hole
Crankcase em ission VIIM slot
Rotary blanking disc
(11) and chckes (12) into the engine.
Tne carburettor also Incorporat es a nign speed mixture
enrichm ent svstem . Fuel from th e fl oat chamb er 12} is drawn
through t ne calibrat ed orifi ce (8) and spray tu be s (7 ) Into the air
hom s of the cerb urettcr.
The crankcase emission cont rol syste m is Incorpo rated into
on. of the carbu rettor barr els and consists of a rotary blanking
12-4
Part 2 Weber carburetors Chapter 12
33
1 'Nhete fitted, rel1'llJYe the . Ir cle, ner . SMm bly from the CIt-burettor.
2
Disconnect t he throttle li nk ege wh ere nece ssary.
3 Disconnect th e inner and out er cho ke cable fro m the st art ingdevice.
4
Disconnact the fu al inlet hose; and return hoses wh are
fitted .
5 Remove th e crankcase em ission ho se from the cerburert cr.
6 Unscrew end rem ove th e carbu rett or reta ining nuts and
spri ng w ashers and w ithdraw t he ce rburen oe complet e over the
mounting studs.
7 Remo ve th e gasket s from th e inl et manifokl and clee n all
traces of gas ket from th e cen tect fa0ll8 of the manifold and carbu rettor.
8 Protect th e inlet manifokl fro m ingress of for eign m'tter
wh ilst th e carburettcr is removed , by se,ling It w ith mu lling
tape.
9 Refitting is a reversal of removal, but th e following
ad d itlonal po ints shou ld be not ed :
34
a
(a)
Always fit new g.sk.ts lind tight.n the retaining nut$
in diagona f $aquence
t b) Th. idfing a djustm~nt screws shoul d be set as
described in Section 7 and finally tuned a$ de$cribe d in
e ,,~nly
S~ctlon8
t c}
Wh en rermin g the choice (sta rting devic e) cabl e, first
the outer cable to the support then insert th~ i" ne'
cabl. Into th e oP8,.ring fever screw .nd pU$h tM instrument panel control knob fu lly in. Tighten th e inner c.bf.
re taining nut with tfw OPMating ~ver fu lly r . "Msed.
s~cu'e
I
J7
J6
15
Fig. 12 .4 Accele ration ph".. 15K 31
2
15
33
34
35
Float chamber
Throt tle val ves
Oaf/very vil/ ves
Jet n(Ju les
Channa'
36 C. m
37 Lever
38 In/tit and discharge valv.
5
39 Reliction spring
Tho rough ly clean th e cerburett c r exte rior end w ipe dry.
Refer ring to Fig. 12 .5 , lift th e air horns II I and gasket 121
fro m the carbu rettor t op co ver !photol . W here fitted ext ract the
two spilt pin s and re move the sta rte r device co" tro l rod and
con trol lever fro m the carbure tt or t op cover (82) ,
3 Unscrew and remove the ret aining screws (8 5) and
washers (84) in diagon al seque nce and lift the carburettOt" top
cove r 1821 from th e Clrburettor body 14 91. meklng sure tha t th e
gasket 18 11 is not bro ke" (phot o).
4 Uft th e gask et (8 1) fro m t he carburettor body (4 9) .
5 Invert t he carburettor cover (82) end un screw the filter
cover plug Ie) using a 19 mm ri ng spanner end socket. Remove
the washe r (5) (phot o).
6 Remova the filter gauze 131 and , if necessary, extract the
base (4).
7 Using a suitab le diame te r meta l dr ift. lip th e ful crum pin 01
fro m the sup port post s. Do not atte mpt to prise th e split post
apart (phot o).
8 Note wh ich wa y round the needle v,lve return hook Is
positioned, then lift the float assembly (n) end need le from the
cove r lphot ol. Unt'look the need le from th e f1o,t atm.
9 Unscrew and remo ve the needle valve ( 8 ) and w asher 0 9 1
(photo).
10 PIIOII the cerbu rett cr co ver 1821 to one sid e, taking cartl no t
to dam, ge the high spe ed enrichment t ubes.
1 1 Unscrew and remove t he retaining screw s (40 A) and
w ashers (7 11. Remove the starter devi ce 1591 fro m th e earburettcr (photo).
12 Dismant le th e starter devi ce by unscrew in g t he nut Ie 1I
from the sheft 1691 tog et her with th e w asher (6 21.th en cartlfully
remo ve th e \eve' (6 5) and spring (671. Unsc rew the cable clamp
n ut (64) and scre w (6 61. t hen remove the shaft (6gl and fil ter
gaul e (70) .
13 Unscrew and remove t he accelerllt or pump in let , nd
di schlltge velYll (17) from the bo ttom of th e float cha mbe r
Ipho t o).
14 Unscrew the emulsion tube ho lders 18 1from th e carburettor
body (4 9 1and lift out the emu lsioo t ube assem blies (photo1l1.
15 Sep,r'te the emulsion tubes 110) fro m the hold ers (81 then
40 Rerum spring
4 1 Diaphragm
42 CalibrlJttJd dischiJl'fltl hoI.
disc (221. 'Mth th e throttle va ~ s (1 5) closed. crankcase blowby gall Is m etered through th e calibra ted hole (201. Aa the
th rottle valve s ere progr essively open ed. the slot (2 1) admits
I'T"IOfe g,lS to t he e ng ine .
A cceleration
Refer to Fig. 12.4 end not e th at when th e throttl e valves are
closed, t he spring (40) push es t he di aphragm (4 1) outwards
and tu el il drawn fro m the f loat chambe r (2). through the inlet
valva (3SJ Into the pum p chamber. W hen the t hrottle valves are
opened . t he cam (3 6} operates the lever (37 ) end the diaphragm
(4 1) is dllpressed against the te nsion of tM spring (40 ). Fuel Is
forced elon g the channe ls (3 5 1to the delive ry valves 13 31limd i,
inject ed throug h th e pump lets 134 1 int o t he cerbu rettor baf'T'els
in the vi ci nity of the auldliery venturia, The spring (3 91 dampens
any sudd en openin g of the throttle valves and pro long s th e fu el
deliYllry. The calibra ted di scharge ho le (42 ) det erm ines the
maJdmum preasure of fu el injected into the carbu rettor end also
allows eny accumu lated , ir and vapo ur to escape int o the fIo8l
chembe r. The inlet valve (3 81 may also inco rporate a calib rated
discharge rete. wh ereby e further amoun t of fue l ret urns t o th e
float cham ber. By fin e calibration of thi s hole It is possibla t o
determine the exact Quanti ty of fue l injected by the acce lerator
pump.
4
Removal and refitting
Note : Th8 follo win g pro C8dure give s a gener al ra rhe, rhan a
specific m ethod of ' emoving (lnd refi tting r/l6 carburettor, (1$
m uch win depend on the loc(ltion of the C(lrbrJ,.ttor within the
vehic le. On som e applications for inst ance, the retaining nulS
m ay not b6 acceS$/'ble without ,ema"ing surro unding com·
pon ents.
2
Di sallembly
•
5.2 Ft emo vir'lQ th e air horns
5.3 Remo ving the carbure tt or lOp cover
5 .5 Re mo ving t he fue l filte r a nd p lu g
2
5.7 Removing the float fu lcrum pin
5.8 Position of the needle valve on the
flo at assembl y
5 . 1 1 Re mo ving the Starter d e vice
5 . 13 Acce lera tor pump
di scharge valve loc atio n
5. 14 b The emulsio n tu be assembly
5.15 Com ponent pa rts of the em ulsion
tube a ssembl y
~
lnle l
lln d
5 .9 Needle valve seating loc a tio n
5 ,14 3 Em u lsion t ub e ho lders lo cat ion
5 .16 11 Removing th e idling je ts
12-6
/ --
40-" - 71 -
-
2
-~
-
2.
3.
Part 2 Weber carburetors Chapter 12
pull the main jet5 1111 end air ameetor jet!! IS} fro m th e emul sion tubes I ' O} l phol o}. Take care not to dam age th e jets wh en
removing th em and, if pliers are used. interpose a piece of paper
or card to prevent the brass being scratched.
16 Unsc rew the idlin g jet holders (34) fro m the side of the carbcrettoe body (49 l. remove the rubber O-rings (33), th en
separat e th e id ling jets (32) (photos) .
' 7 Whil st depressing the sta rter valve sprin g retai ning gu ides
(75) in tum. prise the spring was hers (76) from the carburett or
body . then release the guides (751and extract the return sprin gs
(74 1 and start er valves f731 (photos). Note from which bore
each valve is taken so that th ey can be refin ed in the ir original
locations. Do not force th e \lalves ~ th ey will not com e out
fr eely ; occassrcoeuv a burr may eltist al Ih e lap of the bore. thi s
must be removed with a fin e fi le.
18 Unscrew and remove th e starter jets (72 1(photo).
19 Un screw and remove the accelerator pump delivery valves
"41 together with the pump jets (16) and w ashers I' 51 (photo),
then separate th e washers and jets from t he valves.
20 Unscrew the retai nin g screw s and w ashers (40 ) and
carefully pr ise the pump cover (39 ) from t he ca rbur ettor body
(photo). Take care not to dam age the diaphragm and if
necessa ry. use a blunt knife to release it .
12-7
2 1 Remov e the di aphregm (38) and sprin g f371.
22 Not e the location of th e aultil lary venturi s (131 and mark
thern if necessary with a penc il to ensure cor rect refining . th en
withdraw them from th e carburertcr body (4 9) (photo). If
necessary. use a wooden or plast ic cower rod inserted from th e
throttle valv e end of I he barrel to tap th e auxili ary ventu ris free.
In the unli kely even t of their being excessively tight. It wi ll be
necessary to obtain the speciai Weber tool no 96 1 0 150 00 3 5.
23 Loosen th e lo cknu ts (57) w ith a 9 mm ring spanner and
unscrew the lo cking screw s (58) (photo).
24 Note th e locations of each choke 1121 then remo ve them
from th e carbcrertcr balTels (photo!. Note that the ChOke ends
with I he sma ller internal diameter are uppermost. If th e chokes
are excessive ly tight. it wi ll be necessary to obtain W eber tool
no 98 009 100.
25 Un screw and rem ove the Idli ng mixture adjust ing screws
(4 ') together wit h the spring s (4 31. washe rs and rubber O-rings
(42 ) tphotol.
26 Unscrew and remo ve the idle speed screw (3 6) and sprin g
(351. w here fitt ed .
27 Unscrew and remov e the blanking screw s l44) (photo) ,
28 Loosen t he locknuts (4 71 with an 8 mm ring spann er. th en
unscrew and remove the air bypass screws (4 8) (photo!.
2
5.16 b Separating an idling jet fro m it s
holder
I
2
3
4
5
6
7
8
9
10
11
12
13
14
15
76
17
18
19
20
21
22
23
24
25
26
27
28
29
5.17a Removing a sta rte r valve spring.
retai ning guid e and spring wa sher
5.17b Removing a starter verve
Fig. 12 .5 Exp lo ded view of the 40 IOF cerb urettor (ty pica l) ISec 51
30 End washar
58 Choke locking screw
Gasket
31 BaH-bearing
59 Starter devic e assembly
Ffrter geula
3 2 Idle je t
60 Lock scre w
Base
33 a-ring
61 Nut
Washer
34 Idle jet holder
62 Sp ring washer
Plug
35 Sprin g
63 Leve r assembly
Fulcrum pin
36 Idle speed screw
64 Nut
Em ulsion tube holder
37 Sp ring
65 Lever
A ir correctorje t
38 Diaphragm
66 Screw
Em ulsion tube
39 A ccelerator p ump co ver
67 Spring
Mainjet
40 S crew
68 Housing
Cho ke
4 1 Idle mixture scre w
69 Sector shaft
A UJcifiary II'Bnturi
42 O-ring
70 Fflter gauze
Dellvery va/ve
43 S pring
71 W eshtlr
COPPo/ washtlrs
44 B fanlcing screw
72 S t8fter jet
Pump je t
45 eou pin
73 Starter v8fve
Inlet valve wirh exhaust orifice
46 Acceleretor aump cam
74 Spring
Stud
4 7 Locknut
75 R etaining guide
Spacer
48 A ir b ypass screw
76 R etaining wesher
Throrr/alever as sembly
49 Carburetror bo dy
77 Floet assembly
Throttle lever
50 Emission control valve
78 Needle valve ass embly
Split pin
5 1 Throttle valve
79 GUket
S pring
52 Ret ilining scrtlw
80 A lremative fue l inltU
Pressure pin
53 Throttte shett
8 1 Gulcer
S pring
54 Link arm
82 Carbureftorco ver
Adjus ting scre w
55 Retum spring
83 S rud
Nut
56 Carburetror body
84 Washer
Tab washer
5 7 Lockn ut
8 5 Retaining screw
Wave washe r
Air horn s
12-8
-------'------~
{
48-.@:
~
.
....
..
47
- .,
5.1B Removing a starte r jet
5.19 Removing the accelerator pump
delivery valve and jet
5.2 0 Withdrawin g the accelerator pump
cover from the carburettor
2
5.2 2 Remo ving an auxiliary vent uri
5.23 Choke loc king screw locati on
5. 2 4 Remov ing a choke, showing
location indentation
Fig. 12.6 Exploded view of the 40 and 44IDF carburenor [..ries 28. 29 and 26. 27 1(Sec 5)
1
2
3
4
5
Screw
8 ush
Starter cantrot 'ever
Gaskllt
Needla vetve assembfy
6 Emulsion tube holder
7 Auxffiary venturi
8 A ir COm!! ctor j et
9 Choke
10 Emulsion tube
11 Ma in jet
12 FufCflJm pin
13 DeiNery lIalve
14 Pump j er
15 Copper washers
16 Stud
17 Inlet valve with emaust Orifice
18 Idle j et
19 a -ring
20 Idle jet hofder
21 8 aft-bearing
22 Endwasher
23 Wave washer
2-«A Throttfe fe ller
24 8 SpaCBr
2 5 Tab washer
26
27
2B
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Nut
1dfe speed screw
Sprin g
Diephragm
A ccelerator pump caller
Scre w
Cam
Rolf pin
Bfanking screw
O-rin g
Washer
Idle mixture screw
Spring
A ir bypass screw
Locknut
Cerlwrenorbody
Throttle plate
Retainin g screw
Washer
Anchor pfate
Throttfe shaft
Washer
Return spring
49 Emission con trol vafve
50 Locknut
51 Choke ' m;king screw
52 WUher
53 Screw
54 Staffar dellice (40 ID F 28 and
441DF 2 6)
55 Fifter gauze
5 5 Staffer device (40 ID F 29 and
44 IDF 27)
57 Starter j et
58 Staff er valve
59 Spring
60 Rt1teining guide
6 1 Re t~ning wash er
62 Float assembly
63 Plug
64 Washer
55 8 ase
66
67
68
69
70
71
12
73
Filtsr gauze
Gasket
Carburetfor cover
Stu d
Spring w asher
Retaining screw
Cable focknut
Sp fit pin
74 Staffer control rod
12-10
5.25
Re mo ving
Part 2 Weber carburetors Chapter 12
an
id ling
mix t ure
5.2 7 Removing a blanking scre w
5.2 8 Re moving an air byp ass sc rew
adjusting screw
5.29 Throttle spind le end nut locati on
and loc lctab
5 .3 3 Remo ving a throttle v alv e
29 Bend btIc k the locktabs (2 81 on one or both end s of the
throttle spindle (53 1 depending on the application, then
unscrew ,mel re mo V9 the nut s (2 7) [photo). If th ese life very
ti ght. use We ber tool FlO 9802 3 700 to hold the sp ind le whirst
th e nut is lOO $ened. If th is preCllut ion is not taken. th e spindle
(5 31 may beco me bu ck led . Do not loosen I tight nu t w ith t he
throttle v alve s bei ng forced against the barret w all s.
30 Remove th e nutls ] (2 7). t ab wesbertsl (2 81, spacer ( I S) and
th rott le le ve r (2 1J a s a pplicab le to t he ce rburettor.
3 1 Unscrew and remo ve the thro tt le valve ret aining screw s
(52). being careful no t to exert excessive pr essure on th e
spindle (53 l (photol.
32 Note the posit ion of th e throttle spindle and valves in relat ion to the barrels and if necessary, mark the valves w ith a
penci l.
33 Tum the spindle to the fu lly open position and w ithdraw the
two thro ttle valves (5 1) trom t heir location slots (photo).
34 Y sing a suit able pi n punch. drive the roll pin (4 5) through
•
5 .34 Accelerator pump cam roll pin
removal
the cam (4 6) and spindle 1531. To ensure corr ect refitting. m ark
t he cam and spind le in relation to each oth er (pho to).
3 5 Using a plastic mallet. drive the spindle (53 ) from the carburettor. Before doing th i s, chec* t het t he spindle is f ree of any
burr s and use a fin e file if necessary. to remove th em.
36 Recover the w ave w asher(s) (29) and beari ng end
walherl s) (3 0) ttl e accelerator pump cem 14 6).
37 Drive the remaining bearing (3 11 from the carbur etto r body
(4 9). Wh ere th e thr ottle lever (54) Is swage d onto th e spindle.
use a suitable diameter length of m eter dowe l rod to remove the
bearing. Wh ere ret ain ing nuts are located on each end of the
t hrott le spin dle, remo ve the bearing and washe r and use the
spind le to remove the bearing.
38 Wh en f itt ed. rem ove t he return spring (65) from the th rottl e
spindle {54).
39 When fitted. remove the cra nkcase emission rot ary disc
(SO) from th e throttle spin dle.
40 If necessary, un sCNIw t he id le spee d SCNIW (2 8) ,md spring
Part 2 Weber carburetors Chapter 12
(2 5 ) fro m the throttle lever (2 1). t hen remove the split pin (221.
pressure pin 12 4) and $prin g (2 3) .
6
mm.
7 The carbu rettor body should be thorou ghly cleaned etter
overhaul . preferably u5ing claen fu el and air pressure . Th e leed
plugs shou ld be renewed end retained in pos itio n by using the
W eber tool nos 9801 0 700 or 980 10 BOO as a punc h until th e
plug 5 are expanded Int o their bores.
a Check the float assembly tor dam age and leakage. Shake
Ihe float s to det ermine w heth er fu el has ent ered. If the fIoa l s
are damaged or fu el is present . the assembly m ust be renewed .
9 Check t he acce lerator pum p lever and diap hragm fo r we ar
and dama ge and renew th em as necessary.
Assembly
Note: All componen ts shou ld be clean and dry before starting
rht! assembly pro cedura.
1 Fit the spring (2 3) and pressu re pin (24) to the throttle rever
(21 ) and secure with the split pin (22 ).
2 Fit the idle &peed screw (261 and spring (2 51 to the th rottl e
lever 12 11.
3 Whe n fitted slide Ihe crankcase emission rotary disc (50 1
7.3 a Crankcase emission rotary di sc
locating pe g .
onto the throttle spind le, making sure that the loca ting pi n Is
fully engage d with the slot IphotosJ.
4 W hen fitted, locate the return 5pring (55) over the throttle
spindle 1541 and engage the hook.ed end on th e throttle lever
arm.
Speciel overhau l procedurel
After carrying out the general cveraul procedure5 given in
Chapter 4, the fo llowing special prcceccre s muld be com plet ed:
1 Using a hand chuclt and the special tool availab le from
W eber r a tool hire agent. reform the main jet seati ngs at the
bottom of th e emul sio n tube ho using we lls by c;arefu lly roUiting
the tool in alternate directions. Finl5h the seati ngs w ith the
addition al sce ctet too l by tapping it gent ly wh ilst rolating it at
the same ti me.
2 Usin g th e same procedure as descri bed in paragraph 'l ,
refo rm the idling jet soat$.
3
Using th e same procedure as described in paragraph l ,
refo rm the starter valve seats.
4
Using the same procedu re as described in paragraph 'l ,
refor m the starter Jet seats.
5 If t he emulsi on tube we lls ere di scolo ured and cc nelde rabre
sediment has accumulated. the bo res mu st be rem ovad using
the appli cable Weber tool and a hend chuck. Tum the t ool
carefull y until it moves freel y, then continue turning It Whilst
removing it.
6 Check the internal Channels of th e carburettor body end
COVf!r by inj ect ing fue l from a syri nge and observing w hethe r it
emerge s free ly. It any c;hann els are blocked , it will be necessary
to drill out the lead plugs and use W eber tool nos 9 80 14 3 00.
9 801 4400 and 98 0 14 500 t o clear the m. These tool numbers
rf er to the t hree channe l dieme t ers of 1.0 mm, 1.5 mm and 2.0
7
12-11
7.3 b . . . and slot
5 U sing a suitable diameter length of tubing, drive the bearing
13 11 fully into the carburettor body (4 9) . M ake sure that the
inner be aring w a5her ia insen ed in to the body. where fi tted.
6 It a new am 146 1 Of spindle (53 1 is being fined . rum the
cam as necessa ry so that it is a firm sliding fit on the spind le.
7 On throttle spindles fined with two end nuts, place the
remain ing ba ll-bearing on an open vice and gently tap the
spindl e into it. Where nece ssary, the inner washer must be
located on the spind le fir$t.
8 Insert th e throttle spindle (53) into the carburettor body
{4 91. at the same time locate t he accelerator pum p cam (4 6 1
between the two barrel s w ith Its shoulder as show n in Fig. 12.5
(phot o). Also insert th e reurm spring (55) in the location hole
where applicable.
9 Using a length of tubing. support the bearing (3 t 1 In the
main body then tap the spindle (531 fully into position (photo).
10 Fit the bear ing end washerls) (30) and wave wa shed s} (291
after lubri cat ing the bearin gs w ith e Httle grease.
11 Tum th e throttle spind le (53) t o its appro xim ate closed
po sit ion th en, with the accel erator pump cam (4 6 ) facing away
fro m th e di aphra gm face, a11gn th e ho les in the cam 1461 and
5pindl e 153 1 and drive In the roll pin 14 5 ) until it is in a cen tral
position.
12 Tum the spindle 1531 l aQllinst the tension of spring 55 if
alread y fined ) unt il t he throttle valw slots can be seen from the
flange end of the carbu rettor. then insert one throttle valve (5 1)
in th e location pre viou sly noted and close the valve. Make sure
that th e t hrott le valva i s fitted the eoerect way round so tha t the
angled perimeter seaUi in the ~rrel.
13 Snap th e valve shu t several times in orde r to centra lise it ,
t hen i"l sert and tigh ten the velva ret ain ing llCreWS (52 ) w ithout
exert ing excessive pressure on th e spindle. It is recom mended
that new screws are always fitt ed li S it is QUite easy to CTOSSt hread previously peened SCI'fIW5. lock the screws by peening
with W eber tool no 98010 900 w hil st supporting the spindl e
w it h a length of wood . Alternativ ely. coat the t hreads with a
liquid lock ing agent (fu el resistant) prior to inserting them.
14 Repeat the procedure described in parag raphs 12 and 13
for th e rem aining thrott le valve.
15 If a new spindle (53 ) or cam (4 6) is being nn ee. both must
be drilled with a 0.078 In 12.0 mm) drill to accom mod ate the
roll pin (4 5). To do t his. it is essentia l to obtain the special
W eber fixture.
16 Fit th e thro tt le lever (2 1). spacer (19). t ab w ashedsl (28)
and nutls} (2 7) and lock the m to th e carburettor.
17 Tighte n th e nulls) 12 7) and lo ck them by bending th e
lockt abs (28) . Do not overtighten t he nut s oth erwise the spindl e
may be di storted.
18 Insert th e air bypa. ss screws (4 8) and scre w them In until
7 .8 Fin ing th e throttle spind le th rough
t he aCCelerator pu m p cam
2
12-12
Part 2 Weber carburetors Chapter 12
7.9 Fitting th e th ronle spin dle bea ring
7.3 1 Fitting a starter valv e spri ng. reta iner and spring washer
the y e re fully seated , the n tighten th e loc kn uts (47).
19 Insert and lig hte n th e blankin g screws (4 4 ).
coil spring (67) w it h it s end in the locati on jere. Fit t he lever
(6 5) over the shaft (591 and at the seme tim e hook th e end of
t he spring (6 7) Over t he lever, then locate th e w asher {52) and
nut {5 1) and tig hten the nut.
37 Check t he ope ratio n of t he sta rte r device, t han fi t the cab le
securin g nut (6 41 and screw (66) and fil t er gauze (70 ).
3 8 Offer the startet dev ice up to th e cerburen c r bod y and
make sure th at the sector lugs locate in th e starter valve
grooves, th en Insert the reta ining screw s (40A ) and w ashers
(7 1) and t ighten the screws. Check that the sta rt er device
operates smoo th ly.
39 Tighte n the needl e valve seating (78 ), tog eth er w ith It new
gask et (79 1,int o th e carbe rertce cove r (821,
40 Hook th e needle (781 onto the flo at erm 177) then lower the
needle into th e Sl ating. Insert t he fu lcru m pi n {7 1 through th e
posts and float assem bly (77 ). If necesury, gently pinch t he
split po st to seOJre the pin usi ng a pa ir of pliers.
4 1 The float level adju stm ent must now be checked In t he
foll owing manner: Hol d the carburettor cev er v ertical so that
th e flo at s are hang ing fro m th e fu lcrum pin w it h th e float level
arm in li ght contact with th e need le ball lie w ithout th e ball
being depressed]. Using a vernier caliper, check t hat the
di sta nce from the float t o t he cover face as shown in Fig. 12 .7 is
0 .3 94 in ( 10 .0 m m) w it ho ut th e gasket in place (photo). If not.
bend t he tab retaining t he needl e hook as necessary .
42 Tilt the co ver so tha t the floats move awa y fr om the cov er
a~ th e tab m akes contect with the need le valv e seat ing. Now.
using th e same method as described in paragr aph 4 1, cheCk
that th e needle valve full y open di men sion Is 1.280 In (3 2.5
mm ) (phot ol . If not . be nd the t ab wh ich contact s th e needle
vefve seat ing as necessary.
43 The differe nce between th e dimensi on s checked in
paragraph s 4 1 aod 42 is th e needle vaive stroke wh ich shou ld
be 0. 8 86 in (22. 5 mm ).
44 Rt the base (41 to th e fi lter ga u~e 131. With t he carburettor
co ver (8 2) Invert ed, press th e fi ltar gau ze Into the inlet cavity.
45 Fit the washer (51 to the fi lt er cover plug (e ), then tighten
the plug into t he cover (8 2) .
4 6 Place the gasket (8 11 on t o the top fece of th e carburettor
body 14 9) .
4 7 lower th e carbu rett or cov er (82) ont o the main body (49 )
over the st uds , the n Insert t he rete lnlng screw s (8 51 and
washers (84 1 and ti ghten th em It little at a t ime in dia gonal
sequence.
4S Fit th e starte r device control rod and lever (w here fi tte d)
using new split pins.
4 9 Locate th e gasket (21 and air horns (1) over the st uds and
on t o th e carburettor co ver 182 ).
20
21
the
22
Fit th e idle speed screw (3 6) and spring (3 5) , wh ere fitted.
Fit th e idling mixture adjust ing screw s (4 1) together with
rubber O-rings (421. washers and springs (4 3).
Insert the chok es (12} int o the ba rrels with the smalle r
inte rnal d iameter ends up pe rmo st.
23 A lign the indent at ions in the chokes (12 ) w ith th e ho les in
the ca rbur enor body (4 9), then lightly tigh ten t he loc king
screws (58) int o pos it ion and t ighten the locknu ts (571.
24 Fit the auxili ary venturis (13) in their orig ina l location s.
m aking sure that the locat ion spring s engage w ith th e grooves
in the b arrels lind th at t he supp ly of ch anne ls are in alignme nt
w ith t hose in th e cerbc rett or body. TIlIt extend ed ve ntu rls mu st
elso be uppermo st.
2 5 Suppo rt th e carburettcr body (4 9) wit h t he pum p
diaphr agm face up permost, t hen locate the spring (3 7) on the
face in a centr al position .
26 Place t he diaphrag m (38) aga inst th e pump co ver (39) and
ret ain with the fingers and thumb, then Insert the retaining
screw s and washers (4 0) thro ugh t he di aphrag m .
27 locat e th e di aph ragm and cover on the carburett or and
engage two or three t hreads of the retaini ng screws. Operate
the pump lever severeI tim es th en hold it SO that the di aphragm
Is not t ension ed. TIghten th e ret ainin g screws (4 0 ) evenly in
di agonal sequence. Check th e opera tion of th e pump by opera t ing th e thro ttle lever.
28 Assem bla the accelerator pu mp jet s (161 t o th e delivelY
valve s 114) with the copper washers 1151. the n tighten the m
into th e carburettor body {4 91.
29 Insert and t ighten t he starter jet s (721 into th e carburettor
body (4 9) .
3 0 Fit th e starte r valves (7 31 into th eir respectiv e bo res.
foll ow ed by th e return spring s (74 1end retainers (7 5).
31 Depress the reta iners 175) in tu m and locate th e spring
w ashers (76) In the carbu rettor recess es (photo!, fu lly pre"ing
them in w ith t he fl at blade of a screwdriver.
32 Press the id ling jets (32) Into th e holders (341. fit the rubbe r
a -r ings (3 3 1, then tigh ten t he hold ers int o t he carburettor body .
33 Press t he air correct or jet s (9) and m ain jet s (1l} into th e
em ulsion t ubes {l Ot, then pres s the holders (81 onto the top of
th e emulsion tub es (10 ).
34 Insert and tighten t he em ulsio n tube assernblles into the
cerburett c r bo dy (49),
3 5 Insert and tight en the acceler ator pu mp inlet and discharge
valv e (17).
3 6 Asse mb le the shaft {69 1 to the sta rt er devi ce so tha t the
align m ent li nes on each sector are facing each other, then fit the
Parl2 Weber carburetors Chapt er 12
12-13
5
3
~
"
2
,
1
j
6
~
I O.O m ~
3 2.5
m'~~---:
7.41 Checking th e flo at level closed position
Fig. 12.7 Float Ievaladj us trne nt di mensions (Sec 7 )
r
2
3
4
Carbure t tor co ver
Ne edle valve assembly
S troke adjusting tab
Fulcrum pin
5
6
7
N eedle and r eturn hook
Height adju sting tab
Float assem bly
2
.\ \11
50 With the carburettor comp letely assembled, the idling
adjust me nt sc rews sho uld be turned to their prelim ina ry sett ings . To do th is. first scre w in t he throttle idling adjus tme nt
sc rew (wh ere fitted ) unti llt ju st t ou ch es th e throttl e lev er, t hen
continu e turning for a further 2 turn s. Working on th e idl ing
mixture volum e screw s in turn, fully screw th em in unti l they are
in contact with th e ir seats. th en back t he m off 2 co mplete turn s .
Final adjustm ent s will be necessary wi t h th e carburettor fitted
on the engine (refer to Sect ion 8 ).
8
Tuning
N ot e : Refer to Chap ter 3 f or general no t es on tuning.
1 Set th e idli ng adjustment screws to their prelimina ry position s as descri bed in Section 7.
2 Connect a tachometer to t he engine in accor dance wi th th e
manufactu rer' s instructions.
3 It is now important to underst and th at each barrel of each
carbu rett or mu st be synchronized in order to deliver equal
amounts of air/fu el mixture to each individual cylind er. To check
this. it wil l be necessary to obt ain a length of tu bing
(approximately 1 metr e) of about 5 mm to 10 mm (0 .2 5 in to
0 .50 in) internal diam et er. Altern ativ ely a avnchrontser as
illu strated in Chapter 8 may be used.
4
Remove the air cleanertsl if fitted, then run t he engine until
norma l ope rating temper ature is reached. To ensur e th at th e
engine is really hot eno ugh. drive it hard over a 5 mil e di stance.
5 Switch off the engine and di sconnect th e accelerato r rod
connections from each oarbur ettor.
6 Where two carburettor thr ottle spindles are link ed, turn th e
adjustment screw on the li nk 2 turns from th e fui ly shut position.
7 Start the engin e and adju st each idling speed adjusting
screw (except link adjust ments) by equal amoun ts until th e
engine is id ling at the approximate recomm ended speed. Thi s
will vary accord ing to th e applicat ion and state of tune of the
engine but an average wi ll be around 800 rpm.
8 The barr els of each indi vid ual carburett or mu st now be synchronised to pass identical quantitie s of air during id ling. To do
thi s, loosen th e locknuts and check th at th e byp ass screws are
7.42 Checking the flo at level ope n position
both in light conta ct w ith their seats. Place one end of th e synchron ising t ube in th e middl e of one air int ake and listen at the
oth er end to th e amount of hiss present . A lternatively, use th e
synchroniser to record th e air flow through th e air intake. Check
both air intak es of the carburett or to determine wh ich one is
passing th e great est amount of air, th en adjust th e remaining
barrel to giv e an ident ical volume . Finally, ti ghten t he adjustment locknut s. Carry out thi s procedure independently on each
carburettor fitt ed to the engine.
9
Each carburettor must now be synchroni sed with t he
remaining carburettors. To do thi s. allow th e engi ne to idle and
check t he volume of air flowin g through one air intake of each
cerbc ret tc r. using t he length of t ube or th e synchroniser. Determine th e carbur ettor which is passing th e medium volum e of air
and adjust t he idle speed adjustment screws of the remaining
cam urett ors unt il they also pass identical volum es of air. Whe re
the thrott le link age is arranged from a common shaft, th e
individua l throttle levers wi ll have to be adjuste d by loosening
the locknuts.
10 If necessary. from each id ling speed adjustment screw by
equal amo unts to bring the engin e speed with in the recommended idl ing limits.
11 The mixture screw adjustm ent s on each carbu rettor must
now be set and synchronised. Since each screw was turned to
12-14
Part 2 Weber carburetors Chapter 12
It. pt1lliminary se tt ing . it can be '$$u med that they a re
re asor'lably s ynchron ised to start with. With th e engine id ling ,
turn
ttl e screw s by equ al i1mounts It a tum initially l and
observe wheth e r th e e ng ine speed te lls o r inc re ases. Ma ke
sever,l adju stm en t s in a sim ilar manner until the eng ine run s at
tn e highes t speed commensurete with even firing.
12 tf ne ce ssa ry, aga in t um e a ch idling speed adjustment screw
by equa l amoun ts to bring the engine speed within th e recommended idling limits.
13 The fin al mixture screw synchronisation can be determin ed
by allow ing th e eng ine to idle , the n to remove e a ch spart plug
lead in tum and observe the reducti on in engine rpm on th e
tachometer. The red uction sh o uld be iden ti ca l fo r ea ch cyli nd er .
.1.
t hus pro vin g that th e m ixture st ren gth Is also identical fo r ea ch
cylinde r. A. funher ch eck cen be meoe by re mo ving t he spa rk
plugs aft er the engine has be en Idling for approx imately 15
9
minutes. Any w ith black sooty deposits ind ica te that the
pa rticular cylind er is run ning rie:tl. Normally if th e m ixture screw
has not been se t co rrectly. weak ening It by half a tum during
idling will cut the releva nt cylinder.
14 If I'lece ssary adjus t the idling speed serews on ea ch carburenor by equ al amo unt s to obtain the corr ect eng ine idling
s pe ed.
15 Note that on some applicat ions It may be adv isa ble to fit
·ho n er spark plug s whilst lIdjust ing the ClI rbur eMors to preve nt
m isfiring_ However th e or igina l plugs m ust alway s be re fin ed
after completing th e adjust ment.
, 6 Swit ch off th e e ngine and recon nect the t hrottle linkages,
mak ing adjus tments as neeesSllry to prevent th e ca rburett or
seltings from be ing affe cte d.
17 Remove the tachometer from the engine and refit the air
creenensl. if fitted.
Fa ult diagnosis
Symptom
Reason
Engine w ill no t start
Blocked fuel filte r or jets
Flooded a ngine as a result Of depressing accelerator pedal
Uneven Idlil'lg
Leaking ma nifold o r carnureMor flange gaskets
l oose idling je ts or auxiliary ventu rrs
Exce ss ive se diment o r water in cerbc rertoe
Worn throMlespindle
Inco rrect tuning adjustme nts
Carbureltor flood s
W orn needle valve
Laakil'lgor damaged fIoatls)
Inco rrect float level adjustme nts
Excessive sedimen t in fu el
Engine lac ks perform ance
InCOITect tuni ng adjustments
Incorrect float level adjustments
Excessive sedime nt in fue l
Thro tt le valve s not fully o pe ning
Acce ler ator pump faulty Ot lea king
Exce ss ive fuel consumption
Needl e valve not seating
Leaking or dam aged Iloat ls ]
Incorrect float level adjus tments
Choked air filter (if fitted )
13-1
z
Part 2 Weber carburetors
Chapter 13 Type 36 DCNF, 40 DCNF,
42 DCNF, 44 DCNF
Contents
Assem bly
Construction
Sec tion
7
section
Ope ration ..•.. ..... ....... .. . . . . . . .. . . .. .. .
3
..... ..•. ..• .. . . . . . • . . . . . . . . . ...
2
Remo val and refining •.• .... . . .. . . . .. . . . . .. . ...
4
Disassemb ly ••.•••••.•. .• . . . . . . . . . . . . . • . . . . .
Fault diagnos is ••.•. • . . . • . . . . . . . . . . . . .. . . . .. .
5
9
Spe ci, 1ove rhau l proced ures
6
Tu ning
B
Introduction
1
... ...•...... . . .. . .. . . . .. . .. .. . ... . .
13-2
1
Part 2 Weber carburetors Chapter 13
Introduction
The carbu rettors covered by thi s Chapter are of vertica l
downdraught type and each barrel of the cerburertc r is of
id e ntical dia meter.
The throttle valves are of t he synchronised , simu ltaneous
operation type and are lo ca te d on a sing le s haft.
The identification mark is located on t he main body on the
outer face of the fi oat chamber wa ll.
2
31
Construction
The main body and cover of the Weber DCNF carburettor
are of die-cast alum inium or zinc alloy (Mazak) constr uction.
The mounting fl ange is machined fl at for fi tt ing on the inlet
manifold.
The throttle spindle is made of steel and t he thrott le va lve
plates of brass.
All fuel and air jets and emulsion tubes are of brass construction and are secured to the m ain body by screw fi nings.
The inte rnal channels of the maln body are mainly drilled
and where necessary, sealed with lead plugs.
The throttle spindle is supported by two ball-bea rings
mounted in the main bod y. Washers are located at each end of
the spindle to prevent air being drawn t hrough the bearings.
The fuel f loat essemblv isccn stru cted of thin brass sheet
end comprises two halves soldered together.
The accelerator pum p is of the diaphragm type and the
operating lever is actuated by a cam plate attached to the end
of the t hrottle shaft .
f----ttt- 32
33
35
Fig. 13.1 Cold stert ing phase (Sec 3 )
3
Operation
Cold starting
The starting device fi tt ed to type DCNF carbu rettors
operates independently of the main circuit and m ay be considered as a separate carburettor with in the main carb urettor.
Refer to Fig. 13.1 and note that wh en the chok.e cab le is
pulled, the start ing device operating lever turns the contro l
shafts wh ich lift the starting valves off their seats. Fuel from the
float chamber (8) is drawn through channels (34) into the starting [eta (32 ) where it is emu lsified with air entering t hrough Ihe
top of the atartinq jet s (32). The mixture is then d rawn through
channe ls (33) where lt is further emu lsified w ith air from the
hole (3 1). After passing the starter valves (3 7) wh ere additiona l
air from holes (36 ) weakens the mix ture, the fi nal mixture is
drawn through channels (3 5) Into t he engine below the t hrottle
valves (14}.
The starting device has a progressive action made possible
by the tapered end of the valve heads and lowering the valves
will reduce the amount of m ixtu re admitted to the engine until.
whe n comp letel y shut, the supply w ill cease.
Idling and progression
Refer to Fig. 13.2 and note thai when the engine is idling
with the throttle valves (14) closed, fue l is drawn through the
main jets and emulsion tu be w ells (6), along channels (1 8) 10
the idling jets (19) where lt becomes emu lsified w ith air ente ring thro ugh the calibrated bushes (20). The mixture then trave ls
through the channels (17), past the adjustab le mixture screws
(1 6). through the idlin g feed holes (15) and into the carburettor
throats at the engine side of the throttle valves (14} . The idling
mixture screws (16) have tapered ends and can t herefore be
adjusted to admit more or less mixt ure as necessary.
When the throttle valves are opened slightly to increase the
engina speed. the pro gression holes (13) are bro ught into act ion
to provide additional fuel and to enab le th e engine to reach the
speed when the maln system starts to fu nction.
In order to ensure that each carburettor barrel passes
8
Float cham ber
3 1 Air holes
34 Channel
35 Channel
36 Channel
32 S tartingi et s
37 S tarting valves
14 Throttle valves
33 Channel
identica l amounts of air. in parti cular wh en the engine is idl ing.
the m ajority of DCNF carburett ors incorporate elr compensati on
screws in each barrel. wh ereby air can byPClSS th e Ih rottl e
valves (14) via the startlnq device ducts (3 5). This system
ensures identi cal vacuum below each t hrottle valve and
therefore ensures ident ical mixtures d uring idling and progression.
N ormal running
Refer to Fig. 13, 3 and note that under fu ll throftle and high
speed cruise conditions. fuel is draw n from the float chamber
(8), t hroug h t he main jets (7) to t he emulsion t ubes (6). The fuel
becomes emul sified with air drawn through the air corrector [ets
(1) and is then draw n th rough the nozzles (2). auxllla rv vent uris
(3) and chokes (4) into the engine.
Acceleration
Refer to Fig. 13.4 and note t hat wh en the throttl e valves are
closed. the spring (24) pushes the diaphragm (28) outwards
and fuel is draw n fro m t he flo at chambe r (8). throug h t he ball
valve (3 0) into th e pum p chambe r. Wh en th e throttl e valves are
opened . the cam (2 5) operates the lever (261and t he diaphragm
(2 81 is depressed aqelnst th e tension of the spring (24). Fuel is
forced along the channel (23) t o the delivery valve (22) and is
injected thr ough the pump jet s (21 } into t he carburettor barrels
in the vicinity of the auxiliary vent urls. The spr ing (27 } dampens
any sudden openin g of the throttl e valves and prolongs the full
deliv ery. The calibrate d discharge hole (2 9) allows excess fuel
and any accumula ted alr and vapour to escape into the floa t
chamber.
- - - - - -- - - - - - - - - - - - -- - - - 13-3
13
i
A g . 13.2 Idling and pro g ression phese (Sec 3 1
6
Emulsion tube wells
18 Channel
13 Progression hok s
15 Idle feed holes
16 Idle m;xtUIfJ screw
19 I dfejers
14 Thro rt1e v(lfves
17 Channel
20 Calibrated bushe s
2
12
3
o
'4
•
9
I
7
Fig . 13.3 N orma l ptul se (Sec 3)
1
2
3
4
A ir CO"ector jets
Norrfe!
A UIC/7illlY venturis
Chokes
5
Em u/sion tubes
6
7
Em ulsion tube wells
Meinjet$
8
Floar chembe,
9
10
11
'2
FJof1l
Fulcrum pm
N eedle
Needfe lIaWesearing
2
Part 2 W eber cwburetars Chapter 13
13-4
21
\
22
29-_
25
24
8
23
Fig. 13 A AcceJeratjon pha_lSee31
8 Float chamt¥r
14 Throttle YaMS
2'
Pump jer .
22 DeI;ve,y VB~
4
27 Reli ct ion spring
28 Diaphragm
29 Calibrated disch8rge hole
23 Cha" r*
Z4 Rtdum I{Jrlng
25 c sm
26
O~ing ~
Aemow l and refitting
Note : The fo llowing procedun glw. B gt!fl~' rather than B
specific method of removing lind refitting the cBrburettor. BS
much will depend on thlfJ loeli rion of the Cll rb ure ttof within the
"ahlcle. 0" some applfcarfons fo r Instance, the retaining nuts
may not be accessible without removing surrounding com-
ponents.
t Where fitted. remove the air cleaner assembly from the carburettcr.
2
Di sconnect th e throttle linkage and choke cable.
3 Unscrew the fuel inlet union and recover the two gaskets.
4 U nscrew and remove the carburettOl' retaining nuts and
spring washe rs and wit hdraw t he carburettor co mplete ove r the
mo unting stud s.
5 Remove the gasket fro m the inlet man ifo k:l and clean all
tr ates of gasket from t he contact fa ces of the ma nifold and carbura n Ol'".
6 Protect th e inl et manifold from ingress of fore ign mattllf
whilst the carbc rettcr is removed by sealing ft with masking
tape .
7 Refi tting is a re~~ l of remova l but the following
additional poi nts should be noted:
(II) AlwllYs fit II n~w g8$1(et end tighte" t~ retaming mJU
evenly in diagonal sequen~
fb) Th~ idling adjustment screws should be ut liS
described in Section 7 li nd f",1I11y tuntteJ Btl deS(;fi~d In
Section 8
(c) When refitting t he Choke (st8fTing devke) cab/e, first
secure th e out er cab'~ to the supp ort then insefT t/¥ inner
cable into the operifting lever nut and push the instrume nt
pan el control knob full y in. Trghten the inner cilble retain ing
screw with th e operating lever fully released.
30 Ba" Vil/ve
:.--=0:"...
- .....
- -.".. - - -- - - - - - -- Thoroughly clean the carbure tt or exteriOf" and w ipe dry .
2 Where 8ir horns are fitted. remov e th e retain ing screw s li nd
w asher. and withd raw the air hom assemblv.
3 Referring to Fig. 13 .5. unscrew and rem ove th e retaining
screws (861and wash ers (8 5) in diagonal sequence end lift th e
carburettor top cover ( 1J from th e eere urettcr body (5 1), mak ing
filre th at the gasket (3) is not bro ken (photo).
4 Uft the gasket (3) from the cerburencr body (51 ).
5 IrMlrt the carburettor cover (1) and unscrew th e filter cover
plug 1781, using a 19 mm ring spanner or socket (photo).
Remo .... the washer (79 ).
6
Remove the filter gauze (8 11 and extr act the b ase (BO).
7 Using a filitable diameter metal dr ift. ta p t he fu lcrum pin (9)
from the suppo rt posts (photo). Do not att empt to prise th e spl it
post apart.
8 Uft the float assembl y (1 8 ) from t he cover and extract the
nHdIe from the needle valve luting (1 1) (photo).
9
Unscrew 8M remove the need le valve seating (11) and
lt OI.
10 Unscrew aM remove the retain ing screw 171 and rem ove
wa sher
the wilner and bush (8 ) (photo).
11 Lift the operating arm (1 3) and disengage th e rod (4 Ol'" 6 )
from the m rter dsvice.
12 Extract the sprrt pin (5 1.nd ramove the rod from th e operatIng arm (141 (photo). Remove the clamp screw (151 if
ne08 uary.
13 Unsaew and remove the reta ining screw s (6 9) and
w ashers (70) and remove the starter device (6 1) from the car burenor (photo) .
14 Dismantle th e sterter device by unl crew ing the nut (58)
from the shaft (62) tog ether with t he washer (67). then carefully .
Part 2 _
13-5
carburetors Chapter 13
.~
5 .3 Removing the carburettor tOp cover
5.5 Removing the fuel filter and plug
5. 7 Aemov ing the flo at fulcrum pin
2
~
5.8 Removing the
need le valve seating
5.13 Removing t he starter device
;\.
-,
5.12 Sta rter device operating rod split
pi n locat io n
5.15 Removin g an emu lsion tu be
5.16 Separating the maln jet and air
corrector jet from the emu lsio n t ube
remove th e lever {66) and spring (6 5). W ithdraw the shaft (62)
a nd filter gauze (6 4) .
15 Unscrew and remove the air corrector jets {l2} fro m the
carburettor body (51 J and lift out the emu lsion tube asse mblies
(photo).
16 Separate the emulsion tubes (17) fro m t he air corrector jets
(12) and main jet s (2 S1 (photo), Take care not to damage t he
jets whe n remo ving them and. if pliers are used, interpo se a
piece of paper or card to prevent the brass being scratched.
Alternative ly, insert a small d rill through the em ulsion tube
holes to retain it w hilst the jets are turned off each end.
17 Unscrew th e idling jet holders (2 S) fro m the sioos of the
carburettor body (5tl. remove the rubber O-rings i2n then
separate t he idlin g jets (26 ) (photos).
t 8 Whilst depressing the starter valve spring fetaining guides
(7 5) in turn, prise t he spring w ashers (74) from the ce reueertc r
body, then release the guides (75) and ext ract the return springs
(76) and starter valves (77 ) (photos). Note from wh ich bore
each valv e is t aken so that th ey can be refitted in t heir ori ginal
locations.. Do not terce the valves if th ey w ill no t come out
freely ; if a burr exists at the top of th e bore, remove it with a fi ne
fil e.
19 Unscrew and remove t he starter j et s (73) {phot o).
2 0 Unscrew and remove the accelerat or pump delivery valve
116) together with th e pum p jet (23) and copper w ashers (24)
(photo), t hen separate the was hers and jet from the valve.
2 1 Unscrew th e retaini ng screws and w ashers (31 ) and wit hdraw the pu mp cover (22) fro m th e carburetto r body (phot o).
Take care not to damage the d iaphrj'
7.
·of
31
37
ft:\
~~
34-A 36-A
5.17a Removing the idli ng Jets
5.1 7b An idling Jet end holder
5.1Sa Removing
co mponents
the
starter spring
2
5.19 Removing a starter jet
5.18 b ... and starter valves
5.20 Removing the accelerator pump
de livery valve and jet
Fig. 13 .5 Explo ded v iew of the 36 DC NF carbureno r (tYpica l) (Sec 5 )
1
2
3
4
5
6
7
8
9
'0
"
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Top cover
Stud
Gaske t
Operating rod
S plit pin
OperatIng rod link
Screw
Bush
Fulcrum pin
Gaske t
Needle valve assembly
A tr corrector jat
S tarting device leve r assembly
Stertlng device lever
Clamp screw
Delivery velve
Em ulsion tube
Float
A cceleretor pump cover assembly
Pivot pin
Lever
Cover
Pump / elS
Washers
Mein jet
Idlejet
RubbarO-ring
Idle je t holder
Return spring
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Diaphu/gm
Screw
Nut
Tab washer
S plicers
Cam
Spacers
Wave washer
Specer
End washer
8 all-bearlng
Throttle leve r assembly
Lever
Adjustment scre w
Spring
Pressure pin
Spring
Spfitpin
Throttle valve
Re taining screw
Throttle $pind/#
Caroorettor body
Re turn spring
Throttle lever
Spring
Idle s pee d scre w
S pring
Washer
Idle m ixture scre w
59 Air bypass scre w
60 Locknut
6 1 Sta rting device assembly
62 S hah and sector
63 Housing
64 Filter gau;ce
65 R eturn spring
66 Lever
67 Washer
68 Nu t
69 S crew
70 Wash er
71 Choke
72 Auxifiaryven tur!
73 Starterjet
74 Retaining clip
75 Retflining guide
76 S pring
77 Starter valve
78 Plug
79 Gflsket
80 8ase
81 Filter
82 Fuel inlet bolt
83 Gasket
84 and B4A Inlet union
85 Washer
86 Screw
5.21 Withdrawing the accelerator pump
cover
5 .22 Accele rator pump diaphragm
return spring location
5 .2 6 Removi ng
adjust ing screw
5.27 Idle speed screw locatio n
an
idling rnlxt ure
5.25 Removing a choke
:..§.;
5.28 Remov ing an air bypass adju st ing
screw
5.30a Throttle lever and end nut with
locktab
5.30 b Ac celerator pump cam and end
nut w ith lcc kteb
5.32 Throttle return spring location
5.33 Accelerator pu mp cam and sector
5.36 Removing a throttle valve
5.39 Removing the throttle spindle
~
Part 2 Weber carburetora Chapter 13
was her and cl evis pin .
24 Note the location of. th e auxlllarv venturis (72 ) an d mark
th em if nece s s ary, with a pencil to e ns ure corr e ct refitti ng . Th e
auxiliary v enturis (7 2) ar e lig htly staked int o the ca rbu rettor
body and to re move them , it w ill be nec essa ry to ins ert a
wooden or p la sti c do w el rod t hroug h th e throttle va lve e nd of
th e b arr e ls to tap th em free . If they are exces siv e ly t ight it w ill
be ne ce s s ary to obta in the sp ecia l Weber to ol no 9800 9 200 .
2 5 Using a fin e file , remove the staking from th e t wo barrels,
th en no te the lo catio n s of ea ch c ho ke (71 1a nd s lide th em out of
th e barr e ls. Not e that th e choke e nds with the s ma ller int erna l
di am et ers are uppe rmost (photo}.
26 Un s crew a nd remove th e idling m ixtu re a djus ting s crews
(58 ) to ge the r with th e sp rings 15 6 ) a nd washe rs (5 7 ) w here
fitt ed (photo).
27 Unscrew a nd remove the idle s peed scre w (5 5 f, s p ring (54)
an d s lee ve , wh e re tlrted (pho t o}.
28 l oosen the lo ckn uts (6 0) with a n 8 mm rin g s pa n ne r, the n
un s crew and remove th e a ir by pa s s sc rew s 159) (pho to ).
2 9 Where fill ed , unhook the thrott le return sp ring from the
a cce lerat o r pump e nd of th e throttle sp ind le (50 ).
3 0 Ben d back the loc kta bs (3 3) o n e ac h e nd of th e t hrottle
sp ind le (50 ). th en un s crew a nd rem ov e the nuts (32 ) (photos). If
th e s e a re very tight, us e W eb er to o l no 980 2 3 700 to ho ld th e
s pind le whil st they a re loo s ened; t his will prev ent th e s p ind le
from being bu ckled. 00 not loos en a tight nu t with th e throttle
va lve s bein g forc ed again st th e barre l wal ls; instead, us e a
s crew d rive r to ho ld the thrott le lev e r {53) In the op en po siti o n.
3 1 Remove th e nuts (3 21, tab w a sh er s (3 3) and s pace r (34)
from t he throttle s pind le (Sot tog eth e r w ith th e throttle return
s pring le ve r where fitted.
32 Turn th e t hrott le lev er {5 3) a ga ins t th e ten sion of th e co il
s pring (52) th en ea se it from t he th rott le s p ind le (5 0 ) a nd
remove th e coi l s pring (photo ). Remove th e w ave wa sh er (37 )
to geth e r with w a sh er s (34A a nd 36A) where fitt ed ,
33 Us ing a sc rewd rive r, pri se th e ac ce lerato r pump cam a nd
sector 135J fro m th e th rottl e s pind le (5 0 ), to g eth er with th e
s pace r (3 6 ) wh en fitt ed (photo). Remove th e wave w a sh er (3 7).
34 Un screw an d remove the throttle va lve ret aining sc re ws
{4 9 ). being c a re fu l not to exert excessive pre s su re on t he
s p ind le (50).
3 5 Not e th e positio n of th e t hrott le s pindle and valve s in re latio n to t he barrels a n d if nece s sary, ma rk the va lve s with a
pencil.
3 6 Turn th e s pind le to the fully op en po sition an d withdra w th e
two th rottle valv e s (48) tram th e ir lo ca tio n s lots (p hoto ).
37 Ma rk on e e nd of th e thrott le s pin d le (50) in re lat ion to the
c arbu rettor body (5 1I to e ns ure corr e ct ref ittin g.
13-9
38 Check tha t th e spindle (50 1is fre e of a ny burrs in t he vicinity
o f the valv e retaining screw ho les an d if nec e ss ary, remove
t he m with a fine file.
39 Using a pla stic ma lle t, driv e th e s p indle (50) from th e car bur ettor {photo).
4 0 Rem ov e th e s pace rs (3 8) a nd e nd wa sh er s (39) fro m th e
s pind le a nd carburettor body {phot o),
41 Tap th e s p ind le (5m throu gh the bearing (4 0 ) with th e
bearing pla ced on a vice.
42 Re-in s er t the s pind le 150) a nd d rive t he rema ining bearing
(4 0) from th e c arbu rertor body (5 1). Remov e the be a ring fro m
th e s pind le .
43 W her e fitt ed, unscrew th e idle s pee d sc re w {43 ) a nd sp ring
(4 4 ) from th e th rottle lev er (4 2). th en remove th e s p lit pin 147 1.
pre s sur e pin 145) and sp rin g (4 6).
6
Special overhaul procedures
Afte r ca rrying out th e ge ner a l ove rha ul pro ce dur e s given in
Chapter 4 , th e follo win g spec ial proce du res s ho u ld be co mpleted:
1
Using a hand ch uc k a nd the s pe c ial too l a va ilable from
We ber or a too l hire age nt, refor m the ma in jet s e at ings a t the
bottom of th e e mulsion tube hou sing w e lls by caretullv rot atin g
th e tool in a lternate di re ct ions. Finish th e s ea tings with th e
s pe cia l drift by t a pping it ge ntly whi lst rot ating it at th e s a me
tim e.
2 Using the sa me p ro cedure as d e s crib ed in par a graph 1,
reform th e idlin g jet sea ts.
3 Usin g th e sa me p ro cedure as d e scribed in paragra ph 1,
reform th e sta rter valv e se ats.
4 Usin g th e s a me procedure as de scribed in paragr aph 1,
reform the st a rte r jet seats.
5
If the e m ulsion tub e w ells a re discoloured and con s ide rabl e
se diment ha s acc umu lated , th e bore s must be re am ed using th e
s pe cia l We ber tool an d a h an d c huc k, Turn the tool ca refu lly
until it move s fre e ly, th e n co ntinu e turn ing it whil st removing it.
6 Che ck th e intern al ch ann els of th e carbu rettor body cov e r
by inje cting fuel f rom a s yringe a nd o bs erving w he the r it
em erg e s freely. If any ch an ne ls are b lo c ked , it wi ll be necessa ry
to drill ou t th e lead p lugs and us e W eber too l no s 98014 300 .
9 801 4400 a nd 98014 50 0 to c lear th em . These too l numbe rs
refe r to the thre e ch a nne l di am e ter s of 1.0 mm , 1.5 mm an d 2.0
mm .
7 Che ck th at th e a ccelerat or pum p b a ll va lve is free by
s ha king th e carburettor bod y a nd list e ning to th e ba ll movement,
8 After ov e rhau l, th e carburet tcr bod y s ho uld b e t horough ly
clean ed, pre fe ra bly usin g cle an fuel a nd a ir pr es sure. The lead
plu gs sho u ld be ren ewed a nd re ta ine d in po sit ion by us ing th e
W eb er to ol no 9 8010 700 or 9 8010 800 as a punch unti l th e
plugs are expanded into thei r bor e s.
9 Che c k th e flo at a ss e mbly for dam a ge a nd le a kage: s h a ke
the float to d et erm ine wh e ther fue l ha s e ntered . If th e float is
da ma ge d o r fue l is pre s ent, it must be re ne wed.
10 Check a nd renew if ne ce s sary, th e ac ce lerato r pump lev er
and dia phra gm.
7
Assemb ly
No te: Aff co mponen ts should be clean an d dry b efore starting
the assembly p rocedure.
5 .4 0 Throttle s pind le wave w a sh er, s pa ce r and bearing washe r
1 Wh e re fitt ed, fit th e s p ring (4 6 ) a nd pre s sure pin (45) to the
thr ottle le ve r (4 2 ) and secure w ith th e s p lit p in (47).
2 Fit th e idle s pee d s cre w {4 3 ) and spring (44) to th e throttl e
lever (42 ), wh en fitt ed .
3 Using a s uitab le d iam ete r le ngt h of tubing , drive on e
b e a ring (4 0 ) fu lly int o th e ca rbure tto r body (5 1) at th e
a c ce lerator pump end.
4
Place the rem aining ba ll-bea ring (4 0) o n a n op en vice and
gent ly ta p t he sp ind le (5 0) into it, entering th e en d with t he
2
13-10
Part 2 Webe r ca rbu retors Chapter 13
short flf reCllss first.
S Insert th e throttle sp ind le (50) into the carbcrettcr body
15 '1. th en m a ke sure th at the be a rings (40) are fully seated o n
the spindle by supporting on e In a suita ble di am et er length of
tubing and usi ng a fu rther length of t ubing to tap t he op posite
be aring.
S Fit the end w ashers (3 9) and space rs (3 81 over th e ends of
the spindle (50) after lubri cat ing the bnrings with a ' little
grease.
7 Tum th e throttle spi ndle (50 ) so that t he t hrottle vefve
ret aini ng screw head rece sses are faci ng the cerburettor moun ting flang e. Place the cercu eettcr body (5 11 on the acce lerator
pump end then locat e the wa ve washer (37) over th e sp indle.
tog eth er w ith the w ashers (3 4 .4. and 36.4.) wh ere fitted .
8 Locate th e retu rn sp ring (5 2) in the ho le on th e body an d
ho o k. th e rem(linin g e nd over th e fla t edge of th e throttle lever
(53). Tension th e sp ring and press the throttl e lever (53) fully
onto the sp indl e (50) .
9 Fit t he tab washer (33) and nut (32). th e n tight en the nu t
and lock. it by bending the tab onto a flat; do not overtig hte n the
nut.
10 Turn th e throttle leve r (53) fu lly open sa th at th e th rottle
valve slots can be seen from the flang e end of th e carburettor.
th en in sert one throttle valve (4 8) in the loc at ion previously
noted and close the valve. Make sura that the throttle valve is
fin ed t he corre ct wa y rou nd so t hat t he al"lgled perimeter seats
in the barrel.
1 1 S r'I8 p the valve sh irt severa l ti mes in ord er t o centr alise it.
then in sert and ti ghten t he valve ret ainin g $Crew s 14 9 ) witho ut
exerting excessive pressure on the sp ind le. It is reco m me nded
that new screws are always fitted as it is quite easy to crossthread previo usly peened screws. Lock tbe screws by pee ning
with W eber tool no 98 0 10 900 wI1ilst supporting the spind le
with a length of wood. Altern atively, coat the t hreads w ith a
liqu id locking age nt (fuel resistantl prior to inse rt ing them.
12 Repeal the procedu re describe d in paragraphs 10 and 11
f or the rema ini ng th ronle valve.
13 l ocale the w ave washer (37) ove r the spind le 150) and fit
the spacer 13 6 1w h en fin ed.
14 Press t he sector int o t he nylo n eccereretcr pump ca m (3 5).
then flt the cam ov er th e spindle w ith th e low est cam con tour
upp ermo st.
15 Fit the spacer (3 4) th rottle retum spring lever wh ere fin ed.
tab washer (33) and nut (32). TIgl1 t en the nut (32 ) w hilst
holding th e th rottle lever (53) open with a screwd riv er, then
lock it by bendi ng the lo c ktab: do not overtight en the nul .
16 W here fitted, hook. t he th rottle return spring onto the leve r
on the end of the spin dle (SOl.
17 Insert the air byp ass screws (59) and screw th em In until
thay are fu lly seate d. then tigl1ten the loc knuts (60).
18 Fil t ne idle speed screw 1551. spring (54) end slee ve wh ere
fitte d.
19 Fit the idli n g m ixt ure adjusting screw s (58) together with
the spri ngs (561and w ashers (57 1. w here fi n ed .
7.2 1a Fittin g an au xiliary
show ing Ih e locati on sprin g
vent urt,
20 Insert the chokes (7 11 Into the barrels w ith the sma ller
k'ltem al diameter end s uppermost.
2 1 Fit \t1e auxniary venturis (72) in Ih eir origina l loca tions.
making su re th at t he locati on spri ngs eng age w ith t he grooves
k'I the barr els and th at t he sup ply channels are i n alig nme nt w ith
tho se in th e cerb urerroe body. Th e extended venturia must also
be uppermo st (phot os).
22 WJth the auxil iary venturia 0 2 1fu lly seated , ligh tly st ake the
earbu ren or upper f ace t o ret ain them . Use a bl ade pin ch and not
a cen tre pun ch to do thi s.
23 As semble t he lever 12 1 J to lhe acce lerator pump cove r (22)
in it s previou sly not ed po siti on, the n drive t he pin (20) th rough
the cover and lever unt il fu lly entered. Where a clev is pin Is
fitted , in sert it throug h the cover and lev er and retai n it with the
w asher and spl it pin.
24 Support t he cerburet tcr body ( 5 1) w ith the pum p
diaphragm face uppermost , t hen locat e the spr in g (2 9 ) on th e
face in th e central posi ti on.
25 PIIICtl t he dlaphraqm (30} over tl1e spring {2 9}. then locate
t he pump cove r (22) over the diaph ragm (30) .
26 Insert th e ret aining screw s and w ashers (3 1) and t igh len
t hem evenlv in di agonal sequ ence. Operate th e throttle lever
and make sure th at th e pum p lever run s srncothlv and is in
con ta ct w ith th e cam.
2 7 Assemb le th e accelerat or pump (23) t o th e delivery valve
1161 with a copper w asher 124 1 eithe r side, th a n ti ght en the
assembl y into t he carburen or body.
28 Insert and t ight en t oo st arter jets (73 ).
2 9 Fit th e starter valv es 07 ) int o th ltir respe ct ive bores
fol lo we d by the return spri ngs 17 61 and retai ners (75).
30 Depress th e reta iners (751 In tum and lo cate the sprin g
washers (74) in the carbu ren or rec esses, pressing th em fu lly In
with the fl at blade of a screwd rive r (ph ot o).
31 Press th e idling jets (2 6) lntc the holders 12 8), fi t th e rubber
O-rings 12 71. th en ti ght en the hol dera into th e ca rburenor bod y.
32 Press the ll mu lsio n t ubes 11 71 onto the main jet s (2 51 and
inl O the air corrector tats (121. Insert and ti ght en the air
co rrect or jets (1 2 ) i nt o the cerbc rettcr body to gethe r w it h th e
emulsion tubes.
33 Assem ble th e shah (62) to Ih e st art ltf device bod y so thaI
l he alignment l ines on each sector ere faci ng each other, then fit
the coil spring 165) with it s end In the loca tio n hol e. Fit the laver
(6 6) ever th e shah (52) and at t he same time hoo k th e end of
th e spri ng (65) over th e lever, then locat e the wa sher (6 7) and
nut (68 ), and tight en t he nut.
34 Fit th e fil t er gauze (64) and check that the starter dev ice
operat es smooth ly.
35 Offer the starter device (6 1) up 10 the cerb urettor body and
make sure th at th e sect or lugs locat e in th e sta rt er v alve
grooves. then insert the retainin g screws (69) and w ash ers (70 )
end l ightlln th e s crew s. Check that the sta rter devi ce op erates
smoothly.
36 Fit the clamp screw ( 151 to the st arter device opera ting arm
114).
7.21 b Show in g the auxiliary vent uri
channel which must face the emul sion
lube we I!
7.30 The starter valves fltt ad in th e main
body
Part 2 Weber carburetors Chapter 13
37 Insert the operating rod (4 or 6) into the arm (14) and screw
w ith the split pin (5).
38 Insert the rod int o the starte r device arm (66 ), then
assemb le the bush (8) and washer and tighten the reta ining
scre w (7) into the carburettor bod y.
39 Tighten t he needle valve seat ing (1 1) together with a new
gasket ( 10 ) into the carburettor cover (1).
40 Lower the needle int o the needle valve seating ( 11),
tape red end first.
41 Lower the fl oat assem bly (18) onto the cover (1) and insert
t he fulcrum pin IS) through the support posts and fl oat arm. If
necessary, gent ly pinch the spi lt po st to secure the pin using a
pair of pliers.
4 2 The float leve l adjustment m ust now be checked in the
foll ow ing manne r : Hold t he carburettor screw vertical so that
t he floa t is hanging fro m t he fulc rum pin wi th the f loat level arm
in light contact w it h the needle ball Ile w ithout the ball being
depressed ). Using a vern ier calipe r, check that th e distance from
the cover face (w it hout gasket ) t o the top of the float as shown
in Fig. 13 .6 is 1.8 90 in (4 8 mm ) for 42 DCNF models and
1.969 in (50 mm ) for other DCNF models (photo), If not, bend
the needle operating tab as necessa ry.
43 Tilt t he cover so tha t the fl oat moves awa y fr om the cover
and the tab makes contact w ith the needle valve seating. Now,
using the same method as described in paragraph 42, check
that the need le valve fu lly open di mension is 2 .224 in (56.5
mm ) for 42 DCNF mode ls and 2.303 (58 .5 mm ) for other DCNF
models (phot o). If not . bend the tab wh ich contacts the needl e
valve seat ing as necessa ry.
44 The difference between the d ime nsions checked in
paragraphs 42 and 4 3 is t he needle valve stroke which sho uld
be 0 .335 in (8 .5 m m).
45 Fit the base (SO) to the fil ter gauze (8 1). With the carburettcr cover ' 1) invert ed, press the filter gauze into the inlet
cavity.
46 Fit t he washer (79) to t he filter cove r p lug (781. then tighten
the plug into the cover (1).
47 Place the gasket (3) onto the top face of the carbureuor
body (51).
48 Lower the carburettor cover (1) onto th e main bod y {51),
t hen insert the retaining screws (8 6) and was hers (85) and
5 2
13-11
tighten them a little at a time in diagonal sequence .
49 Fit the air hom assembly, w here fitted. Insert t he reta ining
screws and washers and tighten th em evenly in diago na l
sequence .
50 With the carburettor completely assembled, the idling
adjustment scre ws shou ld be tu rned to the ir prel imin ary settings. To do t his, first scre w in t he idli ng speed adjustme nt screw
until it just t ouches the throttle lever, the n con tinue tum ing for a
fu rther t turn. Working on the idling m ixtu re vol um e scre ws in
tu rn, full y screw them in unt il they are in contact with their
seats, th en back them off 2 complete turns. Final ad justme nts
will be necessary wit h the carburettor fitted on th e engine (refer
t o Section 8 ),
8
Tuning
Note: Refer to Chapter 3 for gener81notes on runing.
1 Set t he idli ng adjustment screws to their prelim inary posit ion s as described in Section 7.
2 Connect a tachometer to the engine in accordance w ith t he
manu fac turer's instructions .
3 It is now im po rt ant to understand that each barre l of each
carbure ttcr mu st be synch ronised in order to deliver equa l
3
4
7.42 Checking th e float closed posit io n w it h verni er calipe rs
6-~
,
,
,,
I,,,
I"
-
"
7
A
B
Fig. 13,6 Float level edjustment dimensions (Sec 71
1
2
3
4
5
6
7
A
B
Spring loaded ball
Stroke adjusting tab
Needle valve assembly
Carbure ttor cover
Fulcrum pin
Height adjusting tab
Float
Needle valve fully closed dimension
Needle valve fully open dimension
7.43 Checking the float ope n position w ith vern ier calipers
13-1 2
Part 2 Weber carburetors Chapter 13
amounts of air/fuel m ixtu re t o each Individual cyl inder. To check
this, it will be necessary to obta in a length of tubing
(approximately 1 metre) of about 5 mm to 10 mm (0.25 i n t o
0.5 in) intemal diameter. A1ternat ivelv. a synchroniser as
illustrated in Chapter 8 may be used.
4 Remove the air cleaner(sl if fitted. then run the engine un tit
normal operating temperature is reached. To ensure that t he
engine is re811y hot e no ug-. , drille it hard over a 5 mile dis tanc e.
5 Switch off the engine and disconnect the accelera tor rod
connections from each carourettor.
6 \rYhef9 two calbtJrettor throttle spind les are linked, tum the
adjustment screw 00 the link a tum in from the fully shut posi-
t
t ion.
7 Start me engioe and adjust each idling speed adjusting
screw (except link adjustments) by equal amounts until the
engine is Idling at the a pproximate recommended speed. Th is
win vary according to the application and state of tune of the
engine but on average will be around 800 rpm .
8 The banels of eacn individual carbu rettor m ust now be synctmmised 10 pass identical Quantities of air during id ling. To do
this, loo sen the 10000lrts and check that the bypa ss screws are
both in light contact with their seats. Place on e end of th e syn chronising tube in one air intake and listen at the oth er end to
the amount of hiss present. Attematiwly, use th e synchroniser
to record the air flow through the a fr intake. Check both air
intilkes Dfthe carburettor to determine wh ich one is passing the
greatest amount of air,1hen adjust the remaini ng barrel to give
an identical IIOluTTlB i1nd finally t ighten the adjustment locknuts.
Cany out the procedure independently on each cerourettor
fitted to the engine.
9 Each caTburettor must now be synchronised with the
remaining cerburettcrs. To do this, allow the engine to idle and
check. the volume of air flowing through one air intil ke of each
carburettof. using the length of tube Of the svnctrronlser. Determine the carburettor which is passing the medium vol ume of air
and iKljust the id le speed adjustment screws of the remaining
9 F..atcS
carbtJrettors until they also pass identical volumes of air.
10 If the engine idling speed is not now within the recommended limits, tum each idl ing speed adjustment screw by
equal amounts as necessary.
11 The mixture screw adjustments on each carburettor must
now be set and synchronised. Since each screw w as turned to
its prel iminary setting, it can be assumed that the y are
reasonably synchronised to start with. Wit h the engine id ling.
tum all the screws by equal amounts (f a tum in it ially) first in
one d irection, then in the reverse direction. Observe whethe r
the engine speed falls or increases and make severa l adjustments unt il the eng ine runs at the highest speed commensurate
with even firing .
12 If necessary . again tum each idling speed adjustment scre w
by equa l amounts to bring the eng ine speed with in th e recornmended limits.
13 To check whether the f inal mixture screw synchronisation is
correct, allo w the engine t o idle, then remove each spark. plug
lead in tum and observe the reduct ion in engine rpm on the
tachometer. The reduction shou ld be ident ical for each cyl inde r,
thus pl"oving that the mixture strength is also identical fo r each
cyli nder. A further chec k can be made by removing t he spark
plugs after the engine has been idling for approximately 15
minutes. An y with black sooty depos its indi cate that the
particular cylinder is running rich. Normally. if t he mixture screw
has been set correctly, weakening it by ha lf a turn during idling
will cut the relevant cylinder.
14 Note that on some app lications it may be adv isable to fit
'hotter' spark plugs w hilst adjusting the carburettors to prevent
m isfiring. However, th e original plugs must always be refi tted
after completing the adjustment.
15 Sw itch off the engine and reconnect the throttl e linkages,
making any arfjustments as necessary to prevent the cerburettor
idl ing settings from being affected.
16 Remove the t acho meter fro m the engi ne and refit the air
c reenerts ). if fitted.
II~
Rea so n
Engine w ill l'lD1: start
Blocked fuel fi lter or jets
Flooded engine as a result of faulty needl e valve or depressing
accelerator pedal
Uneven Id ling
Leaking man ifold or carburetto r flange gaskets
Loose idling jets or auxilia ry venturls
Excessive sedi ment or water in carbure ttor
Incorrect tun ing adjustments
W orn need le val ve
Leaking or damaged float
Incorrect float leve l adjustments
Excessive sedimen t in fue l
Incorrect tuning adjustments
Incorrect float level adjustments
Excessive sedi men t in fue l
Throttle valves not fuliy open ing
Accele rator pump fa ulty or leaki ng
Needl e valve not seating
Leaking or damaged float
Incorrect float level adjustments
Choked air filter {if fitted )
14-1
Part 3 Zenith Stromberg carburetors
Chapter 14 Series CD, CDS and CD-2S
Content s
Introduction .
Construction
Air valve assembly and suction cham ber
Damper assembly
St arter ba r (Series (CD)
.._._
Cold-start valve (Series CDS and CD-2S).
. ,
Sec t ion
1
2
3
. .4
5
. 6
I nt rocluction
The series CD cerbu rettor is the ear liest of the "''' ';OUI ser ies
de sc ribed in thi s miilrlual. Fo r t he pu rpose of in str uc t io n it may
be considered as II'Ie basic; form of S trombe rg co nstant
depre$Sio n carbu renor, since all later se ries are large ly refined
ve rsion s and all u_ the lame basic e lem en ts . Its connru<;tion
and operat ion wil l be deKribed fully in this chap te r, and th is
w ill se....e f o r a bas ic und e rst and ing of lat er ser ies
T he seri e s CDS and CD ·2S d iffer from th e CD in t ha t they
incor p o rate a separate COld-start d .....ice.
None of these carbu retto rs have an y em ission contro l
features. T he uamp le uSild to illu st rat e t h is t e" t is f ro m a 1971
SAAB 99 , 1709 cc (carbure ttor refere nce 3302 ).
2
Co nstr uct io n
T he u nit con sists o f a d ,e .cast a lum in ium bod y in w h ic h is
Section
Operation
'
Disassemb ly
Special overhaul procedures
Assembly ,...............
.
Tuning
.
_
7
8
_
_..........
9
10
11
formed the cho ke bore, a $Uct ion ch am be r and air valve asse mb ly
mounted ver t ica lly above it , a jet assemb ly mo unted co-a xia lly
wi t h the su ct io n chamber b elow- it . and c losed at the base b y a
1I0at chambe r co ve r.
The bod y has a f lange at each end, dri lled for bol ts t o mou nt
th e unit to t he in let manifold at o ne end . and fo r t he attac hm ent
of an ai r clea ner o r intak e system at the o ther. An inve rted .
bell·shaped e"tens ion at the t op of t he body hou se s t he air ...a lve
and d i aphr8~ assemb ly . A cir cul ar grOO\/e is mach in ed at the
rim of the bell to accomodate a be ad moulded on th e ed ge of
the d iaphragm . The in ternal contou rs of the be ll a-etes ea st' ,
ie $ITlooth wit h no mach ining. The int e rio r is in communication
w ith the ou ts ide via a USI- in pas~ge-way which Ierminate s at
t he inlel flange . F ou r tapped holes ar e provided at the top of
the bell for t he suc tion ch am be r t op cover retaining Kfli!Ws. A
large barr in the cent re inl e rce p ts the chok.e b ore at right ilng les
and accepts the air valve assemb ly .
Th e unders ide of tne body has a la rge int erna lly threaded boss
in t o w h ich is scr:;f.-- - - - - - -
jet edlu ste r
petro l in let
Fig. CO2 Th e mllia r external componen ts of th" Se ries CDS carbu rertor
damper
assemb ly
d iaph ragm,- t "<.',
hollow
guiderod;;;-- - - ¥i'!'-\!..
throttle d isc
petro l inlet _-;--'"
jet armee
inle t need le
\
valve assem b ly
needle
58a t ing
float
F ig. CD3 CI'OSS-seetion of the in let valw of the Ser!8$ CD carbu retto r
jet adjusting screw
Fig. C0 4 Cross-section th rough the Se ries CD jet assemb ly
Part 3 Zenith Stromberg carburetors Chapt er 14
hin ge p in are cast to'Nard th e f ront of th e bod y, and a tapped
hol e , co mm un icating via inte rnal passages to a st ub pipe p ressed
in to th e body, is provided fo r fitting th e in let need le valve. T hese
f eat u res ar e enc lose d within a ski rt the bottom of whi ch form s
a sea ti ng surface fo r th e f loat ch ambe r, secu red t o t he body by
sc rew s and is sea led by a gaske t . The chambe r has a ho le in the
ce ntr e t h rough which proje cts the jet asse mb ly , sealed by a rubbe r
O-r ing.
Ot he r cas t fe ature s of t he body in clude bosses bo red to
form t h ro tt le sp ind le bearings, a throttl e stop, bearings for a
sta rter bar (Series CD) or a raised fa ce, machined fo r mo u nt ing a
co ld-st art valve assembly (Seri es CDS and CD -2Sl.
Air valve asse mbl y and suc t io n cham be r
3
The air valv e assem bly co ns ists of a r::.; lin drica l air varve, an d
integral ho llow gu ide rod , clamp ed to the inside of a conical,
synt heti c rubbe r d iaph ragm by a p last ic di a ph ragm f orme r, a
plat e and fo u r scre ws. A fuel mete ring ne ed le is f itted into a
socket at th e bottom of t he gui de rod and retain ed by a locking
screw.
T his assembly is f in ed into the vertica l bore in the u nit body.
The needl e e nte rs t he jet asse m b ly and t he pe rip he ral bead of t he
diaph ragm locat es in th e machin ed groove at the to p of the be ll
of th e body .
The top cover is fitted to th e top o f t he body and secu red by
four sc rews. Th e ole -cast aluminium cove r, tog eth er with th e
d iaph ragm, forms a sea led suct io n cha m be r. The cha m ber is
ve nted via th e t ra nsfer ho les o n t he dow nst ream (throttl e plat e
o r engi ne l side of t he air va lve base ,
T he to p cove r has a ce nt ral guide tube fitted with a ha rd en ed
stee l slee ve bear ing whi ch sup ports t he ai r valv e gu ide rod. (Note
th at t he ai r valve does not touch t he insid e of its base). The guide
t ube is ex ten ded at th e t op of the cover a nd int ern ally th readed
f or attac hme nt of a hydraulic damper.
4 Damper assembly
T he damp er co nsist s of a cy lindr ical, non -return valve assembly
reta ined on the end of a rod by a c irclip , The rod is serrated at t he
top a nd pressed int o a scr ewed p lasti c cap by which it is secu red to
th e to p COVeL Th e caps may b e drill ed to vent th e gu ide tube. The
valve deta il is immer sed in th e oi l in th e h ollow air valve guide rod
an d is so arranged t hat oil c an p ass fre e ly t h rou gh it in a downwards
d irec t ion (ai r valve falling) but pr esents a h igh resista nce to upwards
f low (ai r valve r ising}.
5
Sta rte r har (Series CO l
T he se ries CD has a mechanical devi ce lor co ld -starting . A boss
at each s ide of t he body is bo red (sim ila r to the throttl e spindle
bo sses) to accept a Shaft which pa sses ac ro ss t he cho ke bore
underneath the front of the a ir valve Iie.. up stream 01 th e bri dge!.
The bore is mach ined into the f loor of th e Choke thu s fo rm ing a
semi -circu lar c hannel in wh ic h th e sha ft is a c lose f it . The starte r
bar is mach ined f lat at t he ce ntr e , and in its no rmal pos iti o n t h is
flat f ollows th e slope of th e ent ry to th e br idge . and a sma ll gap
exists b etween it and the underside 01 the a ir valve . Rotat io n of
t he bar raises o ne edge of t he machined f lat until it is in co ntact
wit h th e ai r va lve. thu s clo sil1g the gas-way . Fu rth er ro ta t io n lif ts
th e ai r val ve an d hen ce th e attac hed fuel mete ring ne edle out of
t he jet, thu s incr easing t he annular fu el flow a rea , wh ile
mainta in ing th e gas-way ctosoc.
A ca m· shap ed lever at o ne end o f th e sta rt e r has be ams upon a
tapp et scre w a ttac hed to th e t hro ttle reve r a nd thus provides a
mech ani cal inte rco nnecticn.
6
14·3
Cord-start va lve (Ser ies CDS and CD-2S )
Th e ser ies CDS and CD·2S have a di ffere nt p re vision fo r
cold-starting from the seri es CD, in t hat a sep a rate met er ing valve
is fitt ed ,
A di sc with a number of diff er ent size ho les d rilled on a p itc h
c ircle is rotated t h ro ugh a lim ited a rc within a hou sing to align
with a kidn ey· shaped inlet port in a br ass va lve pla te . The valve
p late is c lamped to a machin ed la ce on t he body by t he housi ng
which is secu red with scre ws.
The hou si ng provides a be ar ing for th e valve di s.c operat ing
sh aft and a manifold lor t h e p assage of fue l, whic h issues from
t he body, t hro ug h th e mete ring holes in th e valve di sc , a nd
pas ses back through anot her kidney -shap ed hol e in t he valv e
di sc into th e body, an d then into th e mi x ing chambe r of t h"
carbu retto r.
The inn er end of t he operating shaft is mach ined to aD
sec t io n to pr ovide posit ive lo cat ion an d drive fo r t he valve d isc
Which has a similarly shaped hole . A circlip f itted to th e sh aft
pro vid es a register for a coil spring vvIli ch loads t he valve d isc
towards th e va lve plate. It is reta ined by sta king at the Inner end
of t h e Shaft. Th e Shaft ru ns in a stee l sleeve bea ring pressed into
the housing.
7
Operat io n
Refer to Part 1, Chapt er 1 - Operat ion, fo r general account of
op eration of the Strombe rg Constant Depression Carburetlor.
1 Cold-starting
Ser ies CD (Ref er to Fig.)
T he rich mixture nec essa ry to sta rt a c o ld en gine is produc ed by
raising th e ai r valv e bv ro tati on of t he sta rter bar. t hus liftin g t he
met ering needle out of th e jet o rifice and inc reasing the annu lar
f uel f low area. The edge of th e sta rt er bar, bein g in contact with
th e und erside of the air valve, also clo ses the air supp ly duct SO
that. init ia lly . t he fu ll depression in the mi xing cha mber is se nsed
at t he jet. A n intercon necting cam and lever arrangemen t outside
t he carbu rettor p rov id es the correct de gree of t hro ttl e opening for
sta rt ing, without d epressing th e acce lerato r. When the eng ine f ires
and runs, th e h igh man ifold dep ression is tran sm itted to t he suct ion
chamber and th e a ir valv e lif ts. With t he e ngine ru nn ing the choke
control is used to set the fast-idle speed nec essa ry t o ensure rapid
warm-up .
Series COS and CO·2S
Opera ti o rl of th e vehicle's 'c hoke' control rot at es t he cold -starr
valve d isc. With t he contro l pull ed full y out th e la rgest hol e in t he
valv e dis c is a ligne d with th e kidn ey-shape d ho le in th e va lve p late
giving t he maximum fu e l flow are a. Petrol flow s up a vert ical
dr illing in th e float cha m be r, throu gh th e cold-start valve por ts,
and is di scha rged via a st ub br ass pipe dir ect into t he mix ing
ch amber. An inte rcon necting ca m a nd leve r arrang ement outtid e
th e carburelto r provides th e co rrect degree of th rottle opening
f or starti ng. T he accelerato r p edal shou ld not be depr essed .
When t he e ngine first an d runs, t he 'c ho ke ' cont ro l ma y b e pushed
in slightly to weaken th e mi xture bu t ma inta in a fast id le speed.
(Rotat io n of t he c o ld-start valve lever a ligns a sma ller here in the
valve di sc wit h th e p ort in t he val ve plate; an d t he last -idl e cam
lift is not so gre at, giving a smaller thr ottl e ope ning!. The vehicle
may be dr iven im med iate ly wi th t he c hoke c ont ro l partly out.
2 Normal running, full throttle and cruise condi tions
As t he engin e war ms t hro ugh, th e degr ee of mixt ure e nrichment
is gradu ally redu ced by retu rn ing th e Cho ke con t ro l to its f ully
home p ositio n
The ope ration of th e car bur etto r is now und er t he co ntrol of
th e th rott le on ly.
At cr uise c o nd it ion th e th rott le plat e wi ll be partl y ope n
wit h th e en gine ru nn ing fast . The ob stru ction p re sent ed by th e
t h ro tt le red uces t he depr ession in the mi xing chambe r. a nd
3
14-4
Part 3 Zenith Stromberg carburetors Chapter 14
thence in the suction chamber and the air valve falls u ntil the
f o rces (weight , spring l oad and pneumatic) act ing above and
be low it an~ in balance. The h igh m an ifo ld depressi o n w ill be
sensed at the edge of the th rottle plate at th e vacuu m tapp ing
Iaut o-t tmm q con nection} o n units so fitted a nd tra nsmitted t o th e
ignit ion distributor to advance t he ign itio n t im ing, with b enef ici al
effects on fue l econcmv.
At fu ll throttle condition th e t hro ttle p late prese nts only
slight obstruction, man ifo ld depression is sensed in th e suction
chamber and the air valve lifts to its lim it . The depression al the
jet is as before but more fue l is drawn ou t due t o the with d rawa l
of the tapered need le. which creates a greater an nula r area. To
prevent mechanical damage (b urn t valves an d p isto n c rowns.
mainly ) which wi ll occur if the mi xture is to o weak at full
throttle, it is usua lly arrange d that the m ixture strengt h is
slightly richer at the 'top end' t han at part thrott le c ond itions.
Th is is achieved by t he taper of the metering needl e .
8
Disassembly
Unscrew and remove damper assembly. Do no t disassem ble
at this stage. Invert carburettor and dra in o il f ro m a ir valve gu ide
rod reservoir .
2 Remove fou r Phi llips-head screws and spri ng was her s sec uring
diaphragm chamber cover. Collect bras ident ity tag and ta ke ca re
not to lose it. Discard sp ring washers.
3 Mark periphery of cover an d body to ensure correct alignme nt
o n reassembly (there is no locat ing device and co ve r cou ld be
re-fitte d in any of fou r diffe rent posi tions ) and remove caref u lly.
Remove spring and air valve complete with meteri ng needle,
d iap hragm, diaphragm fo rmer and retaining p late. Note that th e
example illustrated he re has a sp ring load ed meter ing need le
which is not co·ax ial wit h t he air valve guide rod but is biase d to
one side .
4 Remove needle loc king screw and needle asse mbly. Do not
disassemble. For un its fitted wit h adjustable need les, refe r to
Series CDSE , Disassembly, paragraph 3.
5 Remove the four Phi llips·head screws fro m t he a ir valve,
remove steel diaph ragm reta ining plate, p lastic d iaphragm
former and diaphragm . Note t hat diaphragm has lo cat ing registe r
on underside of periphery which engages in a slot in th e recess in
body. It is therefore un necessary to mar k it for reassem bly . Th ere
is a similar arrangemen t on th e inner rim and and air valve.
6 Remove nut from non ·dri ve end of t hrottle sp ind le (Y. in BSF
span ner) . Remove a nd discard star washe r. Disengage th rottle
ret urn sp ring (lo ng tall] fro m top of extension ca rry ing thro tt le
stop scre w least integrally with body ). Remove spec ial wa she r
(wit h beam-shaped ho le!. Remove thrott le lever. Do no t remove
fast-idle ca m sc rew or loc knut . Remove spring.
7 Remove nut f rom other en d of sp ind le. Remove an d d iscard
star washer. Remove spec ial washer with beam's hape d ho le (thi nner
and larger diamete r than p revious one ) a nd f lexible drive co upli ng
comp lete with steel plate. Carefully remove stee l plat e f rom groo ve
in end of coupling. Note th at OUT is stamped on side of plate
fac ing away from carburettor. It has fou r equi -spaced pr ojections
which engage in recesses in the groove at th e end o f t he d rive
coup ling.
S Remove shouldered b rass washer. N o te that f lange is n ear est
10 unit. Remove special steel washer (same as th at descr ibe d in
paragraph 6 ), lever (with square to ngue which e ngages in slo t in
steel drive plate facing outwards a nd a t 10 o'clock wh en viewed
on end of sprind le, carburettor upr ight) , a nd leve r, (on e square
tongue facing uni t body at 9 o'c lock a nd one stra ight p roje ction
at 3 o'ctcckl.
Note that all specia l washers and levers may b e very tigh t on
the spindle an d may req uire force to remo ve th em . Be very
car eful no t t o lever agains t any part of the unit excep t the b od y.
no t to bend the spind le, o r damage t he threads. If the last leve r
(paragraph above ) is very t igh t do no t leve r betw een it an d th e
machined face at the end of the tta t on th e sp ind le, but pr oceed
to t he next operat ion (parag rap h 9 ) an d remo ve the sp indle by
tapping it through t he lever f rom the e nd , whe n th e lever will be
f reed .
9 Re move a nd discar d th e copper scre ws secu ring t he bu tterfl y
p late in th e sp ind le. Open th e throttle and withd raw the p late.
Note that th ere are tw o sma ll ' pips' on the face of th rottle plate
(fac/nil o utwa rds, below t he sp ind le wh en th e t hrottle is closedl.
Using a'v ery f ine file re move bu rrs arou nd screw hol es to p reven t
damage to bea rings a nd sea ls as spind le is withdra wn. Withdraw
sp ind le, not ing th at ex te nsio n with sho rt er length of thread and
lo nger p o rtion with flat s is o n dr ive side.
10 Unscrew an d re move jet adjusti ng sc rew. Rem ove end disca rd
O·rin g. Unscrew jet asse mbl y (5/8 in AfF span ne r). Remove and
disca rd O-ring.
11 Re move six screws and sp ring washe rs secu ring float chamber
t o un it body . Note th at t wo screws a rc sho rte r. Discard sp ring
washers. Remove float chambe r base . If tight, tap gently o n t he
bolt bosses with a wood en- o r plast ic-ha nd led screwd river . Remove
and d iscard gasket .
12 Rem ove jet assemb ly. Withdraw jet an d remo ve sp ring from
it . Separate tw o brass bea rings and rem ove sof t a luminium
washer . Rem ove and dIsca rd C·ring.
13 Rem ove fl oat assem b ly by pr ising f loa t hin ge pi n out of sp ring
steel clip . Remove h inge p in f rom lever a rm. Unscrew inlet
needl e valve assem b ly (5/ 16 in BSF spanned and disca rd soft
a lum inium washer.
14 Rem ove nut fr om co ld·sta rt valve spi ndle (Y. in BSF spa nner ).
Re move and di scard interna l star washer.. Rem ove specia l wa she r
(w ith beam -shap ed ho le l. With valve close d, d isen gage short tail
o f return spri ng f rom act uat ing leve r/fast-id le ca m a nd remove
lever and spr ing .
15 Rem ove two countersu nk-hea d scre ws (slac ken off p ro gressively ;
cotc-sran valve is sp ring load edl. Re mo ve sc rews. remo ve and
d iscard star washers . Remove the co ld -sta rt valve body a nd brass
valve port p lat e. No te that a bras sp igot pressed into car b u retto r
body locates in a cu t-o ut in valve plat e, p reventing incorrect
fitt ing. Remove the valve d et ail fr om h ou sing . Remove the cli p
from th e sp ind le and co llect th e sp ring. Th is allows th e two
circu lar valve di scs to be loose on t he sp indl e. Thei r rem oval is
p revented by stak ing o f th e sp indle end.
16 Remove the throttle stop screw and sp ring. Remo ve th e
brass vacuum t appin g uni on . Do not attempt any fu rthe r
disassembly.
8 .1 Thi s is how the damper is re moved
•
8. 2 We halle put the damper back: this
indicates the scrlrN$.
5.3 Watch t he sp r ing when you lift t he
erver ao.'."'V
8 .311 00 not d Ismantle the die phnlgm
sti ll in t M body
8.4 Great care is needed here so that
8.4a Never use more t ha n 'finger' fo rce
8.5 A dumpy screwdriver is a ll t hat
sho u ld be necessary
nothing is demaged
3
8.6 Try to record th e o rd er, for easy
reeet th rottle wim;les
14·11
loosen the throttle interco nnect ing lin kage clamping bolu .
Chet;k t hat t he damps ere free on the spi ndles and t hat
ope rat ion of one th rottle sp ind le does not affect the other.
4 Set slow-ru nn ing sc rews
Unscr ew eac h slQW-i"unning screw 10 , trow t he thrnttlll p1l t e to
fu lly close , screw in until end o f senw just contacts th ll
casting and screw in _ f urth.r 1% turns to open the th rottles by
eq ual amo un ts . Check th.at the fast-i dle sc rews a re c lea r of the
fast· idle cams.
5 Synch ron ise throttles _rid set idle speed .
Start engi ne and warm up to narm8l wo rking tlllfTJPlK'a1ur• .
Sy ndl ro nise the throttle OPllnings by list llning to the hils at the
air intak e 10 eac h u nit . A $ho n length of 0.25 in 16 mm l bOre
rubbing tub ing. on e end he ld to t IM ear and t he ot he r en d he ld
ju st inside t he inta ke, is idea. fo r t his. Adjust th e slow-ru nn ing
so;rllWS unti l the hiss is ttl, same fQr eec b un it .
T ighten the clampi ng bo lts on the thrott le spi ndle
int erco nnec ting link age.
Adj ust the slow-ru nn ing sc rews by exactly eq ual amou nts t o
gille the desired id ling speed.
6 Set mix tu re st rength
Adj ust the jet adjustin g screws (screw in to weaken, ou t to
en rich mixture! by e;>[8ct ly eque l amou nts u nt il the fas test
idling speed co nsistent wit h ev. n run ning is ob tained_
7 Check mf x rure st rength and re-adjust id le speed
Chec k th e mixture stren gth as d etailed in tu ning p rocedu res fo r
~ ngl e ca rburetto~ .
a
Set fast-idle screws
Set the filSt-id.le screws 3$ de tail ea in tun ing p rOl:edures for single
ca rbu re tt ors .
9 L.oc k so;rews lind f ill dlWnPltrs as detailed in tu ning
p rocedu res fo r singl. ca rbu renors.
...
3
-.£'
Fig. CD7 The .ir 1111.,. lifting p in
R
C
E n g ine
r pm
Fig. COS Mixture st rength as
w - to o wwk
I
fu nction of ex haust smoke
c ' j U$r righ t
r : to o rich
Time
Fig. COO Mixturl strtngth on' lIf'ph
14-12 - --
- - - --
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
f ig. C0 10 Tw in carb ure ttor rnu ltip ll! con nectio....
tte=Oi- - - -
/10
II
-If
~I
Fig. CDl1 Tuning multip le carburntor set-u ps. Adj ult t h e throttle nop screws to eq ua lise ' h i$$' in ea ch eereu -en c r
.......
"t
&
,
,
,-
Part 3 Zenith Stromberg carburet ors
Chapter 15 Series CDSE and CD-2SE
Con t ent s
Section
Int rod uction
Construction
_
..1
2
"
J et and needle arra ngement. .......................................
.
3
Adjustable need le assembly
....4
Special cvemeui procedures.............
....5
Intr od uc t ion
T hi5 eevejcpm eot of t he CO carburetto r has been specific ally
de sig ned to ml! l! l exh auH emi ssion control appli catio ns, and
accord ingly featu re s seve ral soph is t i ca ~d d evices to ena ble the se
st r ingent requi rem ents 10 be m et .
The pr inc ipa l featu re s are a temperaluf\' cornpen sat o r, thrott le
by-pa5$ "alve. idle tr imm ing screw a nd leak ba lanci ng sc rew or
manufactu rin g to lera nce compen sator.
T he e..ample used to illustr ate this tex t is fro m a J agua r V1 2
E·t y pe 5.3 litn! (carbure nor n!fl!r" n~ is 3578A2J. It is o ne of a
mul tip le (tour! ca rb ure ttor install at ion and doe s nOI have a
cOld-sta rt valve .
2
Cons truc t ion
The uni t con sin s of a comple " die·c ast alum In iu m body
closed at the top and bottom respllc tillely by a suc t ion c hambe r
Section
Dissasemb ly
__
Special tool for adjustable needles
Special 10 0 1for adjustable je ts
Assembly ...... .........•..•..•..._ ......•..•.•..•..
Tun ing
_
_.. __
6
...•7
.
••.••.••.•..
8
__ 9
_ 10
eove r and a flo at chamber cove r and con tainin g an airvalYe
assemb ly and lIariab la ja t assemb ly . T he em issio n control device s
are separate sub-assemb lies mo un ted e"ternalfy o n the body.
T he design and dis.posi tion of the main elemen ts (ait lIallll!
and di ap hragm assembly , da mpe r, f loat and inlet nee dle lIallle
mechan ism) is simila r to t he Ser ies CO (ref e r to ap p ro priate
section for a full de sc rip tio n) .
The mete ring needle and je t d iffe r fund amentally , in that t he
jet is fi"ed , and th e fi xed need le is pre -set at the co rreet he ight.
Some un its h ....e adju stab le nee d les f ittad in conjunc t ion with
spec ial a ir valw s. Note that not a ll of the emi ssion control
features are nece ssa rily f itted to all uniu.
Cold-start valve
T h is is the same as that used in the Se rie s CD. A detai led
descr ipt io n is rnctc oee In th e app ropr iate sectio n o f t his man uel.
Temperature compensator
A ho rizontal pa ssage at one side o f th e cerbcrence b ody
3
15-2-------- - - -- ----------_
damper cap
suction chamber top
cover
ootl et flange
id le trim m ing ICrew
temperatu re compensator
petro l i nl et
flOllt cham be r cover
Fig. CDSE2 Th e major ex te m " co mponents of the Series COSE carbunlttor
orifice
b ridge
throttl e prete
air fl ow
Q
. '. "." .-.-. ,, ;,: ~ •..-
inlet
- _ c_ • •' •
.-- .. "
fl~"
_
b i-metall ic
blade
plu g
~
d
id le
tr imming
by pa5s
varve
~ffiW
Fig. CDSi3 Hor izontal cross ·sec tlon th rough th e ch o ke bo re, show ing t he a rrange ment of th e tem per atu nI co mpe nsa to r
id le tr imm ing se rew and by. pass n ln
Part 3 Zenrth Stro m berg carburetors Chapter 15
forms. channel ""hich by.pa s.sel th.ili r valve. one end termin.t·
ing in the milting ch am ber and the other end ope n to .tmosphe~
vi• • d rilling in the inta ke flange. A cir cul ar rece ss in the "".11 of
the un it body at t he mi lting chamber end of the passtge
accommodates the regu lating valve of a te mpera hl re c ompensa tor
dev ice .nached to t he b od y by $Crews.
T he te m peratu re c om pen sa tor consists of a rectangul ar
housing closed by a p last ic cover . It con ta ins a b i-metallic b lad e,
one e nd of Which is rive n ed to the insid e of the hous ing, with an
adju sting scr ew part-way alo ng its leng th . The o t he r end of t he
blade en gages a cylindr ica l pl ug wi t h . conical end, Which slides
in a cyl ind rical exte nsion of th e ho u sin g, form ing a rllgu llt ing
valve .
Varia tion in tempe ra ture of t he bi-metall ic b tade cau te S it to
ne.., mo ving t he p lug in its bore an d regu lati ng the an nu lar area
around the cone, t hus control ling the by-pass air bleed . The
ad ju u ing screw en ab le s a d a nJm position to be se t on in itial
bu ild _It mu st not be ad ju sted in .!Vice.
Thrortte by -pa ss valve
The by-pass va lve provides a means of limiting the very high
manifold depression which occurs when the engine is in the
ov er -run condition. (Re fer to Part 1, Chapter 1 for an
explana tio n of thi s d evice).
It con siS1$ 01 a d iap hr agm clamped to a mec hina d fa ce o n t~
wall of thll uni t by a COWlr. At t he cen t re of the di .phragm il a
combin ed metal vatve p late and spr ing register , into wh ic h f its a
compression spring lo cated at tlla othe r end over a spigo t in t he
cover. Th e sp ring loads th e valve piatt to the c losed posit ion .
Th e cove r also fo rms a diaphragm co ntrol c ham ber , be ing
co nnec ted to t he engi ne in ta kll manif o ld by a small bore pipe.
D@pl'8u io n,sensed in the d iap hr agm ch am ber, w ill tift the
valve at. pre-de te rmined value (I\Orm ally 22 to 2 3 in HgJ,
dietatecl by the comp ression spri"1l p re-load . a nd adm it air fro m
the mixing chambe r in to the in llt man ifold th u s by-pass,nll the
15-3
throttle pla te an d lim;t ing the d ep ressi on. The max imu m b1l:1d
flow is contrOIJeod b y an OI"ifice f itted in the b y-p8 Sl1 passage .
T he by-pa ss valve is p reset and no attempt may tw made to
adjust it in se rvice . A rep laceme nt uni t (for the pa niOollar
appl ica t ion I shou ld be fitted, if it is SU IP'CU"d of ma lfu nction_
Idle tr imm ing screw
T he idle t r imm ing sc rew prOllides fo r very f ine ad ju nnwnt
to t he id ling mi xt ure rBlio to com pe nsa te for t he d ifference
be twee n a new engine that is ' t igh t' and la te r when it is ru n-in .
Th is is ach il Vi!d by regu lat ing an ai r b ll!ll d w hiCh by-passes th e
air v.I Vi! , t hus wlakening ttlll mlxture rat io .
A nlw I nlline may be ru n wi t h' comparatively weak m ixt u re,
Whe" th l idle t r im mi ng scr ew will be full y u nscrew ed, t he
max im um b leed bei ng cont ro lled by t he size of th e dr illing (iln
e xtllnsion o f the passage to t hll tem pe ratu re compensa to r). As
the engine ' f rees off' during th e ru nn ing-in pe riod the screw may
be p rogressively screwed in until it is seated and the ai r blee d is
b lanked off , givin g a rich er mi xtu re.
A ny adjust men t of t his $Crew should be ca rrieod o ut in
con ju nction ""ith an exhau st llaI .... " ly ztr to measu re the ca rbon
monoxide ICOI e mission , ~ tet it to the e'llline manu fac tu rer's
recommended va lue fo r id ling.
Leak balancing screw
A$ explained in Part 1, Chapter 1. the a ir val ve is a c lose fit
in its bore in th e b od y . T he very sm a ll ann u lar clea ran ce aroun d
th e air varve pe rm its a leak be tween the amb ien t p reuu re ,,"ion
be low t he di ap hragm and t he low pressure regio n in th e ch ok e
bor e an d m ix ing chamber, wh ich lowers t he de press io n . It is
e ssent ia l t hll all carburenors fo r a specific applicatio n are
ma t ched ex ac tly in respect of f low. T o compensate f or thll very
smalt variat ion s in co mp o nen t sizel (a ir va lve d iamll ter . nd body
bo re d iame te r! d ee to m.nufac tu ring to lera nces, an acljust.b1e
screw is incorp orate d to p rovide an addit ional air b illed twtween
t hese two regions. Bv adjustment of thi s screw the total leak ma y
be he ld to a control Jeod vatue , irrespective of the 'u nk nown'
dashpot ve nt to sucti on cha-nber
ilir valve
whl n spri ng
.'
llir valva
gu id e rod
::I L /
" XI
leak b alanci ng
Erew
flO"
suc tio n c hrnbe r
3
15-4
Part 3 Zenith Stromberg carburetors Chapter t 5
spu riou s leak. OI"lCe the screw is SlIt, on ini tial bu ild , it mu Ul'lot
be altered and t o pfe'V'lInt tamper ing, th e bore int o w hich it f iu
is sealed w ith. plu g. T h'" bod y, a ir valve and cover become a
matched set a l'ld ne it!ler part may be re placed independently of
jet ori f ice bear ing on a seating in the bush. T he bottom of t he
bush p roj ects through the fl oa t chamber cover ..... here it is sea led
by an O-ring, and is citStellat ed to accept a spec ia l ad justi ng tool.
A sh ielding cap is clipped over the bo ttom o f the bu sh.
the o ther. The suction cham be r cover is w ired t o t he body. iIfld
may o n ly be removed after a sea l has been bro ken, thu s revea ling
that the unit has be, n ta m pered with .
Adjuste blll n.-dle as ...mbly
4
3
J et and need le Irrangllm &nl
One of t hree a lt em at ive arrangeme nts of jet a nd need le
asse m blies may be fitted to thi s instru men t. In each case the
needle asse mbl y is biaSlild to on e sid!! of the
Jn
orifi ce by an
in t egral sp ring.
Fix ed j et and fixed
(p~se t)
needle
T he jet n sem bly is p ressed in to the body end is not adj ust ab le
or removable . The needle asse mb ly is fitted to the socket in t he
a ir valve gu ide rod in a p re-set po sit ion and loell.e d b y a
eonven t ion ,lloclr.ing screw. T he po$ition should not be altered .
Fixed jet and adjustable needle
T he jet anembly is pressed int o t he body and is no t adjust able
or removable. T he need le assemb ly he igh t is adj ustabl e t hrou'ilh
a lim ited range b y an adj u stin g sere ..... f itted in a spec;a l a ir vewe
guide rod . A ke y.....ay and peg ar ra nge me nt rep laces the
co nven t ion al need le lock ing screw and pe rmi ts IIIlrtica l m ovemen t
of t he needle assembly While p reve nt ing its rotat io n in t he
soc ke t, t h us m ai nt a in ing t he correc t angula r re lat ion sh ip w ith
t he jet.
Adjustable je t and fix ed (pre-set) needle
T he need le assemb ly is f itted to t he SO(:ket in t he a ir valve
QUide rod in a pre·set posit ion and locked by . co nven t ional
locking screw . Its posit ion sh ould not be ellered.
T he jet orifice slides in;ll bore in the earburettor b r id ge and is
spring-loaded dow nw ard s, simil ar t o tM essembly in the Series
CO instrument. It is reta ined by a b ush SCf'eWed into t he th re~d
sl....... ve sulTou nd ir'lg the Je t, a shou lder and skid wash er on the
All uni ts are f itted wi t h fi xed jets. Som e un its h ave pr e-set
sp rin g-load ed (bi ased) need les; o t he rs have ediustable biased
need les. f itte d in conjunc ti on w it h a specter air valve .
T he ad just ab le ne ed le assem b ly c omi n s o f a mete ring needle
hel d in a cy lind rica l b ra ss ho lde r.
The t ub u lar hOlder is int ern a lly threaded at t he top to acce p t
the needl e ad ju st ing screw f it te d in the air valve gu ide rod . T he
low e r end is in te rn ally fl anged t o form a seating for a light .
he lica l com pren io n $pring.
The need le is provided with an e nl. "ied head an d has a
flex ib le washe r f itled to I groove near the tOp. T he needle is
load ed t oward s the top of t he ho lder by the $pring acting on t he
underside of the held. It is re t ained by a p in f itled aCfO$$ t he
b ore of th e holder. T he pin is n ot at a r ight angle t o t he ce n tr e·
line of t he ho ld er , but is in clined t o it at a sl ight ang le. T he
sp rin g. p ress ing the head of th e needle in contact w ith t he pin ,
tilts th e needle b y a pre-de term ined amou nt in a certain d ire ction
(norm ally tow ard s t ha c arb u ret t o r inlet!.
T he needle type n um be r is st am ped on the shan k and is
revea led by pulling it ou t of t he holder aga inst t he sp ring load .
T he low er portion of t he ho lder has a keyway cu t in a
parti cul ar p osition re lative t o t he p in, which e ngages wi th the
spring load ed retai ning screw fitted in th e air ~al~e , thus
ma inta ini ng the me te rin g needle t ilt in the corre ct d ire cti o n.
Th e adju sti ng sc rew in th e air valve gu ide rod is loc at ed by a
shoul de r beneath it an d a sp r ing stee l retaining cli p f ined above
it. T he screw is fit ted w it h an O -ring on its d iame ter to $eal it
and prov ide fr ietion loc k ing. and ha s a hell.gonal recess in t he
top to accept an ad justing tool (refe r to S pecia l Overhaul
Proced ure s).
T he screw is no t re movable .
' - - --
air valv e
guide rod
re t ainin'ilc lip (3 )
"
O- rin g
-,
----Tc,.y-~~[j
needle ad just ing screw III
~r i ng
lo aded
r1ltai n ing scre w
delri n was her
me tering need le assemb ly
F ig. COS ES Adj ustlblol m etering needl. asse m b ly
Part 3 Zenith St ro mberg carburetors Chapter 15
5
Special ove rhikll p ro cedu res
PiIrt No .
Desc:ript io n
8 18 175
15 0 ~rjes CDSE (ttmission)
150 ~ries CDS E
175 Series CD ·2S E
175 ~ries CD-2S E
820924
Ol1erhau l limitations
It is stro ngly ntcom me nded that owrt1au l of t his uni t is
restr ict ed to d isassem bl y, cle... ing and re-assem b ly _Damaged
parts should be rep laced (e xcep t fo r match ed asse m b lies, as noted
in Construc tion l and no a tt e mp t shou ld be maje to rep;l ir a lty
item which has a regu lat ing o r me~r ing fu nctio n.
The uni t , d espite hav ing the ap pearance of pre viou s ty pes il
incompa rabl y mOrl! IOph isticaled and may no t be satisfactor ily
dea lt with by t h8 methods detailed in th is manual. It has twt.n
speci fica lly de velope d to meet the req u ireme nts of to xic
em issio n reg u lat ions and is man ufactu red to fa r f iner di man Slon al
tole rance s t han p reviou sly em p loyed.
A damaged uni t ma y be restored to a serviceab le con di t ion
by rep lacem ent of def ect ive items b ut it is unli ke ly that th e
o riginal pe rfo rman ce, w ith regard to the ext raordinar y pre cisio n
of em ission contro l of which t h is unit is cap able. w ill be restored.
Recon d itio n ing of a ~nerally worn u n it is n ot fea sible an d it
shou ld b e re turned to t he manufacturer fo r ove rhau l, o r for
repl acement with a ne w un it ,
Refer to Part 1, Chapt er 4 Overhaul
3
Replacement parts - Stromberg part num bers
Needle valve aS$embly comp le te with a lterna tive
Cod e Ref.
Pil " No .
Descr ipt ion
AY
8 20687
AZ
8 2 1344
822424
1.75 mm (fi l tert!d)
2 .00 mm (fil tered)
2. 2 5 mm (f il tered)
ABA
8 17421
8 19420
4
Gasket prls - Strom tHtrg IMIT.nu mbe rs
Ref. No.
Descripti on
2<5
244
242
150 ~ries CDS E
175 ~ries CD -2SE
175 Series CD-2SE ( Volvo)
5
Hydrau lic dam per o il
Can of Zen ith Lube Oil part No . B 18 562Z.
6
Disassembl y
Unscrew and re move d am pe r nsem bl y . Do not d isassem b le
t h is stage . I nse rt th e carburettor lind dra in the o il from t he air
valve guid e rod reserv oi r,
2 Rem ove f01J r Phi llip s·head screws and sp ring wasns rs $E! curing
d iaphragm chamber caver. Co llec t the br ass identity ta g and ta ke
ellfe not to lose it. D iscard spr ing washers.
3 Carefu lly rem(M! the co yer , If very tigh t , twin sligh tly to
bre ak the sea l be tw ee n it ..d the di ap hragm . RemO\l~ t he $pring .
RemO\lf! th e air va l", complete w ith me tering need le. d iaphr agm .
d iaphragm former and rec",n ing p late. Note that th e needle i. not
eo-ni al w ith the air val\la gu ide rod. bu t is b iased to th8
carbu re n o r inlet by the influence of a sp ring in the me le ring
reed te $lib-assembly. Do n01 remow th e sp ring lOo!ld ed need l,
retaini ng sc..-. In. " a 0. 125 in . A/ F Allen ke y (or spy further di18uem bl y of t he
te mp era tu re compen sator.
13 Do not attempt any furthe r di sessemb ly of th e unit.
6 .1Oa Note t he felt washer
6 .11 Note th e posit io ni ng and t h e gas ket
6 .1 1b T he correct p osi ti o n ing is
obvious here
6 .12 A ll the f iKing scr ews ar e obviou s
here too . Never t ouch t he l'Iyl ol'l nut
7 Soecial tool for ad justable need les
For tuning carbu re tto n with non- ad jun ab le jets and
ad justab le metl!rin g need les, special t ool B 2 0 379Z is required.
The tool con sists of tu bu lar sleeve con t ai n ing an Allen key
w h ich pr ojects trom both t op and bottom. T he t op of the sleeve
has a pa ir of w ings an d th e bo ttom has a loca t ing P'9In use. the red uced d iame tl!r nose of t he too l is inserted in
the hollow a ir valve guide rod (damper essemb ly removed fr om
ca rb ur ettod and th e loc at ing Pl'9 e...gage d in t he m achined slot
et the top of the rod . The A llen key is pushed d own and enga ges
w ith the h. Kagon a l socke t in the needle adj uUing screw (refe r
to Conn ructio n. of th is 5ection of the manual. t or a detai led
de!ICr ipt ion o f th e needl e assemb ly l,
Rotat ion o f t he A llen ke y will raise o r low.r th e nee dle , the
outer sleeve being firm ly he ld to p reven t rotation o f the air valve
arid damage to the diaphragm.
fi=;'==
A llen Key
Fig. CDSE 9 The
~111
t ool f or edj ustilble needles
loca ting peg
15-9
Part 3 Zenith Stromberg carburetors Chapt er 15
the inlet needle va ll/l! lIS2 mb ly IIOd screw into iu tap ped
8
the underside of th e body. F it the h inge p in t o th e f lO3t assembl y
and spring in to posit io n in th e spr ing steel di p, ta k ing ea re not
Fo r t u n ing ca rbu nm ors w it h non-adjust ab le metering needles
to d am age e ith er pa rt . Note th at the float leve r arm shoul d
appear uppermost wi th t he carb o rert cr inve rted . Check that t he
high"'t pain t of th e floa t above the fa ce of the body with the
inillt need le varve c losed is 0.725 10 0.787 in . (16 to 17 mml, an d
ttl at th e leg o n the ar m contacts the need le at a r ight an gle.
Check t hat the float hin ges f ree ly o n its pi n .
2 If the pla st ic flo at cham ba r p lug ha s be en re move d , fit a new
O- ring to t he groo ve end push t he pl ug in to t he hole un til all th e
ba rbe d tongue s ere op en o n t he inside of th e co ver.
3 F it a new gasket (d o not use gask et ce ment ) t o th e ttc et
cham be ' base an d sec u re m il base wi th Six scre ws ilnd new sprin g
washe rs. T ighte n th e
With engine cold d1ec::k th8t
compensat or cone is seated.
and free to move . If any d oubt
,"i1IS replace unit w ith new
auembly
Aepl au $pinelle sea ls or
top up, re-chec k damper
operat io n by ra ising by hand ,
resistance s.ho uld be fel t
Chec k grade o f spring and
refit
Use correct grade of o il o r
Zen ith l u be O il. Part No.
8 .18~2.Z .
R efer to Ap pencHl< II for
correct sp ring, d o not
attem pt to et t er the sp r ing
rate,
Check and rese t
Check ope ration
Replace gaskets and '0' rings
jo l nn o r se l ling p lug '0' r ings
Low engine brak ing
Probably ca u1ed by three
m ain f ktor s:
Fau lty by-pass valve
Repl ace by-pass valve
Nora: No atte mp t s.hou ld be
made to adjust th ese un its
Chee k t hrottl e operatio n,
Stic king t hrottl es
reset
Lo w Engine Powe r
Inoperative ignition reta rd
Check igniti on setting at idl e
and e nsu re functio n ing o f
retard $ystem and that reta rd
man if o ld p rltSsure ta ppi ngs
a re fr ee f rom obstrucacn in
the t h rottle fla nge o f th e
tarburettor
Damege d d iaph ragm
In spe-ct an d rep lace
Chec k di scharge f rom fuel
p ump , Inspect need le va lve
seat ing
Low f uel f to w
Consu lt manufacturer's da ta.
No te: To en sur e rhar all legal exhev at em missio n requ irements are met, th e following ite ms m ust no t be ch anged o r modi fied in anv way :
1
the fuel jet asse mb ly ,
2
th e air verve ,
3
the de p ress io n chamber cover,
4
The foll o wing items mu st no t be adju st ed bu t sh oul d be repla ced co mpl ettl y by factory set un its :
1 th e temperat u re compensator,
2 t he ai r valve return spr ing,
3 the by p ass uni t,
t he positio n of t he fue l metering needl e ,
4
the It erter assem b ly.
Part 3 Zenith Stromberg carburetors Chapter 16
16-9
Notes
3
17-0
Part 4 SU carburetors
Chapter 17 Type H
Contents
Section
Assembly
,
8
Constructio n
2
Disassembly ....................................•...,
Float chambe r and its operation
Int roduct ion
7
4
1
1
"..... ................................
Introduction
The Type H (H orizontal) carburett or is the earliest of th e fou r ty pes
described in t his M anual. For the purp ose of instruction it may be
cons idered as th e basic fo rm of SU instrument since all later ty pes are
largely refi ned versions and all use the same basic elements.
It w as most popu lar in the early 19 50 s, and was fi tt ed as standard
t o many prod uction saloon and sports cars. and as a 'p erfo rmanc e
modi fi cation' t o ot hers. It is often t o be foun d fitted wit h a th ermostati c
carburett or on larger cars w it h a mul tiple installat ion.
Jet assemb ly
Operation .
Special overhaul proce dures
Tunin g
.
.
,_
Section
3
.
5
6
9
2 Construction
The unit consist s of a di e- cast aluminium bod y in wh ich is formed
the ch oke bore. a suction c hamber and pist on assembly mounted
vert ically abo ve it, a jet assembly mou nted co- axially with the suction
chamber below it, and a float chamber assembly attac hed by an arm to
th e body.
The body has a fl ange at each end, dr illed fo r bo lts t o mount the
un it t o th e engine and for t he attac hment of an air cleaner or intake
system. A circular, machi ned platf orm on the upper side mounts th e
17-1
Part 4 SU carburetors Chapter 17
Damper
rod
Sucti on
chamber
Hyd raulic
damper
\~~
o
Su ction disk
Fast-idle
scre w
o
Piston
Throttl e
stop ad just ing screw
~1JZZZ2j:D1t
Needl e
reta ining
screw
Th rottl e
valve
Jet
gland
Jet
Jet
adjust ing nu t
Cor k
sealing
washer
Jet
locking
screw
Fig . 5.1 Cross -section through th e t ype H carburettor ( Sec 2 )
4
suct ion c hamber, w it h a large bor e intercepting the choke bore at right
angl es in which the piston mov es.
The underside of the body has an internally thr eaded boss for
attachm ent of the jet assembly, and a similar boss for attac hment of the
f loat ch amber arm. They are linked to each oth er by a drilling thr ough
th e cast w eb between th em.
Othe r cast features on the body incl ude bosses bored to form
throttle spindle bearings. a lug with a hole to accept th e tail of a j et
return (tension) sprin g, a housing for a pi ston lifting pin, tapped hole s
for vacuum connect ions. and bosses for t hrott le/c hoke interconn ecti ng linkage bearing s.
The suction chamber is a die -c ast alum in ium cylinder w it h a cent ral
gu ide tub e fitted with a hardened steel sleeve bearin g. The gu ide tube
is extended at the top of the chamber and int ernally thread ed for
attachment of 0 hydrau lic camper. l ugs are provided at the chamber
base for attachm ent to th e unit body with screws .
A piston slides in the bearing in the sucti on chamber, th e smaller,
low er diameter protruding into the bore of th e carburettcr bodv . The
pi ston consists of two ports; th e pi ston rod and th e piston disc wi th
inteqral suct ion disc, The piston rod is hollow, to act as an oil w ell for
th e hydraulic damper (w hich is secured to the suct ion chamber). The
piston has two port s drilled from the top and emerg ing on the
downstream (throttle plate or eng ine) side of the pi ston . A tapered
needle is fitt ed to th e base of the pi ston assembly and secured by a
locking screw .
3
J et asse m b ly
Refer to Fig. 5.3. The jet assemb ly consists of th e jet (1) whi ch
slides in upp er bearings (13 ) and low er bearing (7). J et glands (12),
con ical w ashers and w ashers (11 ) are fi tt ed to th e bearing and loaded
to their respective ends by co mpression spring (1 0 ). The assembl y is
fitted to th e unit body w ith nut (4) sealed wi th was her ( 5) and cork
w asher (6) . The bearing is a loose fi t in t he nut. thus permitt ing slight
radial movement of th e j et assembly to centre it relati ve to t he needle,
The assembly is held to th e body by th e clamping acti on of the nut
against th e flange at th e top of the lower bearing . The soft (copper)
w asher (5 ) form s a seal between th e low er jet bearing (7) and t he
body .
The maximum height of th e j et is determined by t he posit ion of the
jet adju sting nut ( 2), the jet being held in contac t wi th it by th e spring
lo ading on the external jet co ntrol lever linkage.
The jet size is identified by a code numb er stamped on one face of
the steel fork .
""""
17-2
Part 4 SU carburetors Chapter 17
0
0
0
1
0
r
I
B
A
C
H. ~ ~2'1
Fig . 5.2 T he t h ree type s of jet ~ Sta ndard (A). The rm ost at ic ( B). and Invieta (el (S e c 3)
1 J et size stamp ed on jel
J et sizes: 9 = O.G9in 1 = 01 in, 125 = 0.125 in
Jet
sp ring
Cap ....,.
nut
J et
adju sting
screw
Fig. 5 .4 C ross -sec t io n o f th e t her mostatic carburettor jet
( S ec 3 )
3
2
1
•"
Fig . 5.3 Explod ed v iew of the Sta ndard jet co m po ne nts
( Sec 3)
1
Jet
2 J et adjusting nut
3 S pring
4 Fitting nut
5 Cop per wash er
6 Cork washer
7 -- Lower jet bearing
8
9
10
11
12
13
14
Jet gland
Washer
Spring
Wash er
Jet gland
Upp er bearing
Wash er
When a thermostatic carburettor is used in conjunction with Type H
unit/so the jet is not required to be manually operated and is therefore
fi xed in a simpl er, leak-proof manner. Th e assembly is referred
to as 11 sea led jet base. Acc ess to the jet, for adjustment, is gained afte r
removal of the cap nut .
The damp er con sists of a cylindrical. non -return valve assembly
retained on t he end of a rod by a circl ip. The rod is serrated at the top
and pressed int o a screwed brass cap, by whi ch it is secured to the
suction chamber. The valve is immersed in the oil in the hollow piston
rod, and is so arranged that oil can pass freely through it in a
downwards direction (piston fall ing), but presents a high resistance to
upwards flow (piston rising) .
4
Float chamb er a nd its o pe r ation
The flo at chamber assembly consists of the chamber, a detachab le
lid incorporating the inlet valve. and a float.
17-3
Part 4 SU carburetors Ch apter 17
The chambe r is a d ie-cast alum inium cy li nder fi tted wi th a central
fl oat guide rod. An exten sion arm at the bottom of t he chamber is
enlarged at its oute r end. and drilled fo r a banjo bolt whi ch secures it to
the uarburettor bod y. Fuel is supp lied to the carburertcr t hrou gh a
drill ing in the arm.
The detachable lid in corporates lugs which carry th e float lever
hinge pin. The inlet valve cons ists of a brass seating screwe d into the
lid, in wh ich slides a steel needle. The position of the needle is
con tro lled by the float lever mov ement Fuel inlet to the valve is from an
external banjo un ion, secured with a banjo boit to a tapped hole in the
lid. A t himb le -shaped fi lter is retain ed in the inlet by the banjo bolt. th e
open inlet end being lo aded to wards it (to seal the periph ery) by a
co nical spring surround ing the fi lter. The inlet assembly is sealed w ith
soft fi bre w ashers.
The top . threaded porti on of the float gui de rod projects thro ugh a
cent ral hole in t he lid and retain s it with a cap nut. A cover cap is fitted
under the cap nut to protect the annular vent from the ingress of dirt.
The lid is located in the ch amber by a machined spigot at th e rim.
The fl oat consists of two brass spinnings soldered toge ther, with a
brass tu be run ning throug h the cent re. The flo at slides vertically on th e
gu ide rod fi xed to th e float c hamber base and operates the inlet valve
via the hinged lever.
Fuel, supplied by an external mechani cal or electr ic pump, enters
th e float chamber inlet and passes thro ugh the f ine mesh fi lter. As t he
fu el level in t he chamber rises, the fl oat rises and operates the inlet
valve, reduc ing the fl ow and stop ping it when a previou sly determ ined
level is attained. Petrol flo ws from the base of th e chamber thro ugh the
drill ing in the arm to th e jet assembl y, and rises to th e same level {ju st
below th e top of the jet w hen in its fUlly raised position }.
5
Operation
Cold start ing
To start the engine fro m co ld, the external, facia-mounted mixture
control (choke) is pulled out, which lowers the jet assemb ly in tts bearings
and glands. With the piston seated on the bridge of the carburettor, this
lowering of the jet increases the annular area between the needle and the
orifice at the top of th e jet. The throttle plate is partly op ened by the
mechanical interconnection betw een the mixture control linkage and the
thrott le lever, See Chapter 1 for explanation of the constant-depression
co ncept.
With the eng ine turning over by hand cranking or by th e starter
mot or, th e depression generated in the inlet manif old is sensed in the
suct ion ch amber via the passages in the base of the piston. The
result ant upw ard load on the piston assembly. du e to the different ial
pressures sensed above and below th e suction disc, lifts the pisto n
against the spring load.
The depression created by the flow of air between the underside of
the piston and bridg e lifts fu el from the jet. The fuel is atormsed in the
mixing cham ber (th at part of th e c hoke bore between t he piston and
the th rottle plate) and passes to th e eng ine, when it should start and
run.
N ormal running, cruising and full throttle
With a co ld eng ine, the mixture must be enric hed to compensate for
the effects of fu el condensat ion on th e co ld surfaces of the indu ction
system, w hich has the effect of w eakening t he eff ectiv e mixture
delivered to th e engine combu stion chambers. This is achieved by
lowerin g th e jet assembly. th us incr easing the annu lar area around th e
needle at any position of the needl e, and permittin g more fuel to fl ow.
As t he eng ine w arms thro ugh. the mixtur e strength is weakened by
progressivel y raising th e jet assembly unti l, when normal w orking
temperature is atta ined, the jet is at its high est positi on, dictated by th e
posit ion of the jet adj usting nut whi ch will have been preset (see
Section 9 ).
Under cru ise condit ions, the throttl e pl ate will be partly open with
th e eng ine runn ing fast. The obstruction presented by the th rottl e
red uces th e depression in the mixing c hamber, and thence in th e
suct ion cham ber, and th e piston fall s until the forces act ing above and
below the suct ion disc are in balance. The depression at the jet will be
the same as before, but as the jet has been raised the mixture will be
w eaker.
The high manifold depression will be sensed just downstream of
the throttle plate at the auto -t iming conn ection (on units so fitted ) and
transmitted to the distribut or to adva nce the ignition timing, w ith
benef icial eff ects on fuel economy.
At fu ll throttl e. the thrott le plate presents only a slight obstructio n:
manifold depression is sensed in th e suct ion chamber and the piston
lifts to its maximum limit. The depression at the j et is as before, but
more fu el is drawn out d ue to t he wi t hdrawal of th e tapered needle,
w hich creates a greater annular area. The mixture strength remains
constant.
A cceleration
A richer mixture is req uired for smooth accelerat ion. This is
ach ieved by in creasing the depression at the jet for any given piston
position by retarding the rate at w hich the pi ston lifts, thu s temporaril y
increasing the air velocity. The hydraulic damper, in conj unction with
the oi l-filled pi ston rod . co ntrols the rate at which the piston rises.
Not e th at the damp er does not limit or reduce th e height to whi ch
the pi ston rises, it merely controls th e speed at wh ich it rises, causing
an im mediately richer mixtu re to be delivered wh en the t hrottle is
snapped open, whi ch gradually w eakens as the piston lift s to its
correct position.
As th e damper is on ly effect ive for upward movement of the piston,
the pisto n falls immediately the th rottl e is cl osed, preventing an
over- we ak mixture being prod uced.
6
Special ove r ha u l procedures
Refer to Chapter 4.
2 The SU part numb ers for gasket and overhaul packs are as foll ow s:
1
Car bu r ett or
mode l
HI
H2
H4
H6
Throttle
diameter
n«
1 / /4"
1 //2"
13/4"
Gasket
pac k
AVE 8005
AVE 8005
AVE 8015
AVE 80 15
Overhaul
pack
AVE 850
AVE 850
AVE 85 0
AVE 85 0
N ote: Overhaul pack s may be difficult to obtain. The '5' suffix on the
gasket pack part numb ers indicates that throttle plate screws al e
included
Di sassembly
1 Clean th e out side of t he carburettcr th orough ly. Remove the banjo
bolt, banj o union and fi bre was hers. Extract the fil ter and spring
assembly from inside th e uc at ch amber lid ( phot o) .
2 M ark the relative positi on of the suctio n c hamber to the body.
3 Remove the damper and its was her. Un screw the ch amber
retaining screws. Lift the chamber straight off ( photos) .
4 Remove th e pi ston spring and washer (if fitt ed), lift out the piston
assembly carefull y and empt y out the dam per oil from the piston rod.
S Undo th e needle locking screw and remove th e needle. If the
needle sticks in pl ace, fir st tap it inwards and then pull it out; do not
bend it (photo).
6 Unhook the lever return spring . Remove th e split pin s and clevis
pin s (phot os) . Remove the fast idle cam piv ot bol t. Not e the position s
of th e alum inium spacing w asher and th e spring w asher. If a
thermostatic starti ng carb uretto r is fitt ed, refer to Chapter 9.
7 Undo th e li nkage assembly. Press in th e piston lifting pin, extract
the circlip from its gro ove and with draw th e pin and its spring
downwards.
8 Withdraw the jet and take off th e jet adj usting nut and spring.
9 Unscrew the jet iocking nut and carefully w ithdraw the assembly.
Lift off the up per jet bearing and co pper w asher. Extract the gland and
brass gland w asher (photos) .
10 Remove the gland spring and extract the lower jet bearing from the
jet locking nut. Extract th e gland and brass glan d w asher from the
bearing . Do not touch th e jet lo cking nut cork w asher.
11 Mark th e position of the lid to float chamber. Un screw the central
nut and remove th e overfl ow pipe and w ashers; the stay, w asher and
cover cap, or the cover cap alone. Record the positi ons of the w ashers
and other co mponents. Lift off the lid, note the gasket. Remov e the
float (photos).
12 Pull out th e hing e pin fo r the hinged lever and detach th e lever
( photo).
4
7.1 Removi ng th e f ilter and spring assembly
7.3A Removing t he damper
7.3 B Lifti ng th e suction chamber away
fro m the base
7.5 Removing the needle from th e pi ston
7 .6A Jet control lever and return spring
7.6B Remov ing the lever clevis pin
7.9A Removin g t he jet locking nut .
7.9 B ... and upper jet bearing
7.11A Removi ng the fl oat chamber lid . .
7.12 Removi ng the needle valve hin ge pin
and lever
7.13 Needl e and needle valve seatin g
(arrow ed)
•
7.11B ... and flo at
r - - - - - - -- -
Part 4 SU carburetors Chapter 17
7.14 Removing the float chamber
7.15A Remo ve the screws n.
7.156 •.. and with draw the th rott le d isc ...
7.1 5C ... and spindle
17-5
4
13 L.ift out th e need le from its seating ( photo) and unscrew the
seating from the lid using a spann er 0 .338 in (8.58 mm) across fl ats.
Do not d is tort the seating .
14 Remove the sc rew reta in ing the s la y to the c a rburettor body (if
titled). Remove the fixin g reta in ing the float c ha mber to th e body
( phot o). Record th e posi tions of the fibr e w ashers and the brass
washer.
15 Remove th e two disc retaining SCIllWS and mark the d isc for
loca tio n. Tw ist the th rottl e and ease out the cnsc fro m its slot in the
spi ndle . Pull out t he spind le from the bod y ( phot os) .
16 Loosen the return spr ing clip bolt and remove too clip, spring. and
return $pring plate ( if fined ). If a clam ped o pe ra ting lever is lin ed ,
lo osen the clamp ing bo lt and remo ve the lever.
17 For Instructions on cl eaning, inspection and repair, refer to
Chapter 4.
8 A ssem bly
N ote: Ensure that all parts ar8 clean and dry before assembly.
1 Fit the spindle t o the body, ensuring that the fixed lever is in the
co rrect positi on . Slide the throttle disc into the siot in the spind le and
f it two new reta in ing screws . Do not t ighten at this slage. Close the
t hrottle, w hen the d isc will centre itsel f in the bore. Check vi sual ly that
contact is made between the disc and the bore throughOut its
circumference . Tigh ten the screws and spread t he spi n ends
suffi ciently t o prevent th e screws unscrew ing .
2 Fit the jet assembly in the reverse order to d isassembl y. using new
gland pack ings . Ensure tha t the washer is un der tbe shoulder of the
low er jet bearing. that t he coned faces of t he gland w ashen race
toward the gland pack ing s, and that the copper washer is fi n ed w ith
the sharp edge towards the upPer jet bearing. Fit tne assembly to the
body, but do not tighten the jet lock ing nut at this stage ( phot os) .
3 Fit the needle t o lne piston . The relat ive pos it ion of the two parts is
critical. and may be eit her of two arrangerTW:Ints acc ord ing to the
contour of the needle at junction of the taper and th e shank [ie scuere
or radiused shou lder ) . Fit and tighten a new l ocki ng screw.
4 Fit th e piston assembly to the bod y. taking care no t t o damage the
needl e. Fit the wash er (if pro vided ) and pist on spring to the piston rod.
lightl y oil the outside of the piston rod and fi t the suction cham ber. Fit
and tigh ten t he securing screws .
5 Remove th e jet, jet locki ng nut. and spring . Refit the adjus ting nut
and screw it up as far as it will go. Refit th e jet and ensure that it is in
the correct relative posi tio n (check positi on of fork). With t he jet
Part 4 SU ca rburetors Chap te r 17
17-6
Fig . 5.5 Co rr ect fitted po s it ion of t he t w o types of piston
ne ed l e ( Sec 8 )
Fi g . 6.6 Needle va lve adj ust m ent f o r float level setti n g
( Sec 8 )
IOGking nut loose, ch eck that the underside of the pisto n is in contact
w ith the top of the jet, w h ich w ill protrude into the bore. The je t is now
accurat ely centred. Tighten the jet locking nut. remove the jet and
adjusting nut. tit the spring and refit the adjusting nu t and jet.
6 Fit the float c ha mbe r valve seatIng to the floa t cha mbe r lid. Fit the
needle. hinged lever and hinge pi n. With the hinged lever resting on
the seated needle. check thilt a 0.44 in (11 mm) diam eter tw ist drill can
be inserted between the forked lever and the lip of the fl oat chamber lid
(photo). If there is a gap. or if the bar lifts the fork ed lever clear of Ihe
needle. adj ust by bending the lever w here show n in Fig . 5.6.
7 Fit a new flo at chamber lid gasket (do not use jo inting compound) ,
the fl oat ( check that it is the correct way up ) and the float chamber lid .
Ensure th at th e lid is in the position marked on disassembtv. Fit the
cover cap and central nut . Of drainpi pe, was hers and nut (alternat ive
detail ). Use new fibre w ashers. Do not overt ig hten th e nu t (photo ).
8 Fit the float chambe r assembly to the carburettor body using new
f ibre w ashers or rubb er grom mets (alternative detail).
9 Insert the fuel inl et filter assembly (spring end innermost) and fit
th e banjo and bol t w ith new fi bre wa shers. Note that the recessed fac e
of the banjo fits tow ard the hexago n end of the bolt.
10 Fit the return spring plate. retu rn spring and retu rn spring clip to the
t hrottle spindl e. Tension th e sprin g by turning the clip on the spindle
and tighten t he clip pinc h-bolt [ pho to ). Fit the linkage assembly using
new split pins. Ensure that t he distance washer and double-coil spring
washe r are in th eir correct positions in relation to the fast -i dl e cam.
11 Top up t he pi ston rod with oil as described in Section 11. then fit
and t ighte n t he damper rod .
8.2A J et assembly
8.28 Refitt ing t he jet assembly
8.7 Refitting th e float chamber lid
8.6 Check ing the tloat level setting w it h a
0 ,44 in (11.0 mm) d iameter twist dr ill
8.10 Thrott le return spr ing (arrow ed)
17-7
Part 4 SU carburetors Chapter 17
9
Tun ing
Note: Refer to Chapter-3 for notes on tuning, with particular teference
to p relim inary procedures. If a the rmo sta tic st arting carb urettor is
fitt ed, refer also to Chapter 2 1.
S ingle carburettor installations
1 Set the throttle adju stin g screw . Warm up th e eng ine t o oper~ll i ng
temp erature, then switch off. Unscrew th, throttl e adj ust ing screw
unt il it is just touch ing its stop, and the thr ottl e is closed. Set th e
thrott le adju sting screw 1 1/2 tu rns open . Ensure that the fast idle
screw is clear of th, fast idl e cam.
2 Set t he jet height. M ark: the components for co rrect reassembly,
and remove the piston and suct ion chamber un it. Disconnect th,
mi xt ure co ntrol w ire ( if fined), or remove the jet cap nut (t hermo type). Screw t he jet adjusting nut/screw until the jet is just flush w it h
the bri dge of the cerbc rertcc or fully up if this pos ition cann ot be
obtained.
3 Set the jet adjusting nut. Replace tl'le piston and SlJction Chamber
un it into its original pos ition. Cneck that the piston falls free ly onto the
bridge when tna lifting pin is released. Tum down the jet adju sting
nut/screw two complete tu rns.
4 Set the idl e speed. Start the engine and adjust the th rottle adju st ing
screw to g ive the desired id le speed . Turn the jet adjusting nu t/screw
up t o we aken . or dow n t o nchen , until the fastest idle speed, consistent
w ith even running, is obt ained . Re-adjust the thr ottle adj ust ing screw
t o g ive the corr ect idle speed, it necessary. Refi t th e j et cap nut on the
thermo -ty pe carburettc r.
5 Check the mixt ure streng th ( CO content) . Th e mixt ure streng th
affects t he co lour of t he exhaus t gases, and th e idle quality - see Figs.
5.9 and 5.10, and th e follow ing tabl es.
( w)
(c)
(r)
Too weak
Correct
Too rich
P ISton lift mg
p;n
J et odjUJllng nu l
Fig . 5.7 Type H cerbu re t t o r tuning point. ( Sec 9)
Colourless, irreg ular note, splashy misfire
Regular and even no te
Blackish. regular or rh ythmical misfire
Check for correct mixtu re by slowly pus hin g t he lift ing pi n up about
0.03 1 in (0.8 mm ) aftltr free movement has been taken up. The graph
ill ustr ates t be effect on engine rpm
indi cati ng th e mixture strength.
(r)
( c)
(w )
Rich
mix ture
Correct
mixture
Weak
mixture
as the lifting pin raises the pist on,
rpm increases cOfJ$iderably
rpm increases very slightly
rpm imm ediattlly decreases
6
Connect and set t he mixture con tro l wire (except on thermo -ty pe
carburettor ) . Connect the mixtu re contro l wi re and adju st with about
0.06 25 in (1.6 mm ) free movement befo re it starts to pu ll on th , jet
lever. Pull the choke knob at the fac ia unt il t he link age is about to move
the carburett or j et, and adju st the fast idl e screw to give an eng ine
speed of about 1000 rpm w hen the engin e is hot.
7 Fill the damper. Finally top up the piston dampe r with engine oi l.
unt il t he level is 0.5 in (13 mm) abo ve the t op of the hollow pist on rod .
On du st -proofed carbu rettors (identifi ed by no vent hole in the damper
cap, and a transverse hol e drilled in the neck of th e suc tio n chamber).
th e o il level shou ld be 0.5 in (13 mm) below the top of the hol low
piston rod .
Fi g. 5.8 I n iti al Jet he ig ht setting ( Se c 9)
w
--
R
C
W
Fi g . 5.9 D iagram at effect on ex h aust of mixt u r e strengths
at i dle speed ( Sec 9 )
Time
•
Fig . 5.1 0 Graph sho w in g effect o f pisto n lift ing p in o n idle
spe ed at differen t m ixtu re stre ngths ( S ec 9 )
4
17-8
Part 4 SU carburetors Chapter 17
Multiple cetborenor installations
Before th e att empted luning of any cerburertoe msteneucn. it is
essential to mak e sure th e valve clearances. poi nts gap and spa rk plug
gaps are correct. Succ essful tun in g can not take place if anyone of
these is 'our. Mult iple cerburertce set- ups have th eir problems
compounded if th is is not strictly observed.
9 Remove the air cleaner (s) and check for thronle li nkage ad ju stment , smoothness of action and that the das hpots are t opped up
properlV_Run the engine to norma l oper ating temperatu re. th en sw itch
8
off.
10 Slacken a clamping bolt on one of t he thr ott le spindl e interconnecti on couplings between the cerburetto rs.
11 Unscrew both thr ottl e stop adju sting screw s unti l they are both j ust
t ou ching their stop s with the throttle Closed. Turn bo th screw s
clock wi se 1 1{2 t urns exactly.
12 Remove th e pistons and suction chambe rs.
13 Disconnect the jet co ntr ol int erconnect ing rods and cab les on the
non-mermc cerbur errors, or remove the jet cap nuts on thermo-type
carbu renors. Turn the jel adju sting nuts or screws until each jet is flu sh
wllh the bridge of it s carburettor.
14 Refit th e pistons and suct ion chambers. Top up t he piston rods
with o il, refit and tighten the damper rod s. then check th at eac h piston
falls freely by pressing th e small lift ing pin upwards and letting th e
pistons fall onto th eir bridges . A distinct 'click' should be heard. Tum
dow n the jet adj usting nuts or screw s 2 turns exact ly .
15 Restart the engine, and tu m the t hrottle stop adjusting screws by
equalamounls to giv e the deslred idle speed. To make sure that both
carburett ors are synchronised. use a length of tu bi ng placed between
the carburettor intak e and the ear. and adjust the throttJe screws
fracti onally until the hiss from both un its is the same. Alternatively, use
a bal ancing device (fl owmet er) in accordance w it h its manufactur er's
instructi on s.
16 W ith the cerburettors correctly synchron ised, tum the jet adju sting
nut s or screws up or down by equal amou nt s unti l the fastest idle
speed is obtained , consistent w it h even runn ing. If necessary. re-adjust
the thrott le st op adj usti ng screw s by equal amo unts unt il the correct
idl e speed is re-cbtein ed
17 Now check the mi xtur e strengt h on eac h carburettor seperetetv.
using the proc edure described in paragraph 5. Stop the eng in e.
18 Rel it the jet cap nuts on ther mo -type carb urett ors.
19 W ith bot h th rottles cl osed. tighten the cl ampi ng bolt on th e
interconnection coupling wit h the pin of the lin k pin lever resting
against t he edge of the pick-up lever ho le. Wh en forked levers are
fitted. set the crank ed levers so that the pin is 0.006 in (0.15 mm) from
the low er edge of the fork. This makes sure that both (all) carburettor
thrott les operate simultaneously.
20 Wh ere cold start co ntrol ( choke) cables are fitted. recon nect them.
tog ether w it h the intercon necti ng rods. and adju st th em with referenc e
to paragraph 6. making sure th at both oper at ing arms move
simultaneously.
21 Refit the air cleaners and re-chec k for cceeet mixture strength.
Fig . 5 .12 Co ntr o l couplings on m u ltiple ca r b ur en o r
in st al lat i o ns ( S ee 9 )
Fi g . 5.11 Balan cing twin carburettcre (Sec 9 )
1
Throttle stop adjustme nt screws
2
Throttle spindle coupling
3
Choke control coupling
Part 4 SU carburetors
Chapter 18 Type HD
Contents
Section
Section
7
Assem bly •.......•.•..•..•..•.••.•..•..•..•..•.•........
Constr uction
.
DisaSS&mbly
Introduction
2
.
.
,
1
Jet assembly
.
Operat ion
.
Spec ial overhaul proced ures .
Tun ing
.
______________
3
4
5
8
Introduction
The Type H 0 ( D iaphragm ·jel ) carbur ettor wa s introduced after the
Type H. It was manufactured in larger sizes on ly - 1'/2 in, 13/4 in and
2 in. being models H04, HD6 and HOB respect ively. and w as there fo re
generally fitled to larger and heavier cars.
The c haracterist ic fu tures of Ih e Type HD are t he method s of
metering f uel fo r idling. and 01 sealing th e jet base.
2
Construction
The pis ton and suction ch amber assembly is of the sa me ge neral
design as that of the Type H. The dashpot bo re may be eith er
dustpr oo fed or noo -du stproofed . alld may therefore have uri -d rilled or
drilled piston damper cap s respect ively.
Th e jet slides w ithin a bearing. secured t o the un derside of the
body. by the same method as in the Type H. and is surrounded by an
open -ended cyl ind rica l ho using. cast integrally with the body. The
hous ing is closed by a jet hou sing. incorporating t he jet act uat ing lever
assembly hinged in integrally -cast lugs. and an exte nsion of t he
float -chamber. th e pans being secured to the body by four screws . A
fl exib le d iaphragm (fixed t o t he base of the je t assembly ) is clamped
bet ween the fl oat chamber extensioo and the und erside of the jet
hou sing. and d ....ides the hous ing cavity int o two cha mbers The uppe r
chamber conta ins the jet actuating (low ering) mechanism and the
lower chamber is linked t o th e float chamber vi a a dri lling in t he
------
exte nsion, and is th erefor e fl ooded with fu el. The fu el flows up throu gh
the holl ow jet to the orifi ce et the top,
A helical compression spring. fitted between a cup at th e base of the
jet assembly li nd a locati ng spi got in t he float chamber exten sion. lo ads
the jet upwards.
All H 04 and H 06 unit s al e fin ed w ith thrott le spi ndle sealing gl ands.
w hicl'l minimise inwar ds air leakage wh en the spindle bearings beco me
worn , Some H OB unit s ale also so equ ip ped, w hile others have no
sealing gl ands an d are fined w ith replaceabl e PTFE bus hes.
The gl ands have ta pered faces. and are fitted int o con ical-ended
counterbores in the un it body. A helical compr ession spring. retain ed
by a steel sleeve pressed intO th e end of th e co unt erbo re. compresses
the gland so thatthll bor e closes on to th e th rottle spind le and fo rms a
seal. The gla nds do not require servic ing. and no pro vision is mad e for
their easy remova l.
PTFE bushes are inserted int o ccu nt erbor es in the un it body from
inside the bore of the un it . They are retained in pos it ion by circular
spring clips f Itted to t he thrott le spind le.
The underside of the body has cast ribs . and th ere is a cast pro ject iol'l
at each side of the main bo re. Th e ribs are int ernally -drilled to form a
passage wh ich bypasses the throttle plate w hen it is ctcseo. One of the
side prOJect ion s houses a screwed needle valve. the end of w hich
inlercepts the drilled passage. and fu nc ti ons as a slow runnin g volume
screw . The Other side pro jectio n has a vert ical bore in whic h slides a
cam rod . formin g part of the cold stan enrichment/thrott le opening
inter connection mechanism. The to p end of th e cam rod is fitted w ith a
plate, carry ing an adjusting screw w hic h bears on th e th ron le spindle
4
Part4 SU carburetors Chapter 18
18-2
Aut o
ign ition
union
Feu-/dle
edjustin g screw
J ot
Throttl e
sp in dle glan d
o
Gland
spring
Je'
screw
clamping
Jot
~1~~~~5~~
LJ lit
actuating
lever
Jot
," p
Diap hragm
~""-,,,Je t
spri ng
,"p
Jet
ad jus t in g
0l ixtu re) screw
Idling by-pass
passage
-,
Jot
spring
J et contro l leve r
Fi g . 6.1 Cutaway v iew of the Ty pe H D c arburettor ( Sec 2 )
arm . Th e bottom end is rivetted to an arm, at the end of w h ic h is a ro ll er.
The roll er bears on a cam at the end of th e jet actuating lever spindle.
Th e f loat ch amber assemb ly is o f similar d esign to Type H, in th at it
hou ses a brass flo at slid ing on a central spindle. and the inlet valve is
A
8
clo se d by a hinged leve r mo unted in the d etacha ble tloat c ham be r top.
An ignition timi ng vacuu m tapp ing is provided in the roo f of th e
bore. the fi ne hol e emergi ng at Ihe edge of th e throttle plate when in
the closed posi tion. The hole is bor ed through from a flat pro ject ion
beh ind the suct Ion chamber. Connection is made by an adapter plate
w ith a stub pipe. secured to the body w ith two screws. A gasket is
fitted between the body and the plate.
1
3 Jet assembl y
The jet assembly consists of a brass jet tube . a flan ged co llar on
w hich the jet act uating lever bears. a spring cup and a synthet ic rubber
diaph ragm . The component parts are assembled by cl amping and
pressing and cann ot be separated.
The diaphr agm has a mould ed ctrcumterennat rib on its uppe r
surf ace, which locates in a similar annu lar groo ve in th e underside of
the jet housing and form s the sealing face. Four ho les or cut -ou ts on
the periphery accommod ate the tet hou sing securmg screws.
The jet sil e is identified by a cod e number stamped on th e upper
surface of the flanged coll ar.
4
Operation
The oper ation of the un it tor accelerat ion. full thrott le and cruise
conditi on s is simi lar to t hat of the Type H. The idli ng con ditio n is
d iffe rent as the th rottl e disc is not used for idli ng mi xt ure volu me
regu lation .
When idling (eng ine hot) , the t hrottl e plat e is fu lly closed in the
carbu rettor bore. Mi xtu re fl ows from th e jet [ upstream of the thro ttle)
th roug h the bypass passage. past the slow f\Jnning volume screw and
retu rns t o the bora through a drilling downstrea m of th e th rottle plate.
This gives mo re prec ise contro l of metering small quantities of mixture.
and eli minates the eff ects of irreg ular flow aroond w orn th rottl e plat es,
bores and spind les.
Note that the idl ing mixtu re strength is still determined by the
position of th e jet. and that the slow run ning vo lu me screw o nly
regul ates the volume of mixture,
Fi g . 6.2 S t an da rd (A) and Ro lls Ro yc e ( e ) j ets for the HD
c a r b ur etto r (Sec 3)
1 Jet si~e code location
JelSlz es; 9 .. OOS/n. 1 = 0.1 in. 125
= 0. 125 ;n
At co ld -start condition. the j et is lo w ered (by operation of the jet
co ntro l lever) and the th rottle in terconnection mechani sm ope ns th e
throttle slightl y to a preset amount (determin ed by' adj ustment of th e
fast idle screw) . A rich mi xtur e of increased vol ume is therefore
sup pli ed to the eng ine through both the mein throttl e vallie end th e
bypass passage.
As the engi ne wa rms th rough, th e jet is raised and the throttle is
autom aticall y cl osed by t he interaction of the throttle intercon nect ion
mechan ism. wh en th e 'cho ke' co ntrol is pus hed home.
Due to lhe con struction of the linkage in the jet ho using , it is
poss ible to obta in a fast- id le condition by pu lling out th e 'choke'
control sligh t ly fr om its fu lly closed pos itio n. This has the eff ect of
opening the throttl e before the jet ectu atinq lever starts to low&!"t he jet.
5
Spec i al overha ul p ro c ed ures
Refer to Chap ter 4 .
Part 4 SU carburetors Chapter 18
2
The s u part numbers for gasket and overh aul packs afe 1$ follows:
Carburettor
model
H04
HD6
HDB
Throttle
d iameter
7112·
13/r
r
Gas ket
pack
AUE 805S
AVE 805S
AVE 806S
O ve rha ul
pack
AVE 855
AVE 855
AVE 857
Note: Overhaul pads may be difficult to obtain. The'S' $uffi}( on the
gilsket pack part numbers indica te s tha t th rottle plate screws are
inclu ded
6
Di sassembl y
1
2
3
Clean t he ou tsi d e of t he car b ueett c r tho rou ghly.
U ndo and remove th e damper and washer.
Remove the suction chamber retaining screw s and remove the
c ha mber stra ig ht UP ( p ho to) .
4 Lift off the piston spring. Carefully lift out the piston and needle
assembly ( p hot o). Empty out t he damper 011 from t he piston rod.
S Remove the needle locking screw and w ithdraw th e needle
( photos) . If it sticks in plac e, tap the needle inwards first and then pull
outwards. Do nOt bend it.
6 Record the positions of the float chamber. jet housing. and
cerbur etto e body. Unscrew th e fl oat chamber screws. holding the float
Chamber against th e pressure of the jet spring. Carefully detac h the
float ch amber (photos). If a th ermostat starting carburertor is fitted.
refer to Chapt er to.
7 lift out the Jet spring. mark the jet diaphragm opposite one of the
screw holes in the jet housing and w ithdraw th e jet assembly ( photo).
8 Remove th e screw from the to p of the fast idle pushrod, and lift off
the plate (wit h fast idle adjust ment screw) and th e return spring
(ph oto) .
9 W ithdraw the fast idle pushrod . the; 1 remove th e jet housing .
18-3
co mplete with the jet actuat ing levers ( photos).
10 Slacken and remove the jet locking nut toget her with the jet
bearing ( photo).
11 Record the position s of th e float cham ber and lid . Remove th e
centra l nut retain ing the float chamber lid tog ether with th e vent tu be
banjo and fibre washer. or cover caP. as applicable.
12 Where a banjo inl et is fined. unscrew the banjo bolt fro m th e float
chamber and remove t he bolt banjo and fi bre washers. Pull out th e
filt er and spring assembly from the float chamber lid inlet (phot o).
13 Remove the lid and gasket (photo). Pull out the float lever hi nge
pin from the serrated end. Detach the lever.
14 Extract the f ioat needl e from its seati ng. and unscrew th e seati ng
from th e lid using a spanner 0.338 in (8.58 mm ) across flats (p hoto).
Do not distort the seat ing.
15 Remove the flo at from the ch amber (photo).
16 Shut the throttl e and record the position s of the throttle disc and
the carbcr etto- flang e.
17 loosen and remove the disc retaining screw s. The ends of the
screws will be split to retain them securely - cl ose the split before
attempt ing to remove th e screws. Wit hdraw th e disc from Its slot in the
throttle spindle ( photos) . The disc is oval. and can jam . Talle care to
make sure it does not.
18 Slide out the spindle from its bearings ( photo).
19 Do not remov e th e t hrott le spindle sealing glands.
Note: Some Type HO B carburettors ~re fitted with plastic spindle
bushes and have no spindle sealing glands.
20 Loosen and remov e the slow running volume screw. complete w ith
spring . seal, and brass w asher (phOIO).
21 Remove the two screw s and washe rs holding th e vacu um ignition
take-o ff plate and uni on. Lift off the plate and gasket.
22 Remove t he pi ston lifting pin by extracting th e c irclip from its
groove with t he pin pressed upwards. Wit hdraw th e pin and spring
dow nw ards.
23 For instructions on cleaning. inspecti on and repair. refer to
Chapter 4.
4
6.3 Removin g the suction chambe r
6.4 Removing the piston
6.5A Extract the lock.ing screw ...
6.58 ... and withdraw t h-e needle
6.6A Remove the screws ...
6.6 8 •••and hh off t he float chamber
18-4
Fi g . 6 .3 Type HD je t housi ng co m po ne nts ( Sec 6 )
1
Plate retaining screw
9
2
3
Plille
Spring
4
ShaAep ro of w ash er
10 Floa! chamber screw
11 Jet spring
12 Jet dillphragm
5
6
Marks for replacement
Fast idle pu shrod
13 J er assembfy
14 J et fock in ,q nul
7
Fl oat ch am b er lid
15 J et bearing
8
Jet housin g
CIHburetlor body
6
7
4
riI ~10
I
---- ,
2
_.
.
3~
Fig . 6.4 Piston and need le compone nt s ( Sec 6)
1
2
Piston fod
Vacuum transfer holes
3
Needle
4
Locking sc re w
,
6.7 Withd raw ing tbe jet assembly
6.9B J et housing and levers
6.8 Removing t he fast idle adjUStment
scr e w plate
6.9A Fast idle pushrod an d jet housing
6.10 J et locking nut and bea ring removal
6.12 Removing the ban jo inlet and filtel
fro m the float cha mbe r lid
removal
18-5
Part 4 SU carburetors Chapter 18
6.13 Removing the hose co nnection type
float chamber lid
6.14 Floa t needle (arrow ed)
6 .15 lifting the flo at fro m the floal cham ber
6 _17A S how ing the spl it ends of the
throttle d isc reta ining screws (a rro w ed)
6.178 Extrac t the screws ...
6.17C ... and w ithdraw the thronle d isc
4
6.18 Throt tle spind le removal
7 Asse mbly
Fit the spindl e in its bearings.
2 Fit th e thrott le disc to the slot in the th rott le spind le in the position
marked previously (o n di sassembly) . Not e that the countersunk enos
of the screw ho les in th e spindl e must face outw ards. ie towards the
intake flange of the carbur ett or bod y. rosen two new retaini ng screws,
but do not tigh ten . Adj ust the disc in the slot until it closes lully in the
bore of the cerb ueencc and tighten the screws . Spread t he split ends of
the scre w s just e noug h to prevent t hem turning.
3 Fit the slow runn ing vo lume screw. taking care that the b-ess
washer is fined w ith its concave face loward the seal.
4 Fit the gasket and vacuum ig nition take- off plat e. with screw s and
6.20 Remov ing t he slow running vol ume
screw
new shakeproof w ashers. Do not use j ointing compo und on the
gasket.
5 Fit the piston lifting pin. spring . new ru bber washer . plain w asher
and circli p.
6 Fit the needle to the pisto n assemb ly. The low er edge of the groo ve
mUSI be level with t he low er face of t he piston rod. Fit a new needle
locking screw and t ighten. Inv ert the suction cha mber and turn the
pi ston assembly inside it to ch eck for conc entricity of th e needle.
7 Check Ihe piston key for security in the carburertor body (photo) .
8 Fit the Jet bearing and jet lock ing nut Leave the nu l w ith j ust
enough slack to allow th e bearing to be moved fro m side to side
9 Temporarily fit too jet assemb ly in tile jet beanng in the
previou sly -noted position, and push it fully upw ards. Carefully tecate
the piston and needle in the upper end of the bod y. and push
18-6
Part 4 SU carburetors Chapter 18
do w nw ard s. Th is w ill ce nt ral ise the jet, and the jet locking nut ma y
then be t ightened. Rem ove both th e p isto n and jel.
10 l ocate th e le I housing , complete with th e jet actu ating levers , on
the body in its peevio us jv-n ot ed positio n. t he n lit the fasl id le p ush lod
and lower it onto the cam ( p hOt o) .
me
11 Fit the jet. Jet spring and flo at chambe r in
same relative
positi ons as recorded on dismantling (photos). Fit and tighten I he
securi ng screw s evenly.
12 Fit the fast id le pu shrod spring, pla te a nd plate reta in ing sc rew w ith
a shakeproof wa sher on eit her side of the plene. M ake sure the plat e is
positi oned so that the fast id le ad justm ent screw stri kes squarely on the
lug of the Infonle spind le o pe rati ng arm .
, 3 Smear a liule o il on the piston rod, then fi t the piston to t he suction
chamber w ithou t the spri ng. With the pist on fully in serted, seal the
transfer holes (with plasticine or Similar product), then invert the
assemb ly and allow the suction chamber to fall from the piston . Check
the tim e th is takes. It shou ld be between 5 and 7 seconds If th e t ime
taken exceeds that t he cause w ill be th ick oil on t he piston rod, or an
oil fil m on t he piston or insio. the suction chamber. Remove the oil
7.7 Piston key loc ati on (arrow ed )
7.10 Refitt ing the jet housing
7.11 B Top view of t he jet ( 1) and jet
bearing (2)
8 Tuning
Note : Refer to Chap ter 3 for no tes on tuning. with pa rticular refe rence
to prelim inary p ro cedures. If a thermost atic starting csrcoreuor is
fitted, refer-also to Chapter 2 1.
Single
ca r b u re ttOI ins t affa ri ons
Set the ini tial fast idle and slOw running volume screw s. Run the
engine up to a normal running temperature. SWitCh off th e engine.
Un screw the fast idle adjusting screw w here fin ed to c lear t he mr enre
spind le arm w ith the thrott le closed. Screw down the slow runn ing
vol ume screw onto its seating, then unscrew it 31f2 turns.
2 Set the jet heig ht. Remove the piston and suct ion chambe r un it.
Turn the jet adju sting ( mixture) screw unt il the Jet is flu sh with t he
bridge of the cerburett or.
t
from the pa int s suggested and re-test.
14 Fit the pisto n assembly to the body . and locat e the piston sprin g on
the piston rod . Fit the suction chamber and retaining screws . Tighten
the screw s evenly.
15 Fit the needle seating and needle to the 1I0at c hamber lid
16 Fit the Ilcat lever and press in the lever hinge pin to secure Check
the ucet level as described for th e rvce H carburett or in Chapter 5.
Section 8, paragraph 6 ( photo).
17 Refit the flo at to the flo at chamber.
1B Fit the gasket to the lid, and refit the lid on the float cham ber in the
same posItion as recorded on dismantlinq. Fit the fi bre washer, vent
tube came. plain washer, and nut or cover cap and nut. as applica ble.
Do net overtighten tne nut.
19 Where a banjo inlet is fitted . in sert the filter, spring end first
fo llow ed by the banjo. fibre washers. and ben. The recessed side of the
banjo must face outwards ti e abutting I he bo lt head).
20 Top up the piston rod w ith oil as described in Sect ion 8, then fit
and t ighte n the damper rod .
7.11A Refitt ing the float chamber
7.16 Checking t he fl oat level
3 se t the jet adj usting (mixture) screw . Ref it t he piston and suction
chamber unit . Check t hat the piston falls freelv onto the bridge wh en
the lifting pin is released. Lowe r the jet bV turning the jet adjusting
screw clockw ise 2 1/2 tu rns.
4 Set the idle speed. Start the eng ine and adj ust the slOw runni ng
vo lume screw to give the desired idle speed. Turn the jet adjusting
screw enn- ctockwise to weaken, or clockwise to ncnen, until the
fastest id le speed, con sistent w ith even runnin g, is obt ained. Re-adj ust
the slow running vo lume screw to giv e the correct id le speed. if
necessary.
5 Check the mixt ure strength ( CO cont ent ) as descnbed In Chapter
5, Section 9
6 Connect and set the mixture cont rol w ile (except on thermo-rvpe
cerb ueencr). Connect the m ixture con trol w ire w ith about 0,0625 in
(1.6 mm) free mov ement before it starts to pull on th e jet lever. Pull the
cho ke knob at t he facia until t he linkag e is about to move the
Part 4 SU carburetors Chapter 18
cartl urett or jet OPerted hole in t he body.
the hole in the nut is consid6fably la rger than the externa l d iameter of
the jet holder. thus pemlin 'rlg sideways adjustment of the jet assembly
to centre it relat ive 10 th e need le .
A helical compression spring a nd long nut are fined to th e t hre ad ed
portion at the bottom of Ihe je t holder. Th e underside of the n ut is in
contact w ith the metal collar on the jet assembly moulding. t hus the
venca t positio n of the jet is con trolled by screwing the nut up or down.
The je t is held in cont act with th e nut b y spring loa di ng on the extern al
(choke) l inkage. On type HS4C and HSB cerbueettcrs. the jet hol der is
retained w ith 11 bra c ket lind tw o sc rew s, and the jet posi tio n is ad jus te d
by a lin kage an d adju stment screw .
The jet may be any of th ree sizes, accord ing to the size and
applica ti on of t he carcuret tc r. The size denotes the diameter of the
bore and is 0 ,0 9 in. 0.1 0 in or 0. 125 in. This is id entified by the number
of machined gro oves at the top of the jet. being non e. one. and two.
respectively.
If replacing a jet. ensure l!\at the replacement has the same numbe-r
of grooves , the same colour of jet head (the presnc mou lding). and the
same number ( one. two or three) and colour of pl astic sleeves on the
fleJ( ible feed pipe as the original one. Each ret has a separate part
number, and its ecctceuce is d ictated by the fonow ing features:
...
(~) Angle 01 float ch~mber
( b) Cafbufetlor siu
( c) tmercormection (fight_ Of left -hand)
( d) Jet size
3----1
On mo re recent models the jet adjusting nut may be tamperproof ed.
to discou rage unaut horized adj ustment, by fitt ing a plasti c clamp over
both the adjusting nut and the jet locking nut . The clamp is designed to
break when it is removed, so that a new one must be filted after mak ing
an adju stment. The thro ttl e adj usting screw may be tamperproofed by
fitti ng a metal cap over it. The cap may be levered out using a pointe d
instrument. and should also be renewed aft er making an adju stment .
3
The float chamber is of different design from the previous Types H
and HD, due to the d ifferent design of jet assembly. and a
Slmphfication and improvement in construction and operation.
The chamber is attached to th e cerburettcr body by a single bolt
screwed into a tapped boss cast on t he side of the chamber. This
enables the chamber to be rotated . w ith in lim its. to suit either
horizonta l or semi- d ow ndraught installation . therebv eliminating the
need for different casting s, A.n adapter bush with locating tongu es,
inter posed betwee n the chamber and t he body. ensures correct
orientat io n for any particular installation. The fuel outlet from t he
chamber is arranged so that there is a sedim ent -w ell surrou nding it,
Whe re the out let emerges from the chamber, the boss is tapped to
accept the union nut of the jet connect ion pipe,
The det achable float Chamber lid incorporates lugs which carry the
float lever hinge pin. The fuel inlet is a stu b (brass pipe ) for conn ect io n
10 a push-on fle xible pipe. and the vent is a horizo ntal drilling
immedia tely below it. the outlet being shielded by a baffl e plate 10
prevent the ent ry of d irt and to prevent fuel being ejected fOfcibly from
it should th e inlet valve stick OPen.
The inlet valve may be either the brass type w ith a steel needle. as
on Types Hand HD, or may be a plastic-bod ied. spring-load ed type.
This latter ty pe was introd uced on the Type HS to overcome the effects
of eng ine vibration . w hich tends to affect the seating of the inlet valve.
To further assist in reducing the effects of Vibratio n. th e float
chambe r may be flexibly mou nted by the inclusion of rubber bushes
betwee n it and the cerburettcr body. The float is termed by two plastic
moul di ngs - on some types a steel arm is fitled to the float for
adjustment purposes.
4
3- --tt-
Flo at cham ber asse mbly
Pisto n an d need le
On some applications, the needle is spring -load ed in the piston ,
and biased toward the eng ine side of t he jet. This provides more
accurate metering of the fuel . A. spring seat is fitted inside the piston
rod . and a flanged collar is lined to the top of the needle. The spring
Fig . 7 .4 Tamperproof cap and cl a m p fi tted to later m o d els
(See 2)
1
2
3
4
Thr ottle adjusting screw cap
t tvotue adjusting screw showing cap in p osition
Plastic clamp
Jet adjusting nut
presses the needle collar onto a gu ide. Which is clamped in tne piston
by a locking screw . tM upper surface of the guide is machined at an
angle to prov ide the bias to the needle
5
Operation
The operation of the carbur ettor fo r cold start. idling. acceleration
and crui se conditions is the same as for the Type·H.
6
Specia l overhau l proc edures
Refer to Chapter 4 .
2 Service and repair kit s are available under SU part numbers
accord ing to vehicle mod el. Gasket packs are available under the
following part numbers:
Carbu rettor
mod el
Th r o ttle
d iameter
HS2
HS 4
1' //
1' /2-
Gasket
pa c k
AUE 810S
AUE 8115
19-3
Part 4 SU carburetors Chapter 19
HS6
HS8
AUE812S
AVE 8 13S
Note : The 'S ' suffix on gasJ<.et pack parr numbers indicates that
throtrle plate screws are included
7
Disa ssem b ly
1 Take off the haff le plate from the vent pipe and thoroughly clean
the outsi de of the carberettcr
2 Record the relative positions of the suct ion chamber and the
cerburertor body.
3 Unscrew and remove t he damper and its w asher. Whele a retaining
cli p is fin ed. g ive the damper a sharp tug to release the cli p from the
piston rod ( photos).
:1
4 Unscrew the suction chamber retaining screws and lift ott me
cham ber without ti lting it (pnot o) . Take off the piston sprillg and
washer (if fitted ).
5 lift out the pisto n assembly carefully. and empty the oil from the
piston rod
6 Undo the noodle loc king screw and w ithdraw th e needle ( phot os) .
If it sticks, tap the noodle inwards first and then pu ll outwards. Do not
bend the needle. Where fined . recover the gu ide and spring.
7 If a piston lift ing pin wi l h a external spring is fi n ed. remove the
spring retaining c irclip and spring. t hen push the lifting pin upwards 10
remove it . For the co ncealed - spring type , press the pin upwards.
detach the c irclip. and withdraw the pin and spring downwards.
8 Support the mo ulded base of the j et, and 100s&l1 the screw
retaining the jet pick-up link.
9 Believe the tension of the pick -up lever return spring. and remove
screw and brass bush (if fined ).
10 Undo th e brass un ion nut retaining the fl exibl e jet feed pipe to the
,
L-----'
4
Fi g . 7 .5 Expl od ed v iew of twin H S4 carburettor installat ion ( Sec 7 )
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Bo d y - front Cdrbur,ttor
Bod y - rear carburettor
Pin
Spring
Circlip
Chamber and piston
ass embly
Scr ew
CilP and damp ers aSlSembly
Wash er
Sprin g
Screw
Jet assembly - front
carburettor
Jet assembly -rear
carburettor
Jet be aring
Wash er
S cre w
17 S pring
18 Screw
19 Needle
20 Float chamber
2 1 Washer
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Grommet _ front carburettor
Grommet - rear carburettor
Washer
Plain wilsher
Bolt
Hoet assem bly
Pin
Lid - front carburettor
Lid - rear carbutettor
Wash er
Needle ilnd seat assembly
Scre w
Wilsher
Throttle spindle
36 Throttle disc
3 7 Screw
38 Lever - front carburet/o r
39 Lever - rear carburetror
4() Lever
41 Washer
42 Nut
43 Washer
44 Screw
45 Spring
46 Lever and link assemblyfront carburet/or
47 Lever and link assembly rear carburet/or
51 S crew
53 Le ver - front csroorettor
54 Lever - rear certnnenor
55 Spring - front carburet/or
56 S pring - rear carburet/or
57 Spring - front carburettor
58 Sprin g - rear c"rburettor
59 Bolt
60 Tube
61 Wash er
62 Washer
63 Rod
64 Lever and pin aSlSembly front carburettor
65 Lever and pin aSlSemb/y rear carburettor
66 Bolt
67 Washer
68 Nut
69 Lever
70 Bo lt
71 Sp ring washer
72 N ut
19·4
6
31-':::::~J"".
4
5
c
nn-
6
Fig . 7 .6 Exploded v iew of HS8 carburettor ( Se c 7 )
1
Damp er
5
Body
2
3
Suction cm mbfN
Sp ring
6
7
Floet cha m ber lid
Float
4
Piston
8
Nee dle valve seating
9 Ne edle
10 Float chamber
11 Throttle vaflle spindle
12 Throttle valve
13 Spindle nut
14 Jet IJssemb ly
15 Flexible feed pipe
16 Je t forlc
19-5
Part 4 SU carburetors Chapter 19
r
7.3/1.. Removing a dampe r fined wit h a
retainin g cl i p (arro w ed)
7 ,36 Standard damper
7.4 Removing the suctio n chamber
7.6 A Und o th e lock ing screw ._.
7.68 ... an d w ithdra w the needle
7 ,6C Removing th e spring- loaded type
need le
4
7.10 J et feed p ipe remova l from the flo at
c hamber
7.1 1A Float chamber remove r
floal cham ber ( ph ot o) .
11 U nscrew the bo lt retain ing the floa t cham ber to the ce rbu rertce
body. and w it hdraw th e fl oat enamber. Note the locati on of th e adapter
bu sh and ( w here fitt ed ) th e fl ex ible rubber mountings (ph ot os) .
12 Slid e the jet from its bear ing ( p hOto) .
13 Unscrew and remove the jet locking nut. together w ith the
adj usting nut ( ph ot o). Un screw the adj usti ng nut and separate the
sprin g and jet bearing . On HS4C and H$8 carburettors. un screw me
clamp screws .
14 geccre the seating po ints of the two ends of the pick -up level
retu rn sp ring. Unscrew the lev81 pivot bolt. tog eth er w ith it s
do ubl e-c o il spring washer. or space r. Take off th e lever assembl y and
retur n spr ing (photo ) .
15 Record th e seati ng of the two ends of th e cam lev er spri ng, and
push cut me piv ot bolt tube or tubes. Take care no t to lose the spring .
Lift off the cam lever, noting the washer between the two levers.
, 6 Reco rd the location of the float chamber lid. U ndo the lid retaining
7.11B Float chamber adapter bush location
(arrow ed)
screws and take off the l id and its gasket. co mplete w it h flo at assembly
( photo) .
17 Pull out the f loat hinge pin from th e serrated end . and detach the
floa t [ p ho to).
18 Extract the float needle from its seat ing and unscrew the seating
from the l id , u sing a spanner 0 .338 in (8.58 mm ) across fl ats.
1 9 Shut the thron le and l eeo", th e relative pos ition s of the thron le
disc and the cerbure rtor flange.
20 U nscrew t he two disc reta ining screws . Open and ease out the disc
from it s slot in the th rottle sp ind le ( ph ot os). The di sc is not round but
ov al. and will jam if cere is n ot t ake n.
21 Bend back the tabs of the was her securing the spind le nut. Note
the location of the lever arm in relat ion to the sp in dle and carburenor
bod y: remov e the nut end arm (p hoto) .
22 Withdraw the spindle (phot o) .
23 For i nstru ction s on cleaning. in specti on and rep air, refer to
Chapt er 4 .
19-6
Part 4 SU carburetors Chapte r t 9
7.12 Removin g the jet assembly
7.13 Removing the jel loc king and
adjusting nuts
7.14 Pick- up lever removal (except HS8 )
7.16 Re mov ing the floa t chamber lid
7.17 Float removal
'.2 0 A Rem o ve the s c re ws ...
7.20 B ... and lift out th e throttle disc
7.21 Spind le nul removal
7.22 Removing the throttl e spindle
8 Ass e mbly
1 Oil the spindle. then fit it to th e body. Fit the lever arm, new tab
washer and spindl e nut . Check that wh en the stop on the lever arm is
againsl the abutme nt on the body, the cou ntersunk ends 01the ho les in
the spindle face tow ards th e intake end of the carbu rettor. Tighten the
spindle nut. and lock with one of the t w o pointed tabs. This enables
the tab wa sher to be re -used. Bend th e square tab over t he lever arm.
1 Slide the thro tt le disc int o the slot in the spind le in the same relat ive
position marked on d isassembly, and fit two new thrott le screw s. Do
nOI l ighten at th is stage. Close the throttle, when the disc w ill centre
itself in the bore. Check visually that contact is made between the disc
and the bor e throug hout its circumf erence. Check w ith the throttle
closed that th ere is clearance betw een the throttle and th e carburertor
body_ W ithout moving the disc in th e slo t, t ighten the screw s Bnd
spread t he split ends sufficiently to prevent the screws coming und one
( photo).
3 Scr ew the needle valve se a ting into the flo at ch am be r lid. Do not
ove rtig hten . Ins e rt the ne edl e into t he seating, and c hec k that the
spring -loaded plunger in t he needle opera tes freely. Fit the floal
assembly and retem w it h t he hinge pin. Check th at t he float hinges
freely. Wit h the float assembly rest ing on the needle valve. check that
the gap between th e float lever. or fl oat itself. and the rim of the fl oat
chamber lid is between 0 .126 and 0.189 in{3.1 and 4.8 mm) . Use a
tw ist drill or length of metal bar to milk e t he check (photo). W tlefe a
steel arm is fittl:lCl. adjustment is possible by carefully bend ing t he arm.
How ever. where an all-plastic float is finl:lCl. it w ill be necessary to
increase or decrease the w asher th ickness un der the needle seat
( photos) .
Part 4 SU ca rburetors Chapter 19
19·7
Fig . 7 .7 Floet level setting - $t eel arm type (S ec 8 )
8.2 Spread ing the throttle disc screw spl it ends
Ifll~
Fig . 7 .8 Flo Bt lev e l sett ing - all - plastic t ype (Sec 8)
4 Fit a new f loat chamber lid gasket (do not use joi ntin g compo und)
and fit the lid to the tto et Chamber in th e same relati ve position marked
on d isassembly . Fit and evenly tig hten the securing screws , Fit the
identi ty tag under one of these screws.
5 Fit the float chamber assembly to the carbur etto r body, w ith
spacers between the tw o as necessary, Ensure that th e registers on the
body and the chamber engage correctly. If the chamb er is flexibly
mo unted . te w ith rub ber spacer{s). use new items. Fit and tighten the
retain ing bolt but take care ne t to overtighten.
6 Fit Ihe piston lifting pin. spring, new rubber sealing washer (if
applicable) end ci rclip to the bod y.
7 Fit the needle to t he piston. Refer to Chapter 5. Fig 55. (where a
rigid needle is lined) and ti ght en the screw to secure. Where a
spri ng-loaded needle is fined. locate the spring on the needle collar
and insert them in the pis ton . In sert the g uide so that it is flu sh wi th the
lowe , surface of the pislon, and wi th the slot aligned w ith the locking
screw hole. The small elc h-mal1c. must also be located between the two
vacuum transfer holes Insert end tig hten the lock.ing screw.
8 Check the pisto n key for security in the carburettcr body ( photo ).
9 Fit the jet bearing. washer and loc king nut. Do not tigh ten th e nut .
10 Temporarily fit the jet assembly in the jet bearing . with the fl exibl e
feed pipe locat ed in the flo at chamber o utlet. Push the j et full y
upwards (photo). then carefully loca te the pisto n and needle in th e
upper end of the body . and push downwards. This w ill centralise the
jet. and the jet locking nut may then be tig htened. Remov e both the
pisto n and jet.
11 Fit the spring and jet adjust ing nut to the j et bearing . Fit the gland.
washer and ferrul e to the flexible pipe ( ii remov ed). Check that the end
of the tube projects at least 0.188 in ( 4.8 mm) beyo nd the gland.
83A Checkin g the float level
4
,.
8 _3 B Bencll ng t he steel fl oat ann
19·8
Part 4 SU carburetors Chapter 19
'"
-
=
8.3C All-pla stic fl oat. needle and float cha mber lid
8.8 Piston key (arrow ed)
8.10 Top view of t he jet (1} and jet bearing (2)
8.12 Fitting th e suction chamb er
Lightly smear petrol eum jelly on the ol,ltside of the jet and insert into
the bearing. Insert the feed pipe into th e fl oat cham ber outl et. and
tighten the union nut until the neopr ene gland is compr essed (w hen
the pipe will be held fir mly in the outlet ). Do not overtighten. as th is
can cause leakage il nd possibly stripped threads in the fl oat chamber.
12 Fit the pisto n assem bly to the body. laking care not to damage the
need le. Fit the piston s pring to the pist on rod. Ughtly o il t he o utside of
th e piston rod. and fit th e suctio n chamber in the same relative posit io n
as malt ed on d isassembly (photo). Fit and evenly tighte n the re taining
screws .
13 Top up th e piston rod with oil as dEl$C1"ibed in $e(:tion 9. paragrap h
7. then tit and t igh ten th e damper rod . Wh erl a retainin g cli p is tin ed .
hol d the piston in its raised position whi le inserting th e damper rod.
and press the cli p firm ly into the top of the pisto n rod.
14 Assemb le th e pick-u p lever. cam lever. cam lever spring, w ash&!"
and pi vot bo lt tube (s). Place the lever return spring in position over the
boss , and fit the link age assembly to the carburertor body with the
pivo t bolt. Ensure th at t he d ouble-co il spring washer or speeee
(alternative part) fit s over th e pro ject ing end of the pivot bolt tube.
Register th e angl ed end of th e lever ret urn spri ng in th e groove in th e
pick-up lever, and hook the oth er end of the spring around the
mo ulded peg on the carburett cr bod y. Fit the brass ferr ule to t he hole in
the Ind of th e pick- up lever. Relieve the torsio n of t he return spring,
and fit the link to the jet wi th its retaini ng screw. Fit the baffle pl ate to
the float ch amber vent pipe.
Fig . 7.9 Damper reta in in g c lip fitted in the p iston rod
( Sec 8 )
19 -9
Part 4 SU carb uretors Chapter 19
9 Tuning
N ot e; Refer to ChiJp ter 3 for notes on l unin g, with particular reference
to preliminary procedures
Single carburettor installations
1 Set the throttl e adju sting screw . Warm th e eng ine up to norm al
operating temperature, th en sw itc h off. Unscrew the throttl e adjust ing
screw un ti l it is j ust touching its stop. and the t hrott le is shut Set th e
throt tl e adj usting screw 1 1/2 turn s open. Ensure that th e fast id le
screw is clear of th e fast idle cam.
2 Set th e jet height. M ark the components for correct reassembly,
and remov e th e suction chamb er and piston. Disconnect th e mixture
control w ire. Screw up th e jet adj usting nut (or screw on HS4C
carburett ors) until th e jet is flush w ith th e brid ge of the carburetto r (or
fully up if t his posruon cannot be atta ined) . Refit the piston and
suction ch amber, Check that th e piston fall s freely onto the bridge
wh en th e li ft ing pin is released.
3 Set th e jet adj usting nut/screw. Screw down the jet adjusting
nut/ screw t w o turn s on non -t amperproot type carburett ors. or thr ee
turns on tamperproo fed oarbc rertors.
4 Set t he idle speed. Start the engine. and adjust t he thr ottle
adju sting screw to g ive the desired idle speed. Turn the jet adj usting
nu t/screw up to we aken, or down to nchen, unti l the fastest id le speed,
con sist ent w ith even running, is obt ained. Re- adju st th e throttl e
adju sting sc-ew to give t he correct idl e speed if necessary
5 Ch eck the m ixtu re str engt h (CO content ). as describ ed in Ch apter 17, Sect ion 9.
6 Connect and set the m ixtu re contro l wir e. Connect th e mix ture
control w ire w ith about 0.0625 in (1 .6 mm) free movem ent before it
starts to pull on the jet level. Pull th e choke knob at th e facia until
th e li nkage is about to move the carburettor jet op erating arm, and
adju st th e fast idle screw to give an idle speed of about 1000 rpm wh en
th e eng ine is hot, Return t he chok e knob, and check that th ere is some
clearance between the fast idle screw and the thrott le stop.
7 Fill the damper. Finally top up the pisto n damper with the engine
oil. unt il the level is 0 .5 in (1 3mm) below the top of th e hollow piston
rod. On no n-dustproofed carburettors (i dentif ied by a vent hol e in the
piston damper top ). the oil level sho uld be 0.5 in (1 3mm) above th e
top of the hollow piston rod.
Multiple carburettor installations
8 Refer to Chapter 17, Sec tion 9, bu t ignore references to thermosta t ic carbur et to rs. O n H S8 c arb urettor s, a jet adjusting sc rew is
provided instead of an adjustmen t nut.
Throttle
adjusti ng screw
Piston lifting pin
Jet loc king nut
Fast idle
adjust ing screw
Jet adjusting nut
Fi g . 7.11 Jet height adj ust ment ( Sec 9 )
In sets show cross-section of upp er oert of Jet. and Jet adJusting
nut
Fig . 7.10 H S c erburetto r adjustme nt po i nt s ( Sec 9 )
4
Fig. 7 .12 U si ng an airflow balancing meter on a tw in H S c arb u re tto r inst allati o n (Sec 9)
20-0
Part 4 SU carburetors
Chapter 20 Type HIF
Contents
Sec tion
Sec tion
Assembly ,",
.
Aut omat ic stilrting unit (ASU - tw in cerburettc-s) - testmq.
remover. overhaul and ref illing .....................•...
Cold start enric hment dev ices
.
D isassembly .
.
.
Floal chamber assemb ly
Full y automatIc start ing device ( FASD - tw in carbur ettors )
c hecking and adjustment ......................•..•.••.•.•••.••••.......
1
'0
11
5
9
.
2
~
12
Introd uc t ion
The Type HIF (Ho rizo ntal Integral Float Cha mber ) c.arburenor is the
most recent development of t he SU instrument w orking o n tbe
constant-vacuum princ ip le. It has been designed primarily to meet the
requi rements of exhaust emission control carburat io n systems. Functionally similar to previou s types . the Instrument uses th e variab le
choke/ constant depression princip le 10 achieve the precise mixture
ratio required to contr ol th e toxic elements of exhaust emissio n to
w ith in statutory requ irements. It diffe rs from previ ous ty pes in tha t
add itiona l mixture requi red for cold starting is sup plied separately to
that from the main jet. It is manu factu red in the larger sizes only; HIF4,
HI F6 and HIF 7 being 1.5 in. 1.75 in and 1.875 in throttle bore
di ameters, respecti vely. Metr ic eq uivalents of the ' .5 in and 1.75 in
Fully automati c starting device ( FA.SO - tw in carburettors ) removal. overhaul and refin ing
Introd ucti on
.
J et assembly
.
.
M ixture control
Operation
.
_
PiSlon and needle
.
Special overhaul procedures
Tuning
,
13
4
3
. 7
. 6
. 8
. 14
diameters are 38 mm and 44 mm respectively. hence th !! HI F38 and
HI F44 types.
The oth er characteristic feature of the unit is the absence 01 a
separate float chamber. The f loat and inlet valv e mechanism are
COnt ained in a hou sing underneath th e carbur ettor body. giving the
unit a d istirn.:tive appearance. This housin g also conta ins a
temper ature- sensitive dev ice w hich alters the main jet position in
relation to the metering needl e. th ereby automatically adj usting Ihe
mixtu re rat io to com pensate for changes in fu el viscos ity due to
chan ges in f uel temperatu re (see Chapt er 1). This enables the
carb urett or to maintain a very accurate mixture ratio con trol over a
range of operat ing condit ions .
A.n overrun valv e is incorporated in the th rottl e d isc on some
versions, to lim it th e depression wh en the thr ottl e is closed dur ing
decelerati on.
20-1
Part 2: Chapter 8 Type HIF
2
Fl oat chamber assembly
The float cham ber, incorpo rated in the body cast ing below the
choke bo re, is sealed by a remov able cover plate and rubber gasket . It
ho uses 'it mou ld ed plastic float hinged upon a pivot screwed int o the
w all of the hous ing , a spring-loaded needle valve assembly, and the jet
operating mechanism .
On ASU versions , t he cov er plate form s the lin k base for t he ASU . On
FASD versions, a plastic pic k-up tu be cha nne ls f uel from the fl oat
chambe r 10 the FASD .
3
Mixture contro l
The mechan ism consists of a right- angl ed adj usting lever riveted t o a
bi -metal blade, the end of wh ich engages w ith t he base of the jet
assembly. The lever is fl exibly secured 10 the bod y by a spr ing - loaded
screw. and is adj usted by the jet adju stin g screw in contact wi th one of
its limbs . Screw ing in and out (from ou tsi de) of the jet adjusting screw
lowers and raises the jet respectively. g iving a fine degree of mixt ure
control. At any posit ion of th is lever, t he bi -m etal assembly has an
overr id ing control functi on. and will com pensate for variation in fuel
viscosity due to temperature changes.
No te that Ihe height of the jet is not adjus ted far cold start
cond itions. I his function bei ng performed by a separate device. Once
the jet he ig ht has been set, no fu rther adj ustment is necessary and to
frustrate attempted tampering , provis ion is made far fining a sealing
pl ug in the adl uSlIflg screw t apped hol e.
,
Fig . 8 .1 H IF ce rbu re rr c r f l oa t chamber layout ( S ec 2 )
1
2
3
4
5
Bi 'fmn aflic assembly
Floaf
Je t head
Je t ddjvsting (mixtvre)
screw
Jet assembl y
The [et assembly differs from prev ious ty pes ch iefl y in respect of it s
redundancy in co ld start co nditions. It also differs considerably in
construction, being of alumi niu m allo y and not brass. and has a
separate pressed -in brass ori fice fo rmi ng the jet proper
Th e integral plastic moul din g at its lo w er end forms an inl et for fuel ,
an articul ated con nection fo r th e end of th e bi -m etal jet lever (w hich
con trols its height) , a step to limit its upward movement and a means
of ident ifica tion (of right or left -hand interconnecti on, see Fig . 8 .2) .
The size of t he jet (0 .090 in or 0.10 in) is giv en by the absenc e or
presence of a machined groove at the to p of th e jet tube. The length of
th e jet elsa varies according to the carb urett c r ty pe. The jet assembl y is
not rep airabl e, and must be replaced by a new part complete if
damaged.
5
c over
-
-
-N
2
Fi g . 8 .2 Jet identification ( Sec 4 )
Jet head - blaCk/ right ·hand conn ection. whitelleft ·hand
connection
2 J et assembly
3 Jet size identification - no gr oove/ 0 09 in, one gr oo ve/ O 70 in
Dimens ion X - ' .5 in lor HI F 416 cerburettots, 7.3 in for HI F 7
cafbufettors
u
{), G
Co ld sta rt enrichment d evi ces
Add it ional mix tur e requir ed for co ld starting is sup plied by a
separate cold start valve and is independent of the main jet.
The cold start valve consists of a starte r valve body. a valve spindle
w hich rota tes thro ugh a lim ited arc w it hin it and an O-ring and v . sear
to seal the valve body in its ho using . and to seal th e valve spindle in the
valve bod y, respect ively. A met al seal cover is fitted to prevent damage
to the v - seer. The assembly is fi n ed into a bored- out housing in the
side of the ceeburertcr, and is oper ated by a lever and a retu rn spring .
The valve body has a hole drilled th ro ugh its w all which is linked,
vi a th e annular space in th e housing bore, w ith a fuel supply passage.
A n air bleed hole breaks Into this passage abov e the fue l level
(controll ed by float).
The spind le is holl ow. and is linked to th e passage w hic h term inates
in the cerburettor m ix ing Chamber at the back of the br idge. A hole in
the wall of the spindle corresponds with that in the valve body w hen
the spind le is in a certain position. At each side of the ho le is a tape ring .
mach ined groove. Th e varying depth of this gro ove gives a progress ive
thr ott ling effect as the spindle is turn ed to different pos it io ns.
On manua l choke versions , the cold start device is ope rated by
cab le, and increased engi ne speed is obta ined by a fast id le cam, wh ich
part ially opens the throttle valv e. On th e later electronic ty pe
carbur en c -s. the col d start device is opera ted electrically by a stepper
motor, in con junction w ith a computerised con trol unit.
On some twin carbu ren or eng ines. th e previou sly - described cold
9
6
3 4
7
8
Bi -meta/fic assembly
fetaining SCfew
Float pivot SCfew
Fvel inlet
Needle valve
z
jjj
4
"
Fig . 8 .3 Co l d start en r ic hm ent dev ice ( S ec 5 )
1
2
3
4
5
6
7
End sedl cover
End sui
Starter valve body
a ·ring
Valv" spindle
Fuel svpply
Air bleed
8
9
Fuel delivery to j et bridg e
Comm encement of
enrichment
10 Maximum enrichment
11 Enrichm ent out let
12 Fuel flo w throvgh valve
20-2
Part 4 SU carburetors Chapter 20
start device is not fined to either carburettor, but a separate device
,
I
1Il!IY'~
,
supplies a rich mixture eutometicenv dur ing the engine starting and
warm- up period .
6
~,
Piston a nd need le
8
The spt'ing-loaded needle assembly is secured in the piston by the
needle lock ing screw . A flanged collar at th e lOP of the need le bears
against a protrusion on th e needle guide. wh ic h tilts it under t he action
of the s pring . Th e need le is thu s biased towards a parti c ular position in
the jet either tcew erds Of backw ards dependi ng upo n design 01needle
guid e (location of prol rusion ) . An erched alignment mali; on th e
undersid e of the needle guide ensu res correct assembly. The mark must
be between t he transfer holes.
7
"
"" "
Opera ti o n
Cold starting
W ith the choke control ( on th e car's instru ment panel) pulled fully
out, the cold start valve is rOtated to its fully open posit io n. w hen th e
hol e in the inner spindl e align s w ith the hole in the valve bod y.
provid ing a mall imum free area for fu el flow . The fuel level in the feed
passeqe is below th e air bleed. and t here is no fl ow of fuel until a
depression is generated in th e m illing chamber of the carburettc r.
-
Fig . 8 .4 Pist o n and needle compon ent s ( Sec 6)
,
2
3
4
Piston rod
Transfer holes
Jet needls
N ee dle spong
5
6
7
8
Needle g uide
Locking screw
Nee dle biased in jet
Etch -mar*
Fig . 8. 5 D iagram of HIF ca rbu retto r operati on ( Sec 7 )
1
2
3
4
Damper and oil rsservoir
Atmosphere pressure POrt
Needle end jet
Bi-metal jet le ver
5
6
7
Piston
Vacuum transfer holes
Midure enrichment port
8 Throttle valve
9 B yp ass idle port
10 Flo Bl
A Atmospheric pressure
B Continuous depression
C Manifold depression
20-3
Part 4 SU carburetors Chapter 20
W hen t he depression Is gen enrted by t urni ng over the eng ine (on
the starter meter). fu el is drawn up o ut of the feed passage. and mixes
w ith air drawn through the air bleed to form an emulsion in the ann ulus
surrounding the valve ecev. The mixt ure fl ows throug h the port in the
valve bod y. throu gh th e co rrespo ndi ng ho le in the inner spind le.
through the hollow spin dle. and is discharged in to the mixing chamber
of the cerberertce.
Gradual return of the choke co ntrol to its fu lly home posit ion results
in a eorrespond ing progressive reduct ion in rich- mi xtu re Quantity
delivered. As the main air valve ( piston) w ill also have ope ned when
the e ng ine tired . the net mixt ure str ength w ill a lso weaken.
On electronic type cil rburettors (denoted ev an T suffix ) . the col d
start device is operated electrically by a stepper motor. A co mpu te rised
co ntr ol unit ( ECU - electronic control unit) receives sig nals from t he
eng ine coolant thermistor. air tempera tur e senso r. accelerator pedal
and ig nition con. and from this information comput es the corr ect choke
pos ition. Using electrical impulses. the stepper motor is moved t o its
co rrect position w ithin a 12 0· arc. the first 40" opera ting the fast idl e
cam only. Th e system also incorporates a vac uum valve to furtl"ler
enrich th e mixture on eccelecauc n during eng ine w arm-up.
On some twin cerburenoe installati ons. as FASD ( ful ly auto matic
start ing dev ice) is attached to the sid e of one of the carburenors. and
draws its fuel from the cerburettor float cham ber. A ir is supplied t o th e
top of the unit from the air Clean er mounted on t he carburettors. A
start er jet w ith tapered mete ring need le supplies the fu el. A
sprin g- loaded a;r valv e is located in th e air inlet. and rna.,. be opened by
man ifold vacuum through a delay valve . The bi·metall ic vacuum delay
valve is fi ned between the FASD and carbu rettor. It prevents the air
valve open ,ng during eng ine crank ing . and so provi des a rich mixture
fo r starting . When the eng ine starts. a com puterised co ntr ol module
supplies Current t o the vacu um del ay valve. w hich then opens the air
valve to supply suffic ienl air for the eng ine to run .
The air/ fuel mixture through the FA SD is controlled by the shut-off
valve and starter jet, al"ld since the valve is connected di rectl y to the
tapered mete ring needle. th e mi xture volume may be prog ressively
reduced by moving the two components downwards. The valve
move ment is con troll ed by a wax capsule in con tact w ith the engine
coo lant, and in addition. th e vacuum on the eng ine sid e of the FASO
helps t o close t he valve. Whe n norma l eng ine tempera t ure is reached .
the shut- of! valv e wi ll have complete ly shut. and norma l air / fuel
mi xt ure will be supp lied by th e twin carburettors al one.
An alternative to the FASD is the A SU (aut orneuc starting un it ).
whic h is also fined to one cerbu rett or of a twin carb urettor installati on.
Th is uni t fu nctio ns in a sim ilar manner to the AE D [ automatic
enr ic hmen l device ) described in Chapter 9. except th at it is attached to
the bo ttom of the carb urertcr instead of be ing separate with it s own
fuel supply.
FuJI throttle
With the eng ine at normal runnin g t emperature and the cold start
valve (w here f ,tt ed) out of act ion . the carhurettcr w ill funct ion as a
no rmal H· Type unit mixt ure Quantity and strengt h delivered being
dependent upon the interacti on of th e th rottle opening, the man ifold
depression an d the fu el needl e jet relati onshi p.
A cceler8tio n
Tempor ary enrichment for accelerat ion is pro vi ded by the resistance
to upward movement of th e pist on, caused by the hy draul ic damper. It
is sing le-acting , and has no eff ect on downward movement allowi ng
th e p,st on to respo nd immedia tely duri ng dece leration.
Overrun
An overrun COndit io n occurs wh en the vehicle is 'driv ing th e
englOe', lor example. when descen ding a hill w ith the throttle closed.
In this condition, ~ry high manifold depress ion is produced. w hich is
not con ducive to efficient 'clean' com bustion. The maximum depression is gove med on some versions by the operat ion of a spri ng- loaded
pla te velve in th e throttle d isc. wh ich opens at a predet ermin ed value to
admn air into Ih e mi xing chamber. and thus li mit the depressio n.
Idling
Wh en idl ing . the mixture is conducted throu gh a small bo re
passagew ay belo w the 'fl oor" of the main choke bore , to emerge at a
poi nt adjacent to t he bott om edge of th e t hronle plate. where a cut - out
...
6
\
4.
eee
(') 0
0
Fig . 8.6 Diagram o f typi c al e lectronic tY pe H IF ce rburett o r ( Se c 7 )
7
2
3
4
Carbvre tror
Fvel Shift -off valve
M TJt1vre control stepper
motor
Vacvvm switch
5
6
7
Electronic control vnit
Igniti on coil
Ambient air temperatvre
sensor
8
9
High engine tempefiltvre
wern ing lamp
Engine temperatvre ga vge
10 A ccelerator p edal switch
11 Coolant temperatvre
th ennistor
20-4
IJ-lJ=TY-7
1
2
5
8
H ,12842
Fig. 8 .7 Cross -sec t ion o f t he FASD ( Sec 7 )
1
Vacuum controlled air valve
2
Shut- off vafve
3
4
Start er jet
Tape/ad m etering needl,
5
Vacuum delay valve
6
Bi· m elallic strip
7
8
Needle carrier
vecuom.ooeatea
acc elerator pump
Fig . 8 .8 BVp ass idle system ( Sec 7 )
-/-----(3
Outlet st throttle valve
3
Cold start enriChmen t outlet
4
Jet br idg e
Slot in piston
20-5
Part 4 SU carburetors Chapt er 20
is formed. This results in the mixture velocttv being considerably higher
than if it were ind uced normally, due to the much smaller cross sectional area, wit h more complete atom ization of the mixture,
particul arly at the local hig h depression at the thrott le plate cut-out.
may be fitted . This screws into the float chamber, and should be
removed periodically for cleaning.
9
Disassembly
Fuel temperat ure variation
At all phases of c peraton described above, the precise m ixture ratio
is a lso s u bject to th e heigh t of th e ma in jet, wh ich is controlled by the
fu el temperat ure compensator. W ith increasing fuel temperature the jet
is raised, and with decreasing temperature it is low ered. Thus the
var iati on in fu e l flow whi ch w o uld no rmally ensue as a result of the
c hange of v iscosity is compensated for by an inverse and proport ional
cha nge of annular fuel fl ow area, and the actua l flow is mainta ined at a
con stant value.
8
Specia l overhau l p roc ed u r es
Refer to Chapter 4.
2 Service and repair kits are gene rally availab le under SU part
num bers, accor ding to vehicle model. One gasket pack is available for
all HIF oa rburettors, under the part number A UE 82 1S. The'S' suffix
ind icates th at thr ottl e plate screws 'are incl uded.
3 The t hrottle dia meters app licab le to the carbu rettor models are as
foll ows:
Carburettor
model
HIF4
HIF6
HIF7
HIF38
HlF 44
Throttle
diameter
1 1/2"
13/4"
1 7/8"
38.0 mm (1 .50 in )
44 .0 mm (1.73 in )
4 On some HI F carburettors . and in part icular on the HI F38 fitt ed to
some Aus tin M etro 1.0 H LE models, a carburettor vent filter assembly
Thoroughly clean the exter ior of the cerburertor .
2 On electronic type cerbu rettcrs, remove the vacuum sw itch by
leverin g it from t he moun t ing bracket. Remove the sealing washer from
the short stub pipe ( photos) .
3 On electronic type carburettors. unscrew the three retaini ng screws
and remove the fuel shut-off valve and soleno id assembly ( photos) .
Recover t he gasket.
4 Unscrew the damper rod from the suction chambe r (photo). On
Turbo versions, first unscrew t he securing clamp. On some versions it
w ill be necessary to pull the gu ide clip fr om the top of the piston rod
( Fig. 8.11 ). Drain the oil from the piston rod. If necessary. the valve
may be removed fro m the damper rod after extract ing the spr ing clip
(ph oto).
5 Unscrew th e three retaining screws and raise the suction chamber.
At the same time. lift the piston and w ithdraw the assembly from the
carburett or bod y, tak ing care no t to damage the meteri ng needle
(photos).
6 On the ball -bear ing ty pe suct ion chamber. push up the pisto n, then
extract the c irclip from the top of the piston rod (p h oto) .
7 W it hdraw th e piston and spring from the suction chamber ( photo) .
8 Unsc rew the need le gu ide lock ing screw and w ithdraw the need le,
guide and spring from the pi ston ( photos) .
9 If necessary. remove the screw and piston guide from the
carbure rtcr body (photo) .
10 W here applicable, remove the FASD from the side of the
carburettor, w ith reference to Sect ion 13.
11 W here applicable, remove the AS U from t he bottom of the
ca rbu retto r. with reference to Section 11.
12 Except on ASU versions, mark the relations hip of the float chamber
4
9 .2A Using a screwdriver to prise the
vacuum sw itch.
9.28 ... from the mou nting bracke t
9.3A Extract the screws.
9.3 8 ... and remove the fue l shut-off valve
and solenoi d assemb ly (gasket arrowed )
9.4A Removing th e damper rod
9.48 Dismantled damper rod valve
20-6
Part 4 SU carbureto rs Chapter 20
cover to the carb uretto r bod y. Unscre w the four retain ing screws and
lift off the cover, then remove the O-ring seal ( photos).
13 Unscrew the jet adjust ing leve r retain ing sc rew and w ithd raw the
jet and adjusting lever assembly. Disengage th e j et from th e lever
( ph ot os).
14 W here an FASD is fitted, t um the pick-u p elbo w awa y from the
fl oat ( ph oto).
' 5 Unscrew th e floa t pivot screw and lih out th e fl oat ( photos).
Discard the screw seal.
16 Remove the float needle, th en unscrew the need le valve seal from
the base of the carb urettcr. Wh ere applicable. separate th e fi lter from
the seat ( ph oto s) .
17 Unscrew the j et bearin g locking nut and w ithdraw th e jet bearing.
Recover th e was her {ph ot os) .
18 Remove the circlip from the low er end of the piston lifting pin.
recover the spr ing and wi thdraw the pin.
19 Note t he locati on of th e thr ottle return spring and levers, Unscrew
the nu t after bend ing up the tabs, and remove the w ashers. levers and
return spring ( phot os).
20 Note wh ich way round the throttle disc is fitted , then carefully
unscrew the retaining screws . Slide t he disc from the slot in the spindle
(ph oto) .
21 Remove t he thrott le spind le and the spindle seals (ph otos) .
22 Thi s com pletes th e d ismantli ng proced ure on all but manual choke
versions. On th e electron ic t yp e carburett or. do not atte mpt to remove
th e mixtu re con tro l steppe r moto r as it is set dur ing manuf acture. and
may not operate cor rectly if d istur bed. Note also t hat the steppe r mot or
is a low-voltage un it. and mu st not be con nected to a 12 -v olt supply. It
is not possib le to obtain a new stepper motor, so if it is proved faulty,
the comp lete carburettor must be renewe d.
23 On manual choke carburertcrs , note ho w th e spring is attac hed to
the fast idl e cam lever ( photo ). Bend back the locktebs, th en unscrew
the nut and remove th e w asher.
24 Ho ld th e ret urn spring against th e main bod y. and use a
screw driver to prise the cam lever from th e end of th e co ld start spi ndle.
Remove th e spring ,
25 Remove th e end cover and sp indle seat.
26 Remove th e two screws and w ithdraw th e retain ing plat e, co ld
9.5A Extract the screws .
9.58 ... and wi thdraw the suctio n chamb er
and p isto n assembly
9.6 Removin g th e clrcuc from th e top of
th e pi ston rod on th e ball -bearing type
suct ion cham ber
9.7 Separating th e pi ston and sprin g from
the suct io n c hamber
9.8A Un screw the needl e gui de lock ing
screw {arrowed } .
9.8B ... and withdraw th e needle. gu ide and
spring
9,9 Pisto n gu ide (arrow ed)
9.12A Remov ing th e fl oat chamber cove'
screws
IYV\f\l\f\ 1\AI
UIIIV VVU
===b
=
#
--~C .
••
9.8C Piston and suctio n chamber
components
9.12 8 O- ring seal (arrow ed) on the ftl;)at
chamber cover
9.13A Remove the screw and sprin g •••
9.138 ... and w ithdraw the jet and
adjusting lever assembly
9.13C J et seoereted from the adjusting
lever
9.14 Pick-up elbow (arrowed ) fin ed to an
FASD-eq uipped carbur ettor
9.15A Unscrew the float pivot screw ...
- .,.
9.158 ... and litt out the float
9.16A Remov ing the float needle
9.16 8 Removin g th e needle valve seat
9.16C Needle valve seat and ftOilt needle
9.17A J et bearing and lock ing nut locati on.
Note inner tip of m ixt ure adjustm ent screw
( arrow ed)
9.17 8 Remov ing t he jet bearing and
locking nut
4
9.17C Locking nut separated from jet bearing
9.19A Thrott le return spring (arrowed)
9.19 6 Throttle lever components
9 ,20 Thrott le disc removal
--""""~
•
9.21 B Throttl e spind le and seal (arrowed)
•
.-J.
20-9
---t
" - 8'
23-
25-----
.
:~--1
,
5-
-
"
- - .....,. ~ -
39
38
ij
7
I
" "'I I
","
,I I
I
$ I I @~
t)~~~
'------'i
.,
(
..
"
46
_
4
Fig . 8 .9 Explo d ed v iew of manual choke HI F cerburert c r fo r t win ca rbu rettcr installation ( Sec 9 )
t
Jet bearing wa sher
' 5 Float n eedle
30 Needle guide
2
Jet bearing
16 Flo at
3 1 Piston spring
3
Jet bearing nut
Jet Bssembl y
Lif ting pin
Lifting pin spring
Circ/ip
77 Float pivot
4
5
6
7
32 Needle retaining screw
33 Needle spring
8
A dj usting screw Jell l
9 Jet ad;usting screw
10 S i· metallic je /lever
11 J et spring
12 Jet retaining screw
13 NHdla se, t WISher (if
required)
14 Float needle
18 Pivot seal
19 Float chamber covet seal
20
21
22
23
24
25
26
27
28
29
Float cham ber covel
S pring washer
Cover screw
Piston damper
Damper washer
S uction chamber
Chamber screw
Iden lfly tag
Piston
J et n eedle
34 Throttle sp indle seil{
35
36
37
38
39
40
41
42
Throttle disc screws
Throttle sp indle
Throttle disc
Throttle sp indle seal
Throttle ac tuating le ver
Fut idle screw and nut
Throttle lever
Throttle adju sting screw ilnd
nu'
43 Tab washer
44 Ret aining nut
45 Throttle spring
46 Bod y
4 7 Cold stert seal
48 Cold start sp indle
49 O-ring
50 Cold stsn body
5 1 S p indle seal
52 End cover
53 Retaining plate
54 Cold start spring
55 R etaining screw
56 Fast idl e cam
57 Tab w asher
58 Retaining nut
20-10
, _. ~
I -
3
'- ·- 1
4
I
I
'
,_ I I~~
~9
D
'_I!
~
7
8
i
If
I-
Slt--{5
~
r:
I
- -'
O
®
,
~~i""",,'--
5l
i
11
I
37
Fig . 8 .1 0 Exp loded v iew o f e le ctron ic t ype HI F car b urettor (S e c 9)
1 Piston damper
2 Ci,cfip
3 Suction chamber
4 Pi ston
5 Pisto n spring
6 Locking screw
7 N eedle bias spring
8 Me tering n eedle
9 Needle guide
10 Throttle adju sting screw
11
12
13
14
15
16
G-ring
Mixture adjusting screw
Fuel shut-off valve housing
Fue! sh ut -oft valve solenoid
Throttle return spring
Throttle spindle seal
17 Throttle disc
18 Throttle spindle
19 Cerburettor body
20 Vacuum tub es
21
22
23
24
25
26
27
28
29
30
Bracket
Vacuum switch
Mixtur e control st epper
Stepper motor O-rings
J et bearing
J et bearing nut
Jet assembly
Needle valve seal
Needle
Bi-metal Jet lever
31
32
33
34
35
36
37
Fl oat
J et retaining screw
O -ring
Float chamber co ver
Throttle return spring
Lost motion link
Throttle fev er adjustment
screw
38 Throttle fever
39 Fast idle adJustment screw
20-11
Part 4 SU carburetors Chapter 20
H.1U 40
Fi g . 8.11 Pi ston damper g u id e c lip position ( Sec 9 )
start body, and gasket ( pho t os).
27 Remo ve the O·riny fro m the end of th e cold start spind le, and
w ithdraw the spindle from th e mai n body. Remove the col d start seal
( photo) .
28 For instructions on cleaning . inspe<:tion and repa ir, refer to
Chapte r 4.
9.23 Fast idl e cam
->
9.26A Remove the screws ( arrow ed) ...
9.26 B ... and withdraw the col d start body
assembl y
9.27 Dismantled cold start assembly
10 Assembl y
M anual choke cerborettors
4
1 On manu al choke cartcrencrs. tcce re the col d start seal in the main
bod y w it h the cut -out uppermost.
2 Insert the col d start spind le with its hole uppermost. then fit the
new O -ring.
3 Fit the cold start body w ith t he cu t -o ct uppermost followed by the
retain ing plate with the slotted flange facing the thr on le spindle
location. Use a new gasket, then insert and tig hten th e retain ing
screws.
4 Fit the spin dle seat and end cove r, fo llowi ng by the spring, cam
Fever, loc kwas her and nut. Ma ke sure that the spring is cor rectly
engaged, the n tighten th e nut and bend over the Iocktabs to lock.
All carburett ors
5 On all carbu rett or types. fit t he seal t o the throttl e spi nd le. then
lig htly oil th e spindle and insert it into the main bod y. Press th e outer
seal into th e recess in th e main body.
6 Slide th e thrott le d isc into the spindle slot in its previously -noted
pos it ion ( pho l o ) . Close th e th rott le and insert the screws . hOWllVlIf do
not ti g hten the screws at this stage.
7 Fit the throttle return spring. Ievl:mi and w ashers in t heir
Pfeviously·noted pcsuons. and tig hten the nut . Bend the tabs oYllf th e
nut to lock it. Make sure th at the return spring is correctly located .
8 Slightly open the throttl e. and allow it to snap shut several times in
order t o cenneuse the disc. Also move the spind le laterally, t o
10 .6 Inserting th e t hrottle d isc
20-12
Part 4 SU carburetors Chapter 20
10.14 Checki ng the float lev el dimensio n
determi ne its central posit io n. Fit new thr ottle disc screw s and tighten
them , t hen open the th rott le and spread the screw ends sufficientl y to
lock the m.
9 Inse rt th e piston lih ing pin in the main bo dy. locate th e sp ring, a nd
fit the cim' ;p.
10 l ocate the wash er on the jet bearing , in sert t he bearing in the main
body, and secure by tig htening t he loc king nut
'1 Fit the filt er 10 the needle valve seat. Insert and tighten th e needle
valve seal in the bas e of the cerburettor. locate t he float needle in the
seat.
12 Locate t he fl oat in t he carburertor; then fit a new seal to t he pi vot
sc rew, and insert an d tig hten th e sc rew .
13 wnere fitted . turn th e FASD pick -u p elbo w towards too float.
14 With the cerbu rerto r inverted, allo w t he troet to close the needle
valv e under its ow n w eight. M eaure the di stance from the centre of the
ucet to the face of th e main body, as shown in Fig. 8_12. The distance
shoul d be 0 .04 0 to 0.060 in (1 02 to 1.52 mm) . A steel ru le and vern ier
cali pers may be used to check the d istance (p hoto) . No te that it wi ll be
necessary to reco rd th e width of the rul e and ded uct th is from the
overall d istance. If adju stment is necessary, carefully bend the brass
co ntact arm on t he float as required.
15 Engage the jet w it h the cut -cut in th e adjusting lever, ensuring t hat
the jet head moves freely Position the jet in the jet bearing and , at the
same time, engage the slot in the adjust ing lever with the protr ud ing ti p
of the mixture adj ustment screw. Secure the assembly with the
retai ni ng screw and spring.
16 Except on ASU ver1Iions, frt a new O-ring seal to the float chamber
cover. Fit the cover with th e previo usly · made marks aligned, and
secure w it h the four retain ing screws.
17 Where applicable. refit the A SU to the bottom of the cerburencr.
w ith reference to Section 11.
18 Where appli cable. relit th e FASD to the side of t he ca rb urettor; w ith
reference to Sect ion 13.
19 Refit the pisto n guide , and secure w it h the screw .
20 Refit th e piston needle, spring and gu ide to th e piston , ensurin g
that the guide is fl ush w ith the underside of the piston , and the guide
slot alig ned w ith the locking screw location. Wh ere appl icab le. t he
triangu lar etch- mark on the gu ide should be between the two vacuum
transfer holes in the piston . Refit and t ighten th e lock ing screw.
2 1 Temporar ily refit the piston and suctio n chamber to t he carb urettor
bod y w ithout the spring. Engage the piston in its guide . and. w ith th e
suct ion chamber in its co rrect posit ion relative to th e retain ing screws,
marl<. the piston-to-suction chamber relatio nship w ith a penci l.
Remove the piston and suction chamber.
22 Fit the spring to the piston, aiign the previo usly-ma de marks, and
slide th e sucti on chamber over th e pi ston and spring. Avoid t urni ng th e
piston in the suction ch amber, oth erw ise the spring will be wo und up.
23 On the ball -bearing type sucti o n chamber, push t he piston up and
refit t he circnp to t he piston rod.
24 Refit th e piston and suction chamber assembly, tak ing care no t to
damage the metering needle. Insert and tigh ten the three retaining
screw s.
25 Assemble the valve to the damper"rod , and fi t the spring cli p.
26 Fill the pisto n rod With o il. On standard suction chambers (i e
without a damper rod guide clip , or upper circli p on the piston rod ). the
level must be 0. 5 in (13 mm) abo ve the top of th e hollow pisto n rod.
On ball -bearing suct io n c hambers w it h a dam per rod guide clip, the
level should be at the bottom of the guid e clip. On ball -bearing suction
chambers w ith a circ lip on the top of the piston rod, th e level should be
0.2 5 in (6,5 mm) below th e top of th e hol low piston rod ,
27 Insert and tighten the damper rod and, w here applicable, press th e
guide cl ip tntc th e top of the piston rod at th e same time. On Turbo
version s. ref it and ti ghten the damper securing clamp.
28 On the electronic type cerburetror, fit the fuel shu t -ott valve and
solenoid assembly. together with a new gasket Insert and tigh ten th e
three retain in g screws .
29 On the electronic ty pe carburettor . fi t the sealing washer to the
short stub pipe on the vacuum sw itch . Press the sw itch into position
on the mounting bracket .
11 Automatic st art in g unit (ASU - twin carbu r ettors) testi n g , rem ov al . overhau l and r efitting
Tesc;ng
1 Should it be suspected that th e ASU is not operating correctly,
carry out the following test
2 Remove the air cleaner, and check thaI the A SU outlet hose is
A
/
H.12841
Fig . 8.12 Check ing the float le vel d i m ens io n ( Sec 10 )
A .. 0,040 to 0.060 in (1 .02 to 1,52 mm )
Fig. 8.1 3 Pi st o n damper oil l evel ( Sec 10 )
A
Stenderd suction chamber
8
8 al/ h earing suction chamber
20-13
Part 4 SU carburetors Chapte r 20
secure and that the fu el level in the carburenor with the ASU ettecbed
is correct.
3
Remove the A SU air filler and intake hose aft er loosening th e tw o
clips.
4
Wit h the eng ine cold . start t he engi ne for five seconds. th en sw itch
off.
5 Disconnect the outl et hose and chec k that th e A SU cc uet port is
mciet w ith fuel. If not. refit the out let hose. partially block the inlet POrt.
and start t he engine for a fu rther fiv e seconds on ly.
6 Disconnect th e outlet hose and check again th at the A5 U cutter
port is mo ist with fue l. If it is now. th e intern al thermostatic un it is
proved faulty. and th e ASU shou ld be replaced .
7 Run th e engine to normal operat ing tem peratu re. then check t hat
the ASU inl et pon is cl osed. using a strip of paper to detect any suct io n
thro ug h th e po rt. If it is open, the unit is faulty.
8 Refit t he intake hose and special air filte r, and ti ght en the two cuc e.
9 A further test may be made if diffic ult hot start ing is experie nced.
W ith th e engine hot. remov e the ou tl et hose and bl ank off the po rt in
the in let man ifold . If the eng ine now starts better, th e ASU is proved
defect ive. Check that t he outlet hose is fir mly secured . and is not
deteriorated .
Rem oval
10 First remove the carburettcr with the ASU attached . On some
models. it may be po ssible to remove the A SU w it hout removin g the
carbu rett or, alt hough this is not reco mmended .
11 Loosen t he clips and d isco nnect the in let and outlet ho ses. if not
already removed .
12 Remove the sere..... securing the AS U to th e upper support bracke t
( phot o).
13 Extra ct the screws w hich ho ld the spacer plate and AS U adapt or
plate to th e caeburettce ( photo). Remove the ASU from the carburettce.
14 Remove the upper a·ring . spacer plate . and lower D-ring
(photos) .
Overhaul
1 5 Pull the plastic cov er from t he top of the ASU (ph oto)
16 Remove the screws. and lift ttl e A SU from ttle adaptor plate
( phot o) .
17 Remove the diaphrag m. location dow el. spring, and plu nger from
the top of the adaptor plat e ( phot os).
18 Turn the adap tor plate over. and remove the bott om co ver.
di aphrag m, and locati on dow el ( pho t os) .
19 Remove the c lamp screw and c lamp. the n pull out the air in let stub
and remove t he O- ring (p hot os) .
20 Remove th e screw s. and separate the cov er from the valve body
( phot o). The bi-metal urut 1000ding spring w ill probably remain in the
top cover .
21 Remove th e gask et. N ote ho w I he bi -m etal unit is loca ted , then lift
it from the cut -outs in the valv e body (phot o).
22 Prise out th e O-r ing from the top of th e f uel metering needle
assembl y ( ph ot o) .
23 Remove t he screw s, and lift the valve body fro m th e AS U body
( phot o).
24 Remove the gasket. Note the location of th e air val ve. then remo ve
it from the ASU body ( phot o) .
25 Thoroughly clean all the components. and examine th em for w ear
and damage. C heck the diaphragms for splits and pin hol es. Blow cl ear
all internal drillings using low air pressure.
26 Commence reassembly by locating the air valv e in the AS U body.
Wi t h the sprin g co rrectly pos it ioned. c heck that t he valve clos es
properly.
27 Ref it th e valve bod y t og ether w ith a ne..... gasket, th en insert and
ti g hten the screw s.
28 l ocate a new O· ring over th e fuel metering needle assembl y.
29 l ocate a new gasket on the valv e body. and refit the bi- metal unit
in its previously-not ed pos it io n.
30 Chec k th at the bi -metal unit loading sprin g is in the top cover. Refit
th e top cover and tighten the screw s.
31 locate a new O·ring on th e air inlet stu b. Refit th e air inlet stu b.
and secure with the clamp and screw.
32 Press the locat ion dow el in the bottom of the adaptor plate. and
refi t t he diaphragm and bottom cover.
33 W ith the adapt or plate up rig ht, insert the plunge r. and ref it t he
4
11. 12 Remov ing ASU upper support
bracket screw
11 .13 Removing the A SU-t o- carburen or
adaptor plate screws
11 .14A Removing the upper O -ring ...
11.14 6 ... spacer plat e ...
1 ' .14C ... and lower O-ring
11.15 AS U top cov er remo val
11.16 Remov ing the ASU from the adpator
plate
11.17A Remove the diaphragm •..
11.17 B ... spring ...
11.17C ... and plu nger
11.18A Remove the bottom cover ...
11.188 ... d iaphragm, and locati on dow el
11.19A. A ir inlet stub and clamp removal
11.19 B A ir inl et stub O-ring removal
11.20 Valve body cov er remov al
11.21 Bi- metal unit (arrow ed)
11.22 Fuel metering needle D -rin g removal
11.23 Valve bod y securing screws
20-1 5
Part 4 SU carburetors Chapter 20
Adjustment
7 To carry out adjustment . it w ill be necessary t o obtain a means of
determ in ing when airflow through the FASD has eeesee. A circle of
100 gram we ig ht paper 2.64 in (67.1 mm ) in diameter. w it h a centra l
0.5 in (13.0 mm ) di ameter ho le may be used for this purpo se. A means
of accurately measuring the temperature of th e FASO water jacket is
also required. and fo r thi s pur pose, temperat ure-sens it ive adhesive
labels should be ob tai ned.
8 Remove the air cleaner or in let duct from the cerburett c rs.
9 Prise out t he rubber plug fro m th e end of the adj ustment tu be. and
insert a 1.5 mm All en key so that it engag es t he adjuster ( phot o).
10 Wi pe cl ean the wa ter jacket and atta ch a 6S"C (1 50 "F)
temperature-sensitive label as shown in Fig . 8. 14 .
11 Start th e eng ine (cold) and allow it to idle. If the engine w ill no t
start turn the Alle n key two turns cl ockwi se and try again.
12 With th e engine id ling . loca te the pape.- etrtto ..... detector over the
FASO air intake. so met the passage of air ho lds it in place (photo) .
13 As soon as the water jacket tem peratu re reaches 6S"C (1 SO"F). turn
the All en key clockwise slcwlv until the paper airflow detector
from t he air int ake. ind icating that the fl ow of air has ceased. Should
the de tect or fall before 6S"C ( l S0"F) is reached. t urn the All en key
anti -clockw ise on e turn, th en reposit io n t he detect or. The adju stme nt
must be comp leted wi thin 30 seconds of the 6S"C (1S 0"F) temperat ure
being reached, otherwise the engine must be allowed to coo l fo r at
least one ho ur before starting again .
14 Remov e the Alle n key. and refit the rub ber plug. Ref it the air
cleaner or in let duct.
taus
11.2 4 Ai r valv e location (arrowed)
spring. location dowel and diap hragm.
34 Press th e cov er and adaptor pl ate onto the ASU. then insert and
tig ht en the screws .
3S Press the plastic cover o n the t op of the AS U.
Refitting
36 Refitt ing is a reversal of removal, but fit new a - rings either side of
the spacer plat e. M ake sure that the associated air hoses are in go od
cond iti on.
12 Full y aut o m atic starting d evice ( FA SO - t wi n
ca rbu r ettors ) - check ing an d ad justment
Che cking
1 Check that fu el is being delivered to the cerbu rett cr w ith the FASD
attached . by temporarily disconnect ing the feed pipe. and switching
on the ignition for a few second s.
2 If the cooling system has recently been drai ned and refilled. mak e
sure Iha! all air has been pu rged fr om th e coolant . The presence of air
around th e wa x capsul a inside the FASD will redu ce th e movement of
the shut -off valve during th e warm-up period, resulting in an over- rich
mix tur e,
3 To che ck th at the FAS D cut s o ut cor rectly, run the engi ne 10 normal
ope rating t emperatur e. then con nect an exhau st gas analyser to th e
exhaust t ail pipe. Record t he CO perc entage at id le speed. D isco nnect
th e FAS D ou tl et hose at th e inl et manifold . blank off the man ifold
apertu re. and check tha t me CO read ing remains as previously
recorded. or drops very slightly. Th e FA SO is pro ved fau lty if the CO
read ing drops sign ificantly. Of fluctu ates. StOP th e engine. re-connect
th e outlet hose. and d isconnect th e exhaust gas analyser.
4 It is poss ibl e for a fau lt to occur in the FASD control module
(osuenv located beh ind the instrument panel ) or its assoc iated wi ring.
wh ich prevents th e vacuum c erav valve opening. In such a case. the
engine w ill start we ll from cold. an d w ill fu n w ell w hen ho t. but in the
intervenin g pe riod w ill show symptoms of excessive ric hness (eg
lumpiness and bl ack smoke). Thi s con dit ion is conf irmed if battery
volt age is no t present across t he delay valve term inals when the engin e
is run ning ,
5 If start in g is satisfact ory. but the FASD seems t o stay on 100 long.
check that the cool ant is cirCulating frl:lBlv past the wax. caps ule. On
some models. there is a restnctor in the hose between the FASO and
th e rad iator. w hich may become blocked. Furthermore, on some
models ( notably RovBf 2300/26(0 ) it is possibl e for the coolant feed
to be blocked by the fi tti ng of an inc orrect (early paner n) inlet
manifold gasket.
6 Reluct ance t o start and run when cold may be d ue to fuel
starvation. Remov e the FASD adaptor (acc essible afte r removi ng th e
float chamb er cover on th e cerburet t or}. and Check that th e non -return
valve ball is not d islod ged.
12 .9 1.S mm Al len key in serted in Ih e FASO
Fig . 8 .14 Adj usting t h e FA SO ( S ec 12)
1
2
3
Rubber plug
Affen key
Paper sh ut -off indicator
4
5
Temperature indicator
Control module
4
20-16
Part 4 SU carburetors Chapter 20
3 Drain the cooling system. th en loosen the clips and d isconnect the
coolant hoses fro m t he FASD water jacket ( pl'\oto) . Alternatively. fit
hose clamps to the hoses before disconnecting them.
4 On some models it may be possib le to remove th e FA-SO leaving
the ce rbu rertor in posi tio n. Ot herwise, discon nect the fuet hose.
vacuu m 1'1 0 $0(5) , accelerator cab le and linkage, then unscrew the
mounting nuts and remove th e carc uren or from th e inlet manifold.
5 Unscrew th e throug h-boit s and w it hdraw the FA$ D from the
cerburettc r ( phot os). Be prepared for fue l spilla ge.
6 Remove th e delay valve from t he carburettor. Peel th e gaskets from
the cerburertoe and del ay valve (photos).
Overhaul
ea r bu r en ors ) - remov al. o v er haul and r efittin g
7 Clean th e external surfaces of the FASD .
8 Extract th e screw s. and remov e the cover from t he accelerator
pum p d iaphragm (photo) .
9 Remove the d iaphragm. and lift the spring from the plastic
gu id e/valve (pnoros].
10 Release th e plastic guidelvalve from the spring clip and remov e it
(photos).
11 Clean and examine the parts for wear and damage ( photos) . Check
th e d iaphragm for pin holes or splits. Renew th e parts as necessary.
Note that it is not possible to remove the air inle t cover, as it is rivetted
in positio n.
12 Commence reassembly by engag ing the plasti c g uide lvalv e w ith
the spring cli p.
13 Insert the spring through the plastic gui de/v alve, then fit the
diaphragm w ith t he square tab align ed w ith th e vacuu m hole in the
main body.
14 Fit the cov er. and hold it down against th e spring tension. mak.i ng
sure the screw holes are align ed _Insert and tig hten the screw s evenly.
Removal
Refitting
1 Unbolt and remove th e air cleaner assembly from th e cerburettcrs.
2 Disconnec t the FA SD air inlet and outlet hoses. and also th e delay
valv e w iring (photo).
15 Refitt ing is a reversal of removal, but clean the mat ing surface s and
fit new gaskets. Ref ill the cooli ng system.
12.12 Locating the paper airflow det ector over the FASe air intake
13 Fu lly au t omatic starting device ( FAS O
1356 ... and w it hdraw the FASD
twi"
13 .3 FASD wa ter jacket
13.SA Remove Ihe thro ugh -bolts ( arrow ed)
13.5C The FASD removed
l3.SA D elay valv e remov al
20 -17
Part 4 SU carburetors Chapter 20
13.6 8 Peel the gasket fr om the car burettor
t 3.6e Delay valve loca tio n face on the
cerburertcr
13.8 Accelerator pum p d iaphragm cover
removal
13.9A Remove the accelerator pump
d iaphragm ...
13.60 Removing the gasket from t he delay
valv e
13.9 B ... and spri ng
4
13.10A Remov ing the plasti c gu ide/ valve
13 .106 Plastic guide/ valve retaini ng spring
14 Tu n in g
Note : Refer to Chapter 3 for no tes on tu ning. w ith particular reference
to p reliminary ptocedut es.
Single cerburettor installations
1 Set the th rott le adjusting screw . Run the engine to w orking
temperature, th en sw itc h of f.
2 Whe re nec essary, remov e th e air cleaner or plenum chamber.
3 Un screw the thr ott le adj usting screw until it is ju st touching its stop
with th e thrott le valv e shut (photo).
4 Where applicable. check t hat the cold start lever is fully c losed
(c old -start device out of acno n ). and that the fast idl e adluStln9 screw
13.11 Acce lerator pum p diaphra gm
components
is w ell clear of th e cam . Failure to observe this may result in the mrcttte
be ing he ld o pen w he n. by ext ernal examination, it ap pea rs cicseo.
5 Turn the throttle adjusting screw 1 1/2 turns cloc kwise to set the
th rottle to its init ial posit ion.
6
Set the jet he ight . Remov e the suc tion cham ber lind piston wi'lh
reference to Section 9.
7
Check. that the needle guide is Hush w ith th e bott om face of the
pi ston .
8 Turn the mix ture adju stment screw until t he top of the jet is flu sh
w ith the top of th e jet gu ide. Now tum the screw 2 turn s clockwise
(photos). If the mixture adjusting screw is cove red by a small blue or
red tamperproof plug . hook this out w ith a smalt screwdriver and
d isca rd it .
20-18 - --
- - --
-
-
- - -- - - - - - - - --
-
-
1
11
8
7
2
f ig . 8.15 Ma nual choke H rF earbu rettor t u ning po ints (Sec 14)
t
Suction chamber
2
3
Mixture adjusting screw
Ffoil f chamber
4
Throttle adjusting screw
5
6
7
fast idl e adjusting screw
Piston lift ing pin
Fuel infet
14.3 Throttle adjusting screw location ( arrowed)
8
Vent rube (alt ernative
positions)
9
Ignition vacuum sdvance
connection
10 Cold start fast idle cam
n
Crankcase ventilation
connection
14.8A MIxture adjusting screw locat ion (arrow ed)
-
20-19
Part 4 SU ca rburetors Chapter 20
14 .86 U pper vi ew of the jet (arrowed)
14.14 Coo lant therm istor w iring plug (arrow ed)
9 Refit th e pist on and suct ion chambe r. tog ether w ith the damper,
with reference to Section 10.
10 Set th e idl e speed and mix ture. Refit the air cl ean er or plenum
chamber. N ote th at where th&$e items co nceal the cerburencr
adjus tment screw s. do not refit there , bu t position them near the
ce rbu rett o r and re-connect the vacuum hoses.
11 Connect a tachometer to th e eng ine. and a CO exhaust gas
analyser to the ex haust ta ilp ipe . If an exhaust gas analyser is not
availab le. it w ill not be possible to adjUStt he mixture sett ing accu rately ,
although a reasonabl e adjustment may be possibl e.
12 Aun the eng ine at a fast idle speed until it reaches its normal
operating temperatu re. Where an electnc cooling fan is fitted , this must
have started and stopped at least once. Continue to run the engi ne for
a futher five minutes before commen ci ng adj ustmen t.
13 Increase th e engine speed to 2500 rpm fo< 30 seconds, and repeat
this at three- minu te intervals d uring th e adj ustment pr~ ure . This is
necessary to cle ar both the inlet man ifo ld and exha ust system .
14 On elect ronic type carbu rettors fitted with a stepper mot or (eg
HI F44 E). disconnect the wiring plug from the coolant t hermistor
(phot o). and jo in the two plug termin als toge ther with a suitable
length of w ire. Th is wi ll ensure that the stepper motor mixture control
remains fu lly off. Turn the thrcttte adju stin g screw to reduce th e idle
speed to 900 rpm.
15 If the cooling fan is running. wait until it stops. then turn the
2
4
7
3
6
--1
r __
B
--j H.2015 5
~==+--'
Fig . 8 .16 Elect r o n ic type H IF c arburettor tuning points (S ec 14 )
1
2
3
Piston damp er oil level
Idle sp eed adjus ting screw
Progressive type throttle
"m
4
5
Throttle fever adjusting
screw
Fast idle adjustin g screw
6
7
8
Fils t idle push rod
Mixtur e adiusting screw
Los t motion adjusting tag
A Lost motion gap
8 Fast idle gap
C Ttno ttte le ver and linkage
20-20
Part 4 SU carburetors Chapter 20
th rott le adjusting screw to g ive the desired idl e speed. On elect-erne
type ca rbu rettoes. it is recommended that the desired idle s peed be
a p proached from 8 higher s peed. because if the speed dro ps more than
100 rpm below the reco mmended speed, t he thrott le j aGki ng system
will be ac tiva ted . II thi s occurs. increase the idle speed on the t t ecme
adju stin g screw, and wa it 2 minutes for cond ition s to stab ilise before
repeating the adjustm ent.
' 6 On e le ctro n ic typ e ca rbu retto rs. switch off the engine a n d chec k
the cl earance between the fast idl e pusbrod and t he adju stment screw
( Fig . 8.16 ) u sing feeler gauges. If necessary. tum the adj ustment screw
to obt ai n a minimum clear ance of 0 .00 5 in (0 .13 mm ). A lso check that
the throne lever lost motion gap is 0 .07 ± 0.01 in ( 1.8 ± 0.25 mm) . If
necessary, turn the adjust ment screw or, on models w ith a thro ttl e cam,
bend t he tag to obtain t he correc t cle arance.
17 With the eog ine idli ng. slowly tum the jet adjusting ( milcture)
screw clock.wise (to enrich) or ant i -clockwise ( IO weaken). until the
fast est idle speed which is consistent w it h even running is obtained
No w slo w ly tu rn the screw ant i -c loc kwi se until th e eng ine speed just
beg ins to drop. If an exhaust gas analyser is bei ng used. adj ust th e
screw to obta in the desired CO percentage reading (t ypically 2 .5 ±
1.0%).
t 8 Reset the id le speed if necessary. then sw itch off th e eng ine.
19 Set the fast id le speed (manual choke carbu rettors). Pull out t he
cho ke con tro l knob un til th e arrow on t he fast id le cam is aligned w ith
the fast idle adlusting screw.
20 Start the eng ine. and check mat the fast id le speed is as des ired
(typically 1100 to 1300 rpm ) . If necessary, turn the fast idle adjusting
screw to obta in the correct speed.
21 Sw itch off the engi ne. and push in the choke co ntrol knob. Make
sure that the m ixture control lever is fully returned. and the choke cab le
cor rectly adjusted .
22 Set the fast id le speed (electronic ty pe cerburertoes ). Remove the
brid gi ng wire fined to the coolant Ihermi sto r w iring plu g in paragraph
14, however leave the plug disconnected.
23 Disco nnect the two w ires fr om th e ambi ent air temperature sensor.
located in th e front of the engi ne compartment. Remove the sensor,
and join the two w ires together using a strip of metal.
24 Start th e engin e. The stepper motor shou ld move the fast idle
push rod to the fast id le position, and the engine should run at the
desired fast idle speed (ty pical ly 950 to 1150 rpm ) . If necessary. turn
the fast idle adj usting screw to obta in th e correct speed .
25 Switch off the eng ine, and check that th e rrummum clearance st ill
exists between the fast idle pushrod and adj ustment screw, as
descr ibed in paragraph 16 .
26 Re-connect the ambient air temper ature sensor and the coolant
thermi stor w iring plug .
27 On all models. refi t the air c leaner or plen um chamber where
appl icable, t hen make a fina l check th at the idle speed and mixture are
co rrect.
28 Remove the tac hometer and exhaust gas analyser.
Multiple carburettor insta llations
29 Set th e jet height. Run the engi ne to w onting te mpe ratu re, then
sw itch off. Make sure that the man ual choke, w here fitted, is fully off .
30 Remove the air cl eaner or plenum c hamber as appl icable.
31 Work ing on each carburettor in tum, remove the suction chamber
and pi ston w ith reference to Section 9, th en tu rn the m ixture
adjustment screw until th e jet is flush with the top of th e jet guide.
Now tu rn the screw 2 tu rns clockwise to set the jet at it s initi al positi on.
If the screw is cov ered by a tamp erproo f plug, hook thi s ou t and
disc ard it. Refit the suction chamber and pisto n, w ith reference to
Sect ion 10.
32 Set the th rottle adju stin g screw s. Slacken th e clamping bolt on the
throttle spi ndle interconnecti on cou pl ing between the cerburett c rs.
33 Unscrew both throttle sto p adJl.lsting screw s un til they are both just
t ouch ing their stops w ith t he th rott les c losed. Turn bot h scews
clockwise 1 1/ 2 tu rns exactly, and tighten the locknuts w hEM"e
applicable. Check that th e fast idle adjustment screw is clear of th e
throttle open ing mech anism .
34 Set the idle speed and milcture. Connect a tachometer to the
eng ine, and a CO exhaust gas analyser to the exhaus t ta ilpipe. If an
exhaust gas analyser is no t avaIlable. it will ne t be poss ible to adjust
the mixture setting accurately. allhough a reasonab le adj ustment may
be poss ible.
35 Re-tighte n the clamping bolt on the thrott le spindle interconnect ion coupl ing , t hen run the eng in e at a fast idl e speed until it regains it s
normal oper ating temperature. Whe re an electric coolin g fan is fitted,
th is must have started and sto pped l
.
1·55
1· 50
1-45
1·35
1-35
' ·3 5
0· 5 5 1'6
O-SO 1'6
0· 50 1'6
0-55
0 ·55
0· 5 5
ro
C BS VB EufOlll'
e ,,.,,
D8 S V8 lJSA
8
5340
,,,
177 3
1573
1766
, sse
45
40
40
40
1125
40 OCOE 70/71
2 30
4-50
1·10
36 DeN F 15
36 DCNF I U I8
3 8 nC NF2 1
3 6DCNF2 4
36 DeNF 33;'34
36 DCNF49·501100
1 28
2 29
I 28
I 28
2 28
2 29
3 -SO
3SO
3 · 50
3 50
4 ·50
3-50
1·55
1-20
'·55
1-6 5
40 DCNF I 3·20, 1312)·2 0(1)
40 DCNF1 9
34 DCNF 53/54/ 55/ 88/ 100
40 DCNF 35/3 6/3 7/38
40 DCNF57f58/5 11/60
40 DCNF 57f58/U/6OIl 50
40 OCNF4 5/46/47/48
40 DCNF64,'65166/87
38 OCOE 59 -60
38 DCOE 59N60,I,
38D COE " OM/ll l,1
38 DCOE 11001111
3
3
4
4
4
4
4
4
6
6
6
6
32
32
29
32
32
32
32
32
30
30
30
30
4 · 50
450
3·50
450
4·50
4·50
450
4·50
4 ·5 0
4 ·50
e .oc
6 .QO
1·2 5
1-2 5
1·20
1-30
1· 30
1· 30
1-3 5
\ ·2 5
1·2 5
1·25
40
44
40
40
2
2
3
3
32
36
32
32
4·50
4-SO
4 ·50
4 ·50
\·2 5
145
1· 25
1 25
0·50
0 -50
"'"
1·1 5
1·1 5
1·20
1·2 5
2 36
4 50
145
0·60
23
24
21
22
21
24
21
24
23
24
23
24
23
24
23
24
23
24
23
24
23
24
23
24
23
24
450
4 · 50
450
4 ·00
350
4 ·50
3-SO
4 ·50
3 · 50
450
3·50
450
3 ·50
4 ·50
350
4 ·50
3 ·50
4- 50
3·50
450
3 ·50
4-SO
450
4-50
350
3·500
120
0· 40
0 -50
0- 55
0 ·50
0-4 5
26
27
26
27
4·50
450
4·50
4 ·50
' MW
1800T1 /SA
1600 Alpinl
18 00 Alpin l
2000 Alpint
CH RYLSER UK
A""""",T'9'I'
,
,
CH RYS LER FRA NCE
l 1 00 S~ H
lHXlTl
110D SpeciIII ..... SUi.I
1100 SI:>itCiaI
ll00SpedoI
4
4
4
4
4
1100 11/1 30 7 5
4
"
.
1294
1294
1294
1294
129 4
DcDE H/I 6
DCOE 84/8 5
DeDE 66/87
a CDE68/8 9
1·1 0
1·10
0·4 51'9
0 · 501' 8
0·5 5 1'8
0·55 1'8
, .ec
1-25
6
2 418
308 GT4 1w~ ..I"
36 5 GTe.
6
8
B
8
8
8
8
12
24 18
1991
291 8
292 6
2926
2926
2926
4390
36 5 GTe '. uSA
12 4 390
400 GT('ulol
12 4823
Dino 20B GT4 '75
0 ln0 308 GT4
Dino 308 GT4 ' 75
308 GlB iGT4 ' 71
308 GT4 U $A
eco cr
FIAT
124 Sport 1600
124 SpOlt /R l lly
Dino Caup6 Spj,,-,
Di na Coup6 Sp ider
12 4823
,
ieoe
4
6
6
199 7
2418
2416
101'13·1 5
IOF 2Q!200!211200
0 CNF12
DCNF22123
,
.",
' '''
'·80
0 ·40
0 ·35
0 ·35
0 ·40
.,
.'"
0· 4 5
''''
0 ·45
0·45
0· 4 5
'''' ",
'"m
,' ''' '"
m
\ · 65
1·8 5
1·8 5
1· 65
1· 75
2·00
o.ec 1'1
2 ·20
2·20
2 -10
2· 10
1· 90
1-90
0 ·601'8 0 -50
0 60 1'6 0 · 50
0 ·80 1'5 0 ·4 5
0 ·6 0F60-4 5
lOOF8 0· 4 5
'·00 1'60·45
0·60 1'8 0 4 5
HlOf8 0· 4 5
0·6 5 FS 0 -3 5
0·651'5 0 -35
0-65 f 5 0 ·3 5
0·6 5 FS 0-3 5
FII
1'9
1'2 4
1'2 4
2·10
'· 90
2 ·20
2 ·2 0
0·80 1'6 0-40
0 -90 f 5 0·40
0·7 5 F5 0· 45
0 ·7 51' 5 0 ·50
1· 15
1'9
1·90
0 ·90 1'5 0-40
'·00
0-7 0
""
""
.'"
""
'"
.'"
2 ·3 0
'· 80
1·00Fl 0· 55
\ ·30
.",
1-3 5
1·3 5
FER RARI
Dino 2 48 GT
Dino 2 46 OT US A
'· 25
1·2 5
0·50
1·20
0·55
1·20
0,45
1-80
0 45
1·60
0·50
1-50
1·50
0 5-0
0 ·55
1·70
0-55
1-60
0-60 1'6
0· 55 1'9
0· 45 1'24 '1 -55
0· 4 5 1'2 3 1·2 5
0 ·55
."
'"
'"
'"'" '·00
'" 'a.oo00
."
'"
'"'" ' '''
'"'"
'"
2 -20
2 ·2 0
0·40
0· 70 1" 00 -40
0801'1 0 ·40
0·80 1'1 0 -40
0·llOF4 0·40
0701"00·40
~
D·'"
, .ec
,.eo
''''
'''''
·00
~
~
~
r-eo
r-sc
--
0· 40
1· 75
' .7 5
1·75
' .7 5
'· 75
1· 75
0 ·40
0-40
0· 40
0 -40
0· 40
0 -40
0·70
0 ·40
1· 75
1· 75
1·75
1·75
1·75
' ·7 8
1·75
' ·7 5
"'"
~
-
~
~
~
r.sc
, .eo
', .sc'''
D·"
0 80
0 ·40
040
1· 75
1·7 5
1.75
1,75
0 ·3 5
\ · 75
FIAT - AS A RTH
44 10 F 20. 2 1/200
12 4 Spo rl/ lh llV
FORD
Angll.
4
Escort LlG L
4
Escort GT
4
'"
28!.36OC D4 1
""
"'"
32 DGV' 6 8
28.'30 OGV14A
32 DGV16C/un
Escort GT
4
Esco rt GT SlIO'l
4
Esco rt GT
4
1599
32 DGAV5C
Esco rt GT
4
1599
32 DGAV6C
Escort GT
4
1599
32 DGAV 50
escort GT
4
1599
32 DGAV 60
E. con: GT
4
1599
32 OGAV 5E
""
32 OGAV6E
\ 298
32 DFE2
'29 8
32DGV7A
Cortina Specia l GT
1298
32 OGV15C
, "00
28 /3 6 DCD23
4
28/3 6 DCD 36
1500
r.ac
1-15
1·05
roe
'· 15
r.oe
1-15
1·2 0
'"
'· 20
1·15
1-15
1·20
1 20
1· 15
1· 15
1·20
1·20
' · 15
1-15
1·20
1-20
1· 20
1-25
t-ao
c.ac
0· 4 5
"'"
0 ·45
0 ·45
0·45
0·4 5
0, 45
0· 4 5
0 ·4 5
0· 45
0 ·4 5
0 ·45
0· 4 5
0· 4 5
0· 4 5
0· 4 5
0 50
0· 4 5
0 55
.'"
, .ec
0 -10
i.sc
,. ",
' '''
,.",
1-65
t-eo
\·85
''''
1·6 5
1·50
1· 95
1· 50
1· 95
' '''5
1·8
."
."
..'"
""
.."
'"
"'"
D·'" ' ·00
1·10
1· 70
1·70
r.so
, .ec
''''
0·30
0· 50
0-30
0· 4 5
0-30
0 -30
''''
1·20
1· 50
1-20
1·80
1·20
1·60 .
1·20
0 ·45
0 ·4 5
050
' 00
' ·00
' ·00
, .cc
0-3 0
'00
0 ·3 0
2, 0 0
0 ·30
' ·00
0· 30
a-co
'" ''''
' ·00
,.,><)
1· ' 0
''· '''
20
''''
1·20
''''
1·
85
0 -45
0·45
0-10
''''
r.ec
0·5 5
' ·00
.'"
'''' .'"
' ''' .'"
"
r.se "
"'"
1· 65
'''' "'"
0- 70
0·55
'·00
070
0, 70
0 -70
1· 55
1-40
1· 55
'"sse
'"
""
''''
.'"
."
'·00
'1·70
·00
'·00
1'30
1'3 0
F30
1'30
2 ·30
\· 80
2·30
t-ao
"'"
' ·00
2·05 Fl 0 ·70
0· 50
1·15
2 ·0 5 Fl 0 ·7 0
0·60
0·6 5
A1-3
Part 5 Appendix 1
•
A
c
c
28/36 OCO ) 8
CottinI 1600 GTE
..
1 5ge
32 DB,II.
Coh 1BOO
45 D COE 9
2
3245 1·20 FIB
1-80
0· 50
0 ·4 0
0 ·50
343 ·5 1·45 F2
1-8 5
0 -55
05 0
050
225
32 4-5
1-25 F16
1-80
0 ·50
"ss
0 ·40
0·50
' 00
32 5 ·0 1·2 5 F20
1·60
0 50
0 -4 5
0 ·50
'00
0 ·50
0·50
0 ·50
' 00
Oatso n 6 110
40 DCOE2
2 7 4· 5 1·10 F7
1·6 5
Oats unB2 10 f l0
40 DeOE 2.
33 4 -5 1· 30 Fl 1
1·80
OlOtSlIn 5 10
45 DCOE 13
33 4· 5 1-30 F15
90
O.t.un 510
4 0 DCDE 12
32 4·5 1·35 F15
Oat.un6 10
45 CCOE 13
Dats un 61 0
40 DeOE 2
O"ts un 71 0
45 DCOE 13
Oalsun 7 10
400 COE 2
Datsun 240Zand 2802
40 DCOE 16
Oa,.un 52 1 PU (159 5 eel
45 DCDE 13
ss
sa
rs
0·50
se
0 ·6 0
closed
2·00
0-50
0 -50
0· 5 5
2 ·25
1· 70
0· 55
0-40
0· 55
34 3 ·5 1·30 FI B 1· 80
0·50
ciosed
'2 ·25''''
33 4·5 1·50 FI B 2· 00
ra
se
0 ·50
0 ·50
0 ·45
0 ·55
34 3 ·5 1· 30 F16
1·80
0 ·50
0 ·50
closed
'2·25''''
2
33 4 -5 1· 50 F16
2 ·00
0· 50
"
0 ·4 5
0· 55
' ·00
3
30 4 ·5 1·3 0 F2
1·7 5
0 -50
0 ·4 5
0·55
33 4 · 5 1·30 F16
1·90
0 ·50
0 ·5 0
0 ·55
2
ra
rz
se
rs
ra
Oe!>;un 52 1 PU (159 5 eel
40 DCOE 2
DalSun 620 PU (1 5 9 5 eel
45 DCO e 13
Oatsun 620 PU (1 5 9 5 eel
40 DCOE 2.
Oats un 62 0 PU (1 77 0 ccar>d 19 5 2 cc)
45 DeO E 13
Oltsun 62 0 PU (1 77 0 cc er>d 19 52
2
eel
40
ceO!, 2
2
2
2
32 4 ·5 1·3 5 F15
2·25
1·70
0·5 5
0· 40
0 · 55
33 4-5 1·30 FI B 1·90
0 ·5 0
0 ·50
0·55
3245 1-35 F15
0· 55
0· 40
0 ·55
34 35 1·30 FI B I ·BO 0 ·50
0 ·50
closed
2 -25
334-5 1· 50 FIB
2 ·00
0· 4 5
0 ·5 5
' 00
2 84 -5
1·7 5
1· 70
rz
sa
ra
ra
0· 50
se
Fiat 12 6 GruppoZ
40 DCOE 102
10 Fll
2· 50
0· 4 5
0 ·45
1·00
Fiat 12 4 Sport/R ally GR4
48 1DF 1· 2/100
2
40 4·5 1· 55 Fl l
1-90
0 ·5 5
0 ·40
' ·00
'00
Ford eoo1ina 1500
40 DCOE 2
2
33 4·5 1·2 5 F15
1·70
0· 4 5
0 -35
closed
'00
Ford COo1ina 1SOO (cross flow) and Pinto' SOO
40 DCOE 2
2
32 4·5 1·20 F15
1·80
0 ·5 0
0·40
0 -50
'00
Ford Pinto 2000
45 DCOE 13
34 3 -5 1·4 5 F2
1·85
0 ·55
0· 50
0 -50
2 -25
Ford Pinto 2000
42 DCOE8
2
32 4 -5 1·25 FIB
' ·80
0 · 50
"ss
0· 40
0·50
'''''
Hondl Civic (except CVCCI
40 DCOE 2
33 4 ·5 1·4 0 F2
I ·B5
0· 4 5
0·45
0 ·55
' 00
38 3 ·5 1·55 F2
1·90
0 ·55
0 ·40
0· 50
35 4 -5
50 Fl 1
1·80
0· 5 5
0 ·40
0 -80
1·7 5
343·5
50 F2
1-80
0· 45
0 -4 0
0 · 50
2 ·25
30 4 ·5 1·3 5 F2
2·00
0 ·5 0
0 ·4 5
closed
1 · 75
J aguar XKE(3 ·8 Ind 4 ·2 )
45 DCDE 9
3
Lancia Strl tos
44 10 F 26(21-27
3
Lotus Europa (Renault engine)
45 DCDE 13
Me,ce du B.", 190 S L
40 DCOE 18
2
sa
rs
rs
sa
ea
se
rs
MG Midget Mk 1 end 2
45 DCOE 9
32 5·0 1·40 F18
1·80
0 ·4 5
0·40
0 ·5 0
2· 00
MG Midge t Mk 3
45 De DE 13
34 3·5 1·30 F2
1· 75
0 · 50
0· 50
0· 50
2·25
re
ss
A2-3
Part 5 Appendix 2
,
A
c
o ,
, ,
,
L
0 ·4 0
0 50
'00
0-60
clo sed
225
0-60
cios ed
' ''''
0·3 5
0 ·56
'00
H
MG 1100 Sa loo n
4 5 DCDE 9
325·0 1· 4 0 F16
MGA (. xc.pt tw in cam)
45 DeD E 13
34 3 ·5
1 ·60 F16
· 70
MGB .nd MGB GT
45 DeDE 9
36 4-5 1-65 F16
-60
Ope l Kadene a nd Rallye (to 19 7 0 )
4 0 DCOE 2
2
33 4 ·5
· 15 F16
·50
0 ·50
Ope l Kaden., Rally. a nd Manta {t 97 l o n l
400eDE 2
2
33 4 ·5
15 F16
·50
0 ·5 0
0 ·3 5
0· 55
Qpe l GT 1900
4 0 DCOE 2
2
33 4 ·5
· 15 F16
'''''
· 50
0· 50
0 ·3 5
0 ·5 5
'00
48 1DA4
a
3 7 4 ·5
1· 3 5 F7
1-2 0
0 -70
0- 50
0· 50
' 00
Rena ult R12 Gon:llni
4 5 OCOE S8/S9
z
34 45 1-3 5F9
2 -00
0-55
0- 45
0 60
TOY01a Co rolla 1 100 and 12 0 0
400COE2
2 7 4·5
·0 5 F7
1·55
0 ·60
0 ·5 0
0·50
TOY01a Corolla 1600 InC !
40 DCOE 18
3 0 4 ·5
1 10 Fll
2·00
0 ·45
'"
rs
0 ·50
0·50
To y01a Corolla 1600 (2TC!
40 DCOE18
To yo1a Carina 16 0 0 (n C!
4 0 DCOE18
Toyo1a C.rin. 16 0 0 (2TC!
40 DCOE 18
Toyot. Ce llca 18 RC 8 00 18 RC)
40 OCOE 2
Tovot a Gellca 18 RC 8 00 18 RC)
400COE2
Toyota Coron a (SRC a nd 18RC I
40 DCOE 2
Toyot o Corono {8RC . nd 18 RCI
40 DCOE 2
Toyot o Coron o Mk2 {8 RC ond 18 RCI
40 DCOE 2
1 ·80
0 -45
se
0 -50
re
0 -50
ra
ss
Po rs o ~e
356A, B. C an d 912
Toyot. Coro na MI<2 {8 RC ond 18RC I
40 0COE2
Toyot a Hi-Lux PU (SRC a nd 18 RC)
4 0 DCDE 2
Toyo ," Hi_Lux PU (8 RC a nd 18 RC!
40 DCOE 2
a
z
z
z
z
,
st
sa
rs
,W
ee
30 4 ·5
· 15
t
2·00
0 ·50
0 ·40
0 · 50
30 4 · 5
· 10 Fll
2 ·00
0-45
0· 50
0·50
304·5
·1 5 Fl l
2 ·0 0
0 ·60
rs
rs
0 ·40
0·50
33 4 -5
1·6 0 F2
1-65
0-40
0 -60
closed
33 4 -5
1-4 0 F2
1 ·7 0
0 ·4 5
0·35
close d
33 4·5 1· 6 0 F2
·6 5
0 ·40
"rs
0 ·60
clos ed
rs
ss
'''''
33 4 -5
1-4 0 F2
-70
0-4 5
0 -35
closed
2 ·0 0
33 4 -5
1· 6 0 F2
1 ·6 5
0 ·40
"ss
0· 60
closed
2 ·0 0
33 4 ·5
1·4 0 F2
·7 0
0·45
0 ·35
closed
2 ·0 0
33 4 ·5
·6 0 F2
·65
0 ·4 0
0 -60
closed
'00
33 4· 5 1 ·4 0 F2
·7 0
0·45
0· 35
closed
'·00
·60 F2
1 ·6 5
0·40
0·60
clo sed
2·00
re
rs
se
Toyo t. PUI 18 RC)
40 DCOE 2
Toyo taPU 118 RC)
40 0COE 2
z
33 4 ·5 1·40 F2
1· 70
0·45
0·3 5
closed
2· 0 0
Triumpl1 Dolomita Sp rint
Triumph GT6
48 aCOE
40D COE 2
a
z
4 2 4 5 1- 65 F16
29 4· 5 1· 20 F16
1 75
1 ·9 0
0 -60
0·45
0 -4 5
0·40
040
closed
'''''
'00
33 4· 5
a
sa
se
"
'"
rz
Trium ph GT6 + Mk 2 .nd GT6 Mk 3
400CO E2
1·3 0 F2
·6 0
0 ·50
0 ·45
closed
' 00
42 DCOE S
,
27 4·5
Triumph TR2 . 3 . 3 A. 3 B. 4 ond 4 A
32 4-5
1·4 0 F15
·50
0· 50
0·50
0 · 50
' 00
Triump h TR 2 50 an d TR6
40 DCOE 2
a
2 7 4 ·5
1 ·3 0 F2
1·60
0· 50
0· 45
closed
2-00
Volvo 122 5, 14 4 a nd P 180 0
42 OCDE S
a
32 4·5 1 ·2 5 F15
1 ·60
0 ·50
0 -50
0 -50
' 00
Vo lksw ag en 12 00
Vo lk. w ' gen 1600
Volkswagon 2000
VOI>.sw ag e n Sa loo n 1600 (dua l port! s tock
Vo lk. w og. n S oloon 16 0 0 (d ua l po rt! 1800 co modifica t ion
Vo lk. w a gon Sa loon 16 0 0 ( d u~ 1 port l ~
1800 co mod ificat ion
Volk,w'go n S.ioo n 16 00 (du81 port l _
1800 co mod ificat ion
Volk.wage n Tranoporter 1600 {d u.1 port! _.toc k
Volkswage n Transporter 1600 (dua l port ) ~
18 00 co modifi ca t ion
Vol>.swa ge n Transporte r 1600 {du a l port! ~
18 00 co modjlicatton
Vo lksw a gen Tran spo rte r 1600 (dua l po rt! ~
18 00 oc mo difica t iDn
Volksw age n Transport. r 17 0 0 (type 4 )
Vo lks w8ge n 5 8 10 0 n a nd Tra ns porte r 1600 ~ i g h l y mo dified
36
40
44
40
z
27 4·5
284 ·5
36 4 5
3 2 4 ·5
1·10 Fll
2 ·15
0·50
0 ·40
1 -1 5 Fl1
1 ·7 0 Fl 1
1 ·6 0 F24
'00 0-50 0- 50
1 ·7 5
1-7 5
1 ·7 5
1-7 5
32 4 ·5
Volksw ag en F••t bac k and 5Qu. reba ck 1600
{d ua l po rtl
Vo lksw a ge n Fa.t book ond SQu are bac k 16 0 0
(d ua l port!
Volkswagen 4 11 a nd 4 12 1700 ond 18 0 0
1DF 16f 17
1DF 18 / 19
IDF3B/39
DCNF 12
40 DCNF 12
42 DCNF 9
40 lDF 19
400CN F 12
,a
,
t
2 ·00
2·20
'"
ra
0 -50
0·55
0 -5 5
0 · 50
0·50
0-50
0-80
no ne
·5 5 F24
2·20
0·55
0 ·4 5
no ne
1 ·7 5
344 ·5 1 ·4 0 F25
1·8 0
0·60
0 ·40
no no
'00
,
2845 11 5 Fl l
32 4·5 1 ·6 0 F24
2-00
2 ·20
0· 5 0
0 ·55
0 -50
0· 50
0·55
none
1 ·7 5
1· 7 5
z
z
4D OCNF 12
a
3 2 4· 5 1 ·5 5 F24
2 ·20
0 ·55
0· 45
none
1 75
400CN F9
a
34 4 · 5 1·40 F2 5
1 -8 0
0 ·60
0 ·40
no ne
'00
40 lDF 19
40 IDF 19
z
z
z
2845 1 -1 5 F1 1 2-00 0- 50 0 -50 0- 5 5
28 4 ·5 1 15 Fl l 2 ·0 0 0·50 0 ·50 0 ·55
1 -7 5
1 ·7 5
3 7 4 ·5
48 1DA4
1·3 5 F7
1 ·20
0 ·70
0·50
0 · 50
' 00
1·75
'W
40 DCNF 12
2
32 4·5
· 5 5 F2 4
2·20
0 ·5 5
0 ·45
no ne
4 2 DCNF9
40 lDF 19
2
2
34 4·5 1 ·4 0 F25
284 -5 1 -1 5 Fl l
1·80
200
0·60
0-50
0 ·40
0- 50
non e
0·55
5
A3 -0
Part 5 Appendix 3
Applications list for Zenit h Stromberg
carburetors
T hi. lin give. outline details of Stromberg CD carbu rettors
fitted as st andard equ ipmenllo passenger and lig ht commercial
Ifflhicle s. It is p rese nt ed in tabu la r f orm , a nd t he entr ies are
arra nged in alp ha be ti ca l order aecording to t he na me of t he
ve hi cle man ufactur e r. T he lill is con clu ded w ith the m o re
popu lar app licat io ns of t he co nvarsi on ki ts wh ich have bee n
off ered by va rio us specia list firms fo r f itt ing to veh icles
orig in all y equi pped w it h ot her tv pes of ca rburenors . T heSII are
sim ilarl y arrange d in a lphabe t ica l o rder.
A full y detai led sp are pan s sc hed ul e is ava ilable f rom t he
manufac tur er fo r any specific applica tion . In add ition to II
compl et e illu str ated parts list, this also giv es sta ndar d sening
data. ie fl oat hei ght, fan·idle interconnection sett ing dime nsion ,
lIInd 1II1te rnliltive meteri ng nee dle fo r operat ion at e lev"ted
a ltitude~ lw he n app licab le ).
T he columns lIIre self-eKplanatQry but it shQu ld be noted th at
the ca rb ur ettor reference lcr) , meterin ; needl e m ar king (mnm),
a nd air valve re t urn spri ng co lour Ievrsc}, are inclUd ed fQr
ide nti ficat ion on ly of t hese parts. as t hi. i. th e evide nce actually
foun d on the u nit. T he det ails de oct con stitu t e pa rt num be rs
and sh ou ld no t be q uo te d wh e n orde r ing repl acem ent par ts.
Part nu m be rs co rr esp ond ing w ith m et eri ng needle co de
m arking wi ll be fou nd b y eron-reference t o Appe ndix 2.
Part numbers fo r air valve re turn sprin gs wi ll be found by
cross -refer en ce to Part 2.
Mod e l detai ls
Yea"
"
T,po
mom
""rsc .. .
ALFA·ROME O
17 50 Ber lin a. GT V,
Spider v etcce
197 0
3291
2x175CD-2S E
81AW
No t fi n ed
1969 /70
3212F
3212M
3212 A
3x.17 5CD-2 S E
.,U
.,U
.,U
Natu '1II1
Nliltura l
Natural
HA Van. G PO
1974 o n
aeaaa
150CDS EV
BRITISH ANZ ANI
40 bh p. 2· . u oke
1966/ 67
3090
150CD
H ILLMA N
Imp SpOrts
1974
Imp S por ts
196 6/ 74
3653 A H
365 3L H
306 1 F
306 1A
3068
12 5C D·3
125C D-3
12 5CDS
12 5C DS
2xl50CD
150CD-3
150CD-3
150CD -3
l5OCD·3
150CD-3
150CDS
150CD-3
150CD-3
l5OCD-3
1SOCD-3
l5OCD-3
1SOC DS
1SOCDS
150eD·3
150CD· 3
150 COS
15 0CDS
ASTO N MA RTIN
DSS
BEDFORD
Ra lly Im p, C a m p Dept.
Avenger SC,1300 & 1600cc
Avenger T C, 1300 & 1600 cc
19 6 5 On
19 7 3/ 74
1974
AI/enger , 1250cc
AI/enger , 12 50 cc
AI/enger, 1250 cc
AI/enge r. 1250 cc
T w in ca rb
Ave nge r, 1500 cc
AI/linge r, 1500 ce
Avenge r, 1500 ec
Avenger. 1500 cc
AI/eng er , 1500 cc
AI/enge r. 1500 cc
T w in carb
AI/enger GT , 1500 cc
1973/74
1972 173
1970172
1972 173
1972173
1973174
19 72 173
1972 173
197 1/7 4
197 0 / 72
19 72 / 74
19 72 /74
19 70 / 7 1
3607
3625LH
3625RH
,.2.
3636
32<8
34S8 LH
34S8RH
3635
3609
3377
344.
3249
3389LH
3389RH
3278 L
32 7BR
• A ner spring colour in dic81eJ th ll l co lo u r is at both ends.
• • Gaps in th is column assume th ill/he sam e model, bu l under ano th~r nam e is also lis ted
••
Natu' al
8 50 N
B50N
5K
5K
5'
85 DK
850 M
850M
B5CJ
.SCJ
see
.se u
B5 CU
eeeJ
868 J
868J
55
5AG
85CO
B5 CD
,.,
5.'
Natur al
N atural
Red '
Blue ~
Natu ra l
Natu ra l
Rod •
Rod •
Red'
No t fitted
No t fi tted
Red·
Red ·
Red '
Rod •
Rod •
Blue'
Blu e ·
Blue ·
Blue '
Part 5 Appendix 3
A3-1
Mod_I dlltllll,
Vll ars
"
Typo
m"m
Avenger, 1500 cc
Twin carb (Argentine)
Hi llman GT, 1725 cc
1972/73
3473R H
3473LH
3163F
316 3R
150 CDS
150 CDS
t 50 CDS
150CDS
6Z
6Z
6R
6R
316 1
3198
362 3 L H
36 23R H
345 2R
3452L
60
3182
3162
3554
150 CDS
t 50 CDSE
150C[).3
150 CD-3
150 C[).3
150 CD·3
150 CD-3
150 CD-3
150 CDS
150 CDS
150 CD·SET
19 70 171
32 75
t 50 CDSE
B5BD
1971
19 72 /7 3
1972/73
3417
35 55LH
3555R H
150 CDSET
150 CDSEV
150 CD SEV
B6BD
B5DD
B5 DD
1971 /72
1971/72
3442L
3442R
150 CDSEV
150CDSEV
B5CC
B5CC
1971
1972
1972
340'
3470
3470
150 CDS
150 CDS
150 CD S
6AM
6AM
197 1f72
197 1f72
3547
6D
6D
19 70 ! 7 1
1970/71
3380
3381
t75C D-2S
3x175C D-25
150C DS
t50C DS
HUMBER
Sceptre, 1725 cc
1971f73
19 6 7/7 1
150CO-3
150 CD-3
2xt50CDS
B5CK
B5CK
Scep t re, 17 25 cc
3452R
345 2L
3163F
3163R
30 75 F
3075R
C1866F
C1866R
Minx, 1500 cc and 1725 cc
CI head
M inx, Cl head , emission carb
Hunter GT, 1725 cc
T w i n carb s
Hu nt er GT , 1725 cc
Hu nt er, 1725 cc CI head
Hunter, 1725 cc
Hu nt er, 1725 cc Export
Hunter, 1725 cc
Chrysler Cric ke t 1500 cc
Chrysler Avenger (Plymou t h
Cricke d , 1500 cc emission
carb, USA
Chrysler Avenger (Plymouth
Cricket -Auto }, 1500 cc
emissi on cerb, USA
Chrysler Cr icket, 1500 cc twi nemis sio n carb
Ch rysle r (Plymouth Cricket Spo rt s), 1500 cc emission
carbs, USA
Chrysler Arrow, Iran CI head,
1500 cc & 1725 cc, p lastic air
cleaner
Chrysler Arrow, Iran, 1725 cc,
T w i n carbs
HOLDEN
Holden,6 cyl , 20 2 CI
Ho lden 6 cy 1, 3 cares
Ho lden
H ol den
1969 /70
19 6 7/72
1969/70
1973/74
1971/73
1972174
1971/74
1968/70
196 6/ 72
1972/73
Super Snipe V, 3 li t re & I m peri al 1966/67
Super Snipe IV & Impe ria l
1965
JAGUAR
E T y pe, 4 .2 lit re, em issio n carb
1969/70
E T ype, 4.2 litr e, emissio n carbs
1967 /68
XJ6, 4. 2 li tre (Federa l)
XJ6, 4 .2 li tre water heated
jacket, emi ssion carb
XJ6, 4 .2 li t re, emission carbs
XJ6, 4. 2 l itre, em issio n carbs
1974
1974
19 72!74
1972/7 4
19 7 1/ 72
19 71/72
1969170
3489
3453
352 1
330 5F
3305 R
3165F
3165R
3627R H
3627LH
3598 RH
3598LH
3496RH
3496 LH
3304F
3304R
2x175CD- t
2x17 5CD -1
t75CD-2SE
175CD-2SE
175CD-2 SE
175CD·2SE
175CD·2SE
t75CD-2SE
175CD-2SE
175 CD·2SE
t 75 CD·2SE
175 CD·2 SE
175 CD-2SE
17 5CD·2SE
B5AP
B5CK
B5CK
B5CK
B5CK
B5C M
B5C L
6Z
6P
avrsc ••
R ed
Red
~
~
Blue *
Blue ~
Blue ~
Blue *
Red *
Red *
N atura l
Red *
B5DC
Red
~
5CO
6E
6E
6R
6R
2K
2K
4A
4A
Blue
~
Blue *
Blu e
Blue
Blue
Bl ue
B1AR
B1AR
B1E
61E
Natura l
Nat ural
B1CG
B1CG
BtCG
B1CG
B18T
8 1S T
S t AR
SlAR
Natural
Nat ur al
5
Part 5 Appendix 3
A3-2
Mod e l d at ails
Vears
"
Ty pe
mom
av~ "·
XJ6 , 4 .2 litre, em i$Sioo carbs
1969 f 70
3234'
175CD·2S e
3 234 R
175CD·2SE
B 1A E
B1 AE
Natura l
Natu ral
3527 A I
3527A2
175CD·2S E
175CD·2S E
V12. 5.3 litre, au to matic t ra ns
1973/74
352861
3 528 8 2
V12. 5.2 lit re, manual tra ns
1973/7 4
3567AI
3567 A2
356860
356862
V12, 5.3Iltr. , e utc and man ua l 197 3/74
t.ans, USA
3629AI
3629A2
36 3081
363082
V12, 5.3 111" , auto-tu ns.
Eu rope ...
V 12. 5 .3 lit re, XJ 25 . man·trlllrno
1973/74
197 1m
197 1
V12. 5.3 litre , autO-trans
19 71
LAND ROVER
Range·R over
1973174
Range-Rover
1971
1970
R e n ~·R ov e r
u md
Lend
Lend
Lend
Rover,
Rover,
Rover,
Rover,
2.6
2.8
2.8
2.6
lit re
litre (European}
litre
lit re
L.OTUS
1.6 litre
Elan, 1558 ec. adjust able n"'e d!e
(Ho me)
Elan. 1558 ce. Expo rt, emiuion
19 73174
19 73/ 74
197 1172
196 7/7 0
197 3/7 4
197 0/72
19 71172
wb
Elan, 1588 ec, Export . emission
197 1/72
~,b
2 litre
1974
2 litre
1973174
Elan and Elan+2. adjustable
needle (Home)
196 9/7 0
175CD-2SE
175CD-2S e
175CD-2SE
175Co-2 SE
175C D- 2Se
175 CD-2 SE
etco
B1CO
B1CO
ercc
B1e N
81 CN
357 982
175C D- 2Se
81CN
35 10A I
351 0 A 2
175CD·2Se
B 18 H
B1 BH
B1BH
B1BH
175 CD- 2SE
175CD·2S E
3500B2
339 1Al
339 1A2
33928l
339 2B2
34 02A2
3402Ar
340 3 BI
340382
175 CD·2 SE
175CO·2SE
175CD-2SE
175CD-2SE
175C D·2SE
175CD-2S E
175CO·25 E
I 75CO·25 E
175CD·25E
175CO·2S E
175CD-2SE
175CO·2S E
175CO·2SE
33 18RH
3318LH
3394R
3394L
3293 RH
3293L H
36 18
3539
34 13
3 136
175C O-2SE
175CO·2S E
175C O·2S
175CO·2S
175CO·2S
175CO-2S
175CO·2S
175CO·2SE
175CO·2S
175CO·2S
3517RH
3517LH
3322 L
3322R
3367L
3367R
336 6 L
3368A
37 13R H
37 13LH
3548AH
3548LH
3 296 '
3296R
175CO·2SE
175CO·2SE
175CO·2SE
176C O·2SE
175CO·2SE
175CO·25 E
175C O·2SE
175CD-25 E
175CO·2SE
175CD-25 E
175CO·2S E
175CO·25 E
l 75CO·2S E
175CO·2S E
3499AI
3499A2
35006 '
V12. 5.3 1itre
175CD-2SE
8 1CK
B 1CK
B1CK
B1CK
175C D-1SE
3511 8 1
1971/72
175CD-2$ E
175CD·2 SE
etc e
3578 A I
3578A.2
357981
3511 8 2
V12. 5.3 litre. XJ25. auto-tnllns
175 CD -2SE
17 5CD·2S E
175CD·2S e
er ce
atce
erce
Bl e N
B1BH
B1BH
B1BH
B1BH
BIBH
B1BH
BI BH
BIB H
BlSH
BIS H
B1BH
B1BH
B2AS
B2AS
' AQ
'AQ
'AQ
'AQ
4J
B2AU
4J
4J
BI G
BIG
a 2AR
B2AR
BI G
BI G
BI G
BI G
8 10K
B1DK
B1CM
8 1CM
BI V
BI V
R.d
aeo
R.d
R.d
Blue
Blue
Blue
Blue
Part 5 Appendix 3
A3·3
Model details
VUB
er
Ty,"
m"m
avrsc"·
Elan and Etlln+2 (H o/TW)
1969/70
3236F
3236R
3175F
3175R
175CD-2SE
SlY
SlY
Natura!
N at ural
Elan an d Elan+2 ,
Expor t emission
SAAB
99, 2 litre , 820
99, emi ssio n ca rb o1854 cc
991854cc
991709cc
99, emissi on cere
99 1709<;c
991709 cc
99 1709cc
1968/69
175C D-2SE
175CD-2SE
175CD-2SE
BIG
BIG
Rod
175 CD-2S
175CD·2SE
17 5CD-2S
175CD-2S
B1B R
175CD -2SE
t75C D-2S
SlAG
BIW
BIW
Ble
125CDS
125CDS
6K
6K
3161
3182
3162
150CDS
6Q
6Z
6P
Red
N atu ral
3557
1971 /72
197 1{74
1969/71
1969/71
196 9
346 4
3465
1969
3210
175C D·2S
175CD-2S
1968 /69
3169
1966 on
3061F
3302
3301
3282
S lAG
BI W
BI W
R,d
Rod
R,d
R,d
R'd
SI NG ER
Chamo is Sports
3 06 1R
Gazelle. 1500 cc and 17 25 cc.,
CI Head
Vogue, 1725 cc Expo rt
Vogue, 1725 cc
1968170
196 6/7 1
SUN BEAM
St iletto
1966 o n
J06 (F)
306 nu
2 x125CDS
6K
6K
Rap ier, 17 25 cc
1971 /73
1967/7 1
150CD -3
15OCD ·3
2x15OCDS
B5CK
B5CK
Rap ier , Mkl, 172 5 cc
A lpine, 1725 cc
Alpine, 1725 cc
Alpine GT., 1725 CC , emission
carb
Alpine GT., 1725 CC, emission
carb
A lpine V. 1725cc
1971 /74
1969/7 1
1969/70
3452R
3452 L
3163 (F )
3163(R }
3453
3 162
3306 (F )
3306 (R)
32 1 1{F)
321 1{R )
3059( F}
30 59 (R )
3470L
3470R
15 0CD -3
15 0CD S
150CDSE
150CDSE
150CDSE
150C DSE
150CD
15 0CD
150CDS
lSOCDS
B5CL
3054
HOC D
6'
33 20
3 16 6
l SOCD S
5B'
150CD
15OCD·3
15OCD·3
15OCD-3
6'
Sunbeam Arrow, I ran, 1725 cc
TRIUMPH .
1.300
13 00 (SIII/l!den, co ld cl imate)
1967/71
1969
1966/68
1971/72
Herald 13/60
DOlo m ite 1654 cc 4 cy l
1966/ 71
1970
1967/ 71
1973/74
Do lomite 18S4cc4cyl
1972/73
Dolomite 1854cc
19 7 1/ 73
Vitesse M k I I, em ission carb
197 1/72
Vitesse, 2000 cc IIl k II
1969/70
V itesse, 2000 cc
1966 /68
Vi te sse, 1600 cc
1965/66
TR6, emiss ion c8rb
197 4
TR6 . em ission carb
1972/73
3634RH
36 34 L H
3582RH
3582LH
3334L
3334R
3335R
3335 L
3224(F }
32 24 (R )
3 137 {F }
3 13 7{R )
3027 (F I
3027 {R )
3613RH
3613LH
3508RH
3508 L H
150CDS
150CDS
15OCD-3
150CDSE V
150CDSEV
150CDSE
150CDSE
2x150CDS
2x 1SOCD
2 x 15OCD
175C D-SEVX
175CD·SE V X
17 5CD -SEV
17SCD-SEV
6R
6R
~
Nat u ral
Blue *
Blue *
6P
BSBC
BSBC
B5AU
B5AU
5M
5M
6AM
6A M
B5 DH
B5DH
B5DH
BSDH
B5B W
B5B W
B5BT
B5BT
6AC
6AC
OJ
OJ
7B
7B
B1 AF
B1AF
B 1AF
B1A F
Bl ue'
Blue '
N atura l
N at u ral
Not fitted
N ot fi tted
Blue *
B lue '
5
Bl ue'
Bl ue *
N aturai
N atural
N ot fitted
N ot f itted
Part 5 Appendix 3
A3-4
Model cMu ib
VR~
T R6. emission curb
197 1/72
Ty..
m~
~
33 37R
175CD ·2SE
175CD·2SE
B1AF
Blue
Blue
3337L
TR6, emtssson c arb
TR 6 , em issio n cerb
19 71 /72
19 70
338 5 L
3385R
1968/69
TR 250, em ission eerb
1967/68
YR4A
1965
TR4
196 3/6 5
2496 cc, 6 cyl , European
197 3/7 4
249 6 ec. 6 cvt, Au srrette
'973
175CD-2SE
8 1A F
B1A F
8 1A F
B1A F
3 t131FI
3 1731RI
2x17 5CO-2SE
3 15Q(F I
2.1175C O-2S E
B'V
B'V
B'V
B' V
33651F)
3 150(R I
3069 IF )
3069(A }
C 18251Fl
C 1825 (R )
36 50 RH
3650 L H
3604RH
3604LH
2000, 6 cy t, Euro pean
1973/74
evr. Eu rope en
1972173
2000 Mk II, Home and Euro pe
1971 174
2000 Mk II
19 70/ 71
20 00 Mk II
196 9 / 70
2000
19£6/ 69
2000
1964/6 5
1496 cc 4 c:yl
Spitf ire, 14 96 teA c:yl
Sp it fire 4. em ission ClIrb
Spitfire 4 , emission cerb
Sp itfire, e missio n c erb
1974
19 72174
1972
1971172
1969170
GT6
19721 74
GT6
1972/7 4
GTS, USA, em ission
197 1/72
2000, 6
3633RH
3633LH
358 1AH
3581 LH
Spjtfi ~ ,
cere
GT6 Mk Ill , e mission cerb
1971 /72
GT6 , USA & Sweden, e missio n
ca rb
GT6 . Mk III, e mission ca rb
1971
1970
GT6 . Ste ge II. emi ssion carb
1969/70
GT6 . St ege II
196 9/70
GT 6.200 0
1965 /6 8
GTG. 2000 e mission C8rb
1968/69
Stag VB, European. emission
earb
1974
Sta g V8 , ohc
19 73 / 74
alA F
17 5CO·2SE
2x 17SCD..2SE
336 5 l R l
T R250, emission cerb
..
a
3471 l.
3471 R
3372R
33 72l.
328 1( F)
32 81(Rl
3 116 (F )
3116(R )
C1854 IF )
C 1854IR I
3612
3506
34 2 7
3336
3277
3507R H
3 50 7l. H
34 3 2 RH
343 2 l.H
342SR
342SL
3335A
3335L
33B4R
3384L
3369R
3369L
32 25 (FI
3225(R)
322 3 (F )
3223 lR )
3 09 21F)
3092(R )
3 172 (F I
3 172 (RI
3662 AH
3662LH
3509A H
3 509LH
2 x175CD
2x175CO
15 OCQ·3
'"
'"
2A
2A
8 50G
15OCO·3
t 5OCD·3
6 50 G
l5OC O.J
l5OCD -3
B50G
B50G
15OCD·3
B50G
B5CB
B5C B
B5 BU
BSBU
2xlSOCD
2x 15OCD
2xlSOCOS
2x l SOCO
2x 15OCD·SE
Blue
Blue
Blue
Naw rot
Neturlll
BSOG
5AW
5AW
6J
6J
7A
7A
1SOCD-SEVX
l SOCD-SEV
15 0CDSE
150C DSE
l50C DSE
15OCD-SEV
15OCD·SEV
15OCD·S E
15OCD·S E
15OCOSE
15 OCOSE
l 5OCOSE
l5OC OSE
15OCOSE
l5OCO S E
l50CDSE
150CDSE
2x15OCO-S E
Blue
Blue
Blue
Blue
B50G
85 0 G
l5OCD-3
15OCD·3
15OCOS E
15 0CDSE
15 OC D-3
15 OC D-J
2x 150CDS
Blue
BSCH
B5C"
B5C"
B5AV
B5AV
85CF
8 5CF
B5CF
B5C F
Blue '
Blue ·
Blue ·
Blue·
Blue ·
Blue·
Blue ·
Blue·
Natural
Na tu ral
Netural
Netu ral
Blue·
Blue ·
Blue·
Blue·
B5CF
B5CF
858T
8 58T
B5AJ
B5AJ
B5AJ
B5AJ
8 5AJ
B5AJ
6AC
6AC
6J
6J
6W
6W
175C D·2S EV
175CO·2S EV
B1AQ
a lAQ
175C O·2 SEV
175C D·2S EV
81 AQ
81 AQ
Blue
8 lue
Blue
Blue
Blue
·
·
·
·
·
awe'
Nat u tel
Neturlll
Blue·
Blue ·
--
Part 5 Append ix 3
A3-6
y~
Typo
m_
3213 A
l 50CD
OAB
Blue ·
311SA
' 5OCD
6N
Blue ·
3342
150CD
6N
Blue -
3062A
3393
359 2
3593
150CD
150C DSETV
60
85 AY
Blue·
175C D-2SE
81C Y
R'"
175CO-2SET
81QU
3<04
34046
175Co-2S
175CD-2S
175CD-2ST
175CD-2S
175CD-25T
175CD-2S
175CD-1S
Sl BW
Viva. HB2 3. 1160 cc Borg-
Warner t ra ns. and Fr a m p last ic
1969
air clea ne r
Viva, HB23 , 1160 ee 90 & S L90 Late
1966/ 69
Viva, HB23, 1160 ec 90· SL90, Late
BO'lrWarner
1966/69
Viva , H A 90 & S L.90, 1057 cc
Late
196 5/66
Viva, He 1159 cc, Ca nada
1971 172
Vict or. 2.3 lit re, F E
1913174
Victo r, 2.3 Iit.e. F E. auto t rans 1973/74
Vietor, 2.3 litre. FE
19 72173
Vietor. 2.3 L it r. , F E. Eu rope
19 72/73
Victor. 2.3 Lit re. F E, auto t rans. 197 2/7 3
Victor, 2000 cc F o
Victor. 2OClO ce F0 auto
19 71/7 2
1971 /72
19 70171
175C D-2S E
32 7 1
175CD-2ST
2AM
Blue
3272
175CD·2SEr
B2AP
3383
3599BR
3599BL
175Co-2SE
175C O·2S
175CD-2S
B"
3587R H
3587LH
3411 L
3411R
34 118L.
3411BR
175CD-2S
175CD-2S
17SC D-2S
175CD-2S
17 5C D-2S
175CD-2S
81CL
B1C L
B18 Z
8 1BZ
3800BR
175CE-2S ET
B1DC
3600BL.
175C D·2S ET
Bl OC
1973
3588RH
358BL.H
175CQ-2ST
175CD·2ST
B1CL.
B1C L
1972
3412R
34 12l
175 CD·2ST
17 5CO-2ST
17SCD-2S
175C D-2S
17SC D-2ST
175CD-2ST
17SCD-2S
175CO·2S
175CD-2ST
175CD-2ST
2X 17 5C D·2S
8 18Z
81 BZ
197 3174
a nd FE , a uto t rans
VX4 90 and FinmZl, 2 .4 lit re,
FE
auto t rans.
VX4 9O, FO 2000 ex:
VX4 90, FD 2000 cc au t o
tr an s
VX490, FD , 2 000 c:c:
19 7 1/72
3438R
1971 /72
3438L
3439L
3439R
1970/71
VX4 90, FD 2000 cc a uto
t rans
.... X490, 19 75 ee rhd
1970171
VX4 90, 1975 cc Ihd
1969/70
VX4 9 0 , 19 75 <;;1: r hd a uto
t rllns
VX4 90, 1975 cc lhd , auto
trans
SlBW
>AM
Blu.
and F E, au to t ra ns. Dome stic
and Eu rop ea n
VX4 90 and Fi rllnZl , 2,3 lit re,
HC
3405
3434
3472
3328
3259
32 7.
R'"
SlaW
2AM
2AM
2AM
B2AP
Victor . 2000 F 0
Victor, 2000. 2000S L and Super 1969170
Victor 2000, em issio n ca rtl
1969170
Victor, 2000 FD , a u to t ra ns.
th e rmo-start
1969170
Vict or 2000. F D au to t rans .
thermo-start, em issio n carb
196 9170
Victor F D. 1600 cc a uto emrssian ca m
1970/71
VX4 90 and Fire nza , 2.3 lit re HC 1973174
a nd F E. ma n-t ra ",,, Do mestic
and EutopWn
VX4 90 and Fi renzl, 2 .3 lit re, HC1973
an d FE , ma n-t ran s
VX4 90 and F irenz a, 2 .3 lit re, HC1972
an d PE
VX4 90 and Fi renza 2 .3 lit re , HC1972
an d P E, Europe
VX4 90 and F ire nza , 2.3 lit rto ,
HC
-"
~
1969/7 0
1969/7 0
1969170
3378R
33 7BL
3379R
3379l
329 5 (FJ
3295(R I
3297{F)
3297{R 1
3312!F I
33 12 !R J
33 13!FI
33131AI
2X1 75CO·2S
2X 17 5 CD-2S
2 X175CO·2S
BWC
Bl OC
Blue
Blue
Blue
Blue
BIBZ
B1BZ
IBJ
'BJ
IBJ
' BJ
'BJ
'BJ
'BJ
'BJ
l AS
l AS
l AS
lAS
l AS
l AS
' AS
' AS
Rod •
R'" •
Aed·
Rod •
Part 5 Appendix 3
Vun
~
T y,,"
mom
~
164, 6 cy l
1972173
3580RH
3S80LH
164
1971172
3375L
3375R
Blue
B lu8
Blue
Bl ue
2 litr e, 4 cvl, 8 20 8
197 3/74
2 litte , 4 cY' , 8 208 , Ja pan
1973/74
3668RH
3668LH
3629R H
B1BE
B 1SE
81BE
81SE
SlD A
B1DA
Model details
..
A3-7
VOLVO
3573
11 5CD-2SE
17 5CD- 2SE
175CD-2SE
17 5CD-2SE
17 5CD-2S E
175CD-2S E
175CD-2SE
175CD-2S E
17 5CD-2SE
3574R
3574 L
175Co-2SE
115CD-2 SE
3285
17 5CD-2SE
2X 175CD-2s e
3629 LH
144, 4 cy l
1445, 145S
1972/74
1971 /73
144, 145, 4 cyl, emission
eerb, Ho me and E:o:p o rt
1968171
1425,1445 and 14SS, 4 cyl
1968n1
emi ssio n car b, Horne & Export
3286 (F)
3286( R )
3287( Fl
B1CC
S IB l
8 18l
Blue
B1A N
81AP
S l AP
SlAM
SlAM
Blue
Blue
Slu e
3019
175 CD-2S
4F
Blu e
Blue
BluR
F6003
125CO
SA
Blu e '
F6011
125C D
58
Nat ural
F6012
2 X 125C D
6e
Natura l
Foo14
125CO
5E
Natural
1961/66
FOOlS
125CO
5D
Natural
1963 /66
1959/6 2
Foo16
12 5CD
5E
Natural
19 59 o n
19 59 on
1961163
1961/62
F5029
150CD
15X
Natural
F6032
F6033
2X 125CO
2Xl50CO
5H
7A
Natural
N atu ral
F6037
2Xl50CD
7A
N at ur al
F6051
2X 12 5C D
SA
Natural
F6052
2X 15OCD
7A
Natural
'SOCD
15X
Natural
164 and 1645 , 6 cvr. emrssian carb , H om e and Exp ort
19 68/70
12 1, 131 a nd 144
1966/68
2X 175CO-2Se
BIDA
B1 DA
32 87( AI
CO N V E RSI ON S
BR IT ISH LE Y LA N D CONVERSIONS
Austin seve n !It Mini, 850 cc
1959 on
MorriS Mini M inor. 8 50 ce
1959 on
Ri ley en.aeo ec
1961163
Wo lse!ey Horne t , 850 cc
1961 /63
Austin/Morris,1 100 ec
1963 on
Au..t in A40, 1098 cc
1963 on
Morris M ino r, 1098 ec
19 62 on
196 1/6 4
A ustin H ealey Spri t e. M k II
MG M idget. 948 ec
1961 /64
Austi n A SS
Morris O xford, $er;e.s V
1959 /61
Wo'$lli ay 15/60
Austin A60
Mof"ris Oxford, Ser ies VI
Wolseley 16/6 0
A ustin A 4 0, Mk 11 ,948 cc
Morr is Minor, 948 cc
A ustin Seven and
Mini 850 cc
Fo<
Morr is M in i M inor.
tu ned
850 cc
engines
on ly
Ri ley El f , 8 50 cc
Wolsel ey Hornet ,
850 ~
A l ....nder Engi _
ing Co Ltd
BMC A Series 1098 cc
BMC B Ser ies 1622 ee
M o rris/A ust in M ini Cooper
MG1 100
Vandam Plas 1100
M G Mi dget
Au stin Healey Sprit e
Cer blolreibar S.A . Outfits
A ust in Seven and Mini
Morris Mini MinOt'
Al,lS1in/MOt'ris 1100
Austin seve n and M ini
Morris Mini M inor
5
F5053
A3 -8
Model d et. ils
Ty,.
m=
orIrsc ••
F6007
125C D
6T
Na t u ral
F6036
2X150CD
7A
Blu e'
esoee
2Xl 5OCD
7C
Nat ural
>603'
2X l 50CO
7A
Naru ral
>6002
2X17 5CD
,X
Natural
F6030
2 X 12 5CD
'H
Natural
F6039
2X l5OCO
14X
Natura l
>6025
>6001
2 X125CO
'C
!A
Natural
2X 175CO
2 X125CO
2X15QC O
'0
12X
Nat ural
Natu ra l
F6 04 7
150CD
(pl us
existi ng u n itl
78
Not fitt ed
>6030
2X125CO
'H
Natural
60
7.
Natural
Blue ·
llX
Blue'
T-
FORD CO NVERSIONS
Fo rd Ang lia. l OSE. 991 cc
Fo rd Anglia . 123E , 1200 cc
For d Cort ina, 11 3E , 1200 ee
Ford SO cwt Van, 307 E.
997 cc
A LEXAN D ER E NG I NEE RING CO l TO
997 cc and 1200 cc an d
1500 cc
Ma rcos Ca rs Lt d
Marcos 1500 f o rd
H I L L M A N CO NVERSIONS
ALEXA NDER E NG INE ERING CO LTO
Minx. 1500 IX and 1800 ec
JAGUAR CO NV ERSIONS
Jaguar, Mk VII
1951157
OPEL CONVERSIONS
A LEXAN D ER E NG INEER ING CO
LTD
Opel Kaden
SUNB EAM CONV ER SIONS
Alex ..nder Engin" ,lng Co. Ltd
Alpine
Alloy he1ld
Rapier
TRIUMPH CON VERS IONS
vrtesse 6
T R3 . 3 A and 4
1962/65
1960/63
A lexander Engineering Co Ltd
Heral d 12 /50
vttesse
SAH Acc essories Ltd
13 00
F60 34
>6038
Natura l
VA UXHALL CO NV ERSIONS
Alex~nder
Engineer Ing Co Ltd
Viva
J ack Brabham Co ..... rsions Lt d
Viva HA, 1057 cc
Viva HA90, 1057 ee
Viva HB90 . 1 159 cc
>6041
2Xl25CO
>6044
!SOC D
(p lus e"isting un it!
>6049
l SOCO
' plus exi n ing unit}
VO LKSWAG EN CONVERSI ONS
Alla rd Mo to r Co Ltd
Vo lkswagen 12 00
F6027
150CD
48
Natural
Speedwell Perfo rma nce Conversions Ltd
Volkswagen 1200. 1300
an d 1500
>604 '
2Xl 50CD
5E
Natural
M -1
Part 5 Appendix 4
Meteri ng needles f or Zenith Stromberg
carburetors
T he metering needl ' c!etail ",d fo r iiIl spe cific i1ppliCiltion in
Appendix 1 is th at fit ted as original equ ip ment a nd can be reli ed
upon as be in!il th ' most satisfactory f or all nor mal r un ni ng.
Howevec, whe n it;$ desi red to mak e a chan ", ' tom standa rd to
ak. ca re of some spec ial ' I'q uirement. a s.u'U1 ble re placement ca n
usually be determi ned by re ference to the ,,"die dimensio n
cham.
Need les sh ould be o rdered by the pa r t n u m ber rat her tha n
by t he refe re nce st a mpe d on th e shank of th e need le. A q u ick
er on -refer1! nce chart is in cluded for th is.
Neeenes mark ed wi th a refere nce commencing w ith the let ter
B a re bia..ed or ad jus t ab le as sem blies i1nd cetl onl y be fined to
llpp.-op.-iate carbu ren o rs. On no accou n t shou ld an y c hange be
made to t he need ~ fit ted as origina l eQl,lipmen t in .min'on
contro l ca rbu renorl .
Needle dimensions are taken at 1/8 in . intervals from t M
s houl de r lunde rside of sha nk],
Main meter ing needles to .09O jets
Need le
02082 1
020888
020903
0209 08
81 62422 81640 4 2 8 16 4052 8165612 8168 24 Z 8 168672 816961Z
P.rt
5H
5K
5A
5.
5C
50
5E
SF
5G
.0880
.0809
.0786
.0765
.0745
.0730
.0722
.0714
.0705
.0697
.0687
.067 7
.06 77
.0880
.08 4 '
.08 06
.078'
.076 1
.0742
.0718
.0880
.0823
.0795
.0784
.0777
.0760
.0740
.0715
.0692
.0668
.0645
.062 3
.0623
.1)880
.082 7
.0792
.0779
13
.0880
.0831
.1.1802
.0788
.0775
.0759
.0744
.0726
.0708
.0686
.0664
.0646
.064 1
.0880
.()840
.08 73
.0792
.0775
.0757
.0740
.072 0
.077 0
.0690
.06 70
.0670
.067 0
.0880
.0835
.0815
.0785
.0777
.076 5
.0750
.0730
.0710
.0690
.0670
.06 70
.06 70
N.... .
8 168522 817 10 1Z 8 172972 8 17298Z B1n 49 2 8 1n53l B1775 02 8 177512 817752 Z 8 18 1522 8182 18 Z
No.
1
2
3
4
5
6
7
8
9
10
11
12
.0693
.0668
.0642
.06 17
.0593
.0593
.0 7(;2
.0742
.0729
.0723
.0705
.0683
.0663
.0642
.0642
.0880
.0844
.0798
.0787
.0769
.0747
.072 7
.07 07
.0693
.0670
.0656
.0635
.0635
5J
.0885
.0840
.08 17
.079 7
.0783
.0773
.0758
.0735
.0722
.07 02
.068 /
.0659
.0659
.0879
.0840
.0823
.08 00
.0775
.0758
.0747
.073S
.0723
.07 11
.0700
.0630
.0630
5L
.0880
.0847
.0821
.079 1
.0762
.0739
.0714
.0887
.0660
.0633
.06 06
.0578
.05 78
P. rt
N o.
1
2
3
4
5
6
7
8
9
10
11
12
13
5.
5N
5P
50
5R
.0880
.0835
.0805
.0184
.0760
.0735
.0705
.0693
.0677
.0644
.062 1
.0598
.0593
.088 0
.0844
.082 1
.0791
.0760
.0732
.0700
.0656
.0630
.0616
.0592
.0575
.0571
.0880
.0834
.0812
.0793
.0768
.0146
.0716
.0703
.068 1
.0656
.0630
.0600
.05 7 0
.0880
.0834
.08 19
.08 04
.0782
.0760
.0732
.0718
.0698
.0672
.0645
.0615
.0590
.0881
.08 44
.0824
.0800
.0772
.0739
.0700
.064 4
.0636
.06 13
.0611
.0609
.0609
55
5T
.0883
.0883
.08 44
.08 35
.08 11
.0792
.0761
.0728
.0697
.06 74
.0653
.0650
.065 0
.0650
.0845
.0824
.0797
.0765
.0730
.0687
.0647
.06 15
.058 7
.0585
.0584
.0584
5U
.0884
.0842
.0832
.0806
.0768
.0738
.070 1
.0663
.0639
.0639
.0639
.0637
. 06.16
5V
.0882
.0844
.0842
.08 16
.0788
.076 /
.072 9
BSW"
.0880
.0839
.082 1
.0798
.0762
.071 7
.06 71
.0698
. 0625
.0674
.0674
.0674
.0672
.0671
.0625
.0625
.0625
.062 5
.062 5
5Y
.08 61
.0846
.0827
.0797
.0756
.0715
.0665
.06 11
.0584
.05 53
.05 35
.0535
.0535
5
M-2
Part 5 Appendix 4
Main me te ring ne«llei for.09O jets
N.....
8 182502 81 83022 8 1842 12 8184232 8184242 8 187252 8187262 8187272 8 190702 8191012 8 19 134 2
Port
No.
,
a
3
4
5
5Z
. 08 8 0
.0842
,082 6
.0796
.0 758
6
7
8
. 0636
9
. 06 10
'A
.0586
.0583
.0580
.0580
11
ta
13
Need le
Part
No.
,
a
3
4
5
8
7
8
9
'A
11
tz
13
.0720
.0678
8 5 .0..0.' ·
B5A B H
.088 0
.0836
.0876
.0845
. 082 0
.0825
.0796
.0759
,0713
.0660
.0792
.0762
.0722
.0880
.06 15
.0613
.0613
.061 3
. 06 14
.0613
.0613
.0592
.058 '
.0666
.0650
.0633
SAC
.08 79
.0842
.0825
.080 1
,0718
.0758
.0742
.0725
.07 11
.069'
.0699
.069 '
.069'
SAO
5A E
5AF
5AG
.0880
.0880
.0840
. 08 15
. 08 0 0
. 0778
.075 3
.0736
.0720
.0695
.0880
.0848
.0826
.0813
.0795
.0772
.0757
.0743
.0880
.0854
.0775
.0710
.0763
.0693
.0722
.0745
.0682
.0682
.0682
.0682
.0710
.071 0
.071 0
.071 0
.0735
.0735
.068'
.0667
.0650
.0735
.0735
.0639
.0639
.0043
.0836
.08 16
.0792
.0776
.0762
.0748
.0736
.0724
. 0724
.0724
.0724
.0835
.0825
.08 08
. 0788
B5AH ·· 8 5AJ··
B5AK "
.08S0
.08 64
.0847
.0825
.0786
.0755
.0732
. 084 7
.08 16
.080 1
.0768
.0743
.0855
.084 3
.082 9
.0800
.0766
.0737
.0709
.068 3
.0671
.065 7
.0644
.0635
.0635
. 071 8
.077 1
.0652
.0633
.063'
.0630
.063 0
8 191352819 173 28 191 9 328192 282 8 19 37 0 Z 8 19 398 2 81 9432Z 81951 9 2 81961 62 819622 Z 8199472
5 AL
B5AM--
.0883
.0845
.0823
.0790
.0764
.0730
.068 '
.0846
.0843
.0825
.0801
.0768
.0732
.0695
.0645 .0663
.0614 .0630
.0587 .0600
.058 3 .0590
.058 2 .0880
.058 1 .0580
5AN "
.0883
.0844
.0824
.0791
.0760
.0729
JJ679
.0643
.06 96
.0554
.0549
.0549
.0549
BSAP· ·
B5AC " " B5AR " " 8 5AS"
BSAT H
B5AU ' " 85AV H
.0857
.0847
.0834
.08 08
.0778
.0736
.069 5
.0652
.06 13
.05 73
.0568
.0845
.0832
. CX324
.0862
.0838
.0826
.0786
.0753
.0729
.0720
.071 1
.0655
.0636
.0632
.063 1
.0631
.0846
.0844
.0833
.0807
.0776
.074 1
.0704
.0671
.0638
.0608
. 0868
. 0868
.(>JOO
.0773
.0704
.0673
.0670
.0619
.0619
.0619
.06 19
.0619
.0882
.0867
.0834
.08 79
.0785
.0756
.072 6
.069 7
.0679
.0666
.0653
.0641
.064 1
.0862
.0842
.0826
.0786
.0753
.0729
.0720
.07"
.0655
.0636
.0632
.0631
.0631
.0593
.0883
.0583
.0883
.0840
.0824
.0808
.0772
.0736
.0685
.0638
.060'
.0553
.0545
.0552
.050 9
SAW
.088 3
.0845
.0820
.0792
.0765
.0734
.0705
.0683
.0664
.064'
.0623
.0596
.0573
Need le
Port
819965 Z 8 199S8 Z 82 0 378Z 820386Z 820388Z 820471Z 820493 Z 820577Z 820578Z 820579 Z 820580Z
No.
B5 A Y"
1
.0863
.0837
.0827
.0798
0168
.0709
. 0683
.0667
.0661
.0661
.066 1
.066 1
.066 1
2
3
4
5
8
7
8
8
10
11
tz
13
5AZ
.08 62
.0835
.08 09
.0792
.0760
.0699
.0675
.0673
.0671
.0666
.066 1
.0658
.0658
B5BA " ·
.0846
.0845
.08 37
.08 ' 2
.0783
.0748
.0712
.0678
.0645
.0614
.0596
.0585
.0583
• Oe"'011l1 biased ...""dle assemblies
588
.0879
.08 44
.0820
.0789
.0756
.0724
.0693
.0657
.0632
.0607
.0600
.0600
.0600
BSSe....
8580· '
.0859
.0850
.0837
.08 ' 2
.078 1
.074 1
.0704
.0671
.0638
.0608
.0593
.0583
.066 3
.0866
.0856
.0836
.0809
.0782
.0741
.069'
.0647
.0607
.0569
.0530
.0492
.0483
58E
5 SF
59 G
58P
.(>J6J62
13
.0604
.0600
• Den ot es biased nee dl e asse m blies
.0834
.098 0
.0907
.0888
.08 70
.0840
.08 12
.0782
.0751
.072 0
.0688
.0656
.0625
.0625
.0644
.0964
.0938
.09 74
.0875
.0839
.0798
.0763
.0 722
.068 4
.064 7
.060'
.0505
.0569
.05:12
.0574
.0 55 1
2E
2F
.0980
.0925
.0898
.0876
.0847
.08 1S
.0781
.0 740
.0705
.0670
.0636
.0597
.0597
.0980
.0543
.0906
.0878
.0850
•• Denotes adjUSlable bias ed need le assem blie s
.0828
.08 04
.0790
.0782
.0774
.0765
.0765
.0765
M -7
Part 5 Appendix 4
Main rnetllf"ing needles for . 100 j'b
Needle
Port
No.
8 19061Z 8 190582 8 19 1642
6 1842 62 8184362 Bl85 10Z 818580Z 8 18 7392 8 187 44Z 8 18 9262
B1U· ·
S2V "
BW"
S2 Y"
82Z' •
'AA
F2AB"
.0959
.0923
4
.0867
.0835
.0803
.0942
.0929
.0908
.0872
.0844
.0805
.0 714
.0740
.0700
.0666
.0623
.0580
.0580
.0938
.0896
.0967
.0932
.0905
.0890
.0848
.0978
.092 7
3
.0959
.0926
.0899
.0871
.0840
.0953
a
.0898
.08 70
.0812
.0905
.0872
.084 0
.0803
.079 1
.077 T
.0779
.0770
.0710
. 0667
.0 697
1
5
6
7
8
9
10
11
12
13
.0769
.0748
.0728
.0708
.0689
.0671
.0671
.0807
.0773
.0750
.0730
.0710
.0691
.06 73
.0673
.0943
.091 4
.08 79
.0840
.0804
.0768
.0731
.0693
.0615
.058 0
.0562
.0562
.081 6
.0779
.0155
.0735
.0715
.0695
.0677
.0677
.084 0
.075 1
.0742
.0726
.0710
.0694
B2IoC' • 82 AD "
.0953
.0923
.0895
.0865
.0837
.092 5
.0803
.0665
.0634
.0634
.0 6 15
.060 6
.0578
.0578
.0578
.0 551
B2AE" 82 A F " •
.0953
. 0932
.0953
.0898
.0868
.0840
.08 04
.0898
.0868
.0840
.0804
.0770
.0 700
.0770
.0668
.0636
.0508
.0 580
.0553
.0932
.0700
.0668
.0636
.0608
.0580
.0 553
N_ .
P.rt
8192222 8192482 8 1931 22 8 193622 8 196652 8 197432 81 99532 8201542 820521 2 B20S27Z 8 160392
N~
82AG"
,,
3
4
5
8
7
8
9
10
"
"
13
.0979
.0931)
.0910
.0880
.083 7
.0797
.0759
.0 721
.0683
.0645
.0607
.0569
.0 530
8 2 AH"
B2AJ o •
.0987
.0976
.0951
.0926
.0893.
.0860
.0826
.0793
.0755
.0703
.0661
.0632
.0625
.0625
.0940
.0905
.0887
.0855
.08 15
.0775
.0736
.0595
.0663
.0634
.06 14
.06 70
B2AK" 'AL
'AM
a2 A N" B2AP "
' AQ
Bl AR "
3A
.098 7
.0980
.0912
.0896
.0876
.0838
.0800
.0755
.0733
.0674
.0631
.0599
.0572
.0572
.09 70
.0923
.0905
.0878
.0842
.0801
.0762
.0 7.13
.06 78
.0648
.06 18
.0585
.0585
.0978
.0928
.0959
.093 1
.0902
.0875
.0849
.0825
.0797
.0765
.0 74 1
.0720
.0691
.0668
.0668
.0980
.0936
.0897
.0858
.0821
.0789
.077 1
.075 1
.0716
.0685
.0663
.0640
.0604
.0940
.0901
.0880
.0848
.0808
.0768
.0729
.0687
.0653
.0622
.0600
.0595
.0980
.0915
.0905
.0876
.0838
.0800
.0755
.0733
.0674
.0631
.0599
.0572
.0572
..
Needle
P.rt
No.
8 176462 8182632 B189462 8200062 8 2001 02 820 1572 021061
3B
3C
3D
B3 E · ·
B3 F "
83G B
,
.0980
.09 18
.0888
.0857
.0820
.078 7
.0775
.0765
.0752
.0728
.0700
.0675
.0675
.0983
.0929
.0893
.0867
.0825
.0177
.0732
.0684
.0542
.0626
.0610
.0593
.0570
.0980
.0918
.0888
.0857
.0820
.0780
.0765
.0750
.0720
.0710
.0685
.0665
.0665
.0957
.0944
.0915
.0884
.0849
.0815
.0767
.0 723
.0688
.0655
.0622
.0618
.0618
.0939
.0932
.09 10
.0882
.0847
.08 10
.0 765
.0 725
.06$1
.0655
.0621
.0586
.0586
.0949
.0930
.0918
.0894
08 62
.08 12
.0773
.0735
.0692
.0652
.0618
.0600
.0570
1
3
4
5
6
7
8
9
10
""
13
.0980
.0931
.0887
.08 5 1
.08 15
.0784
.0760
.0755
.0750
.0744
.0737
.0730
.0730
.098 0
.0929
.09 11
.0885
.0855
.08 14
.077 6
.0726
.0687
.0654
.0621
.06 /5
.06 15
.0904
.0880
.0853
.0827
.0797
.0762
.0724
.0705
.0677
.0666
.0655
81 61692 8 166512 8 171762 81 73032
4'
4C
4D
4'
.0980
.0927
.0890
.08 63
.0825
.0785
.0740
. 0595
.0650
.0500
.0555
.0600
.0600
.0980
.0922
.08 76
.0835
.0805
.0757
.0 708
.0656
.0599
.0550
.0505
.046 4
.0464
.0980
.0880
.0866
.084 1
.08 15
.0787
.0752
.0 717
.0661
.0608
.0 565
.0 525
.0525
.0980
.0922
.0896
.0858
.08 11
.0775
.0744
.0594
.0650
.06 77
.0587
.0 560
.0560
5
A4-8
Part 5 Appendix 4
Needle
P. rt
8181372 a 178672 8 183622 9 188512 8195842 Bl i585Z B19S86Z 8 195872 B19588Z 8 195892 9195902 8 195912
No.
40
4H
4J
4<
1X
1
. 09 58
. 09 13
. 08 71
.0964
.0964
.089 7
.0980
,0918
.088 5
.0888
.085 1
. 0820
. 0787
. 0772
.0160
.0745
.0720
.0695
.0675
.0675
2
3
4
S
6
7
8
9
10
11
12
13
.0897
.083 6
.0885
.085 1
.0783
.0817
.0850
.0808
.0 737
.0693
.0638
.0773
.0756
_0721
.0 11 0
.0669
.0 580
.0 5 18
. 0455
.0 4 15
. 04 15
.0677
0645
.0645
.0619
.0 6 19
.0593
.0562
.0593
.0524
.0524
.0 562
• Denotes biased need le 8sll!mbl ies
2X
3X
4X
SX
6X
7X
6X
.0981
.0979
.098 1
. 09 42
.0980
.0973
.0979
.0939
. 0983
.0942
.098 0
.094 1
.091 9
.0935
.09 34
.093 1
.093 1
.091 3
. 09 10
.08 78
. 08 48
. 090 5
.0898
.0870
.0861
,089 1
.085 2
.088 7
.0846
.0897
.0876
. 0855
.0835
. 08 14
.0791
.0769
.0748
. 0730
.0730
.09 14
.0888
.0864
.0839
.08 17
.0 790
.0765
.0 740
.0885
.0858
.0830
.0803
.077 6
. 0 71 4
.0 749
.0 72 1
.0594
.0595
.069 0
.0558
.066 6
. 08 17
. 0787
. 0 7 56
.0 726
.0695
.0564
.0642
.0633
.0837
.0805
.071 3
.0742
.0710
.0676
. 0640
.06 rD
.06 10
.0824
.08 13
.0803
_0788
.0 753
.0 71 6
. 0679
.0 774
. 0734
. 0695
. 0718
.0655
. 0676
.0635
.0644
. 0605
.0573
.0573
.06 16
.0593
.0578
.0 543
. 0543
.05 10
.0505
. 0 760
.0550
A5-1
Part 5 Appendix 5
Metering needles cross-reference chart
for Zenith Stromberg carburetors
No.2 Series
No.1 Ski.
IA
IB
Ie
ID
0 19672
8 .17296
8.18128
B.ICe
B. tCE-
e.tcetee -
8 ,22330
8.22355
8.224 15
8 . 18330
8.
8.22693
1L
B. 18722
B.TeL
IAA
lAS
'A T
IAU
IAV
'AY
8.19504
e.t cu-
8 .20353
B. TeN"
8 .20460
8.20461
8 .1 CP·
B.ICO"
8.20462
B.1CU
B. 1CW
B. fC Y
8.22536
8 ,2 2290
8.22609
8.22645
8.22658
0 .23083
8.23 139
8 .20560
8 , 1E
B. IG ·
8,1G
B. 18394
8 .20672
B. 1CZ
B. 18564-
B. IR
B.IS
a. TU
8. 19000
8 . 18999
B. IDA
H.1De
B.WE
8. 1DF
B.1W
8.1OG
s.iv-
8.19982
a lY
B. 19 4 19
B. 1DH·
B. 1DJ
S.IA F ~
8.1AF
S. I A G
B.fAM
S. f A N
8./AP
8. fA O ~
afAR
8. fAR·
8. fA W
B. f BE
B. IBF"
8. 18 H ~
B. fBK
8.1 8 L
B. 1BM
B.18P
B.IBO
B.I8R
B. I BS ~
8. 19619
8 .20376
8. 19699
8. 19773
8.2000<
8.20091
8.20194
B.2 f 2 17
B.20287
8.2 1848
8.20524
8.20799
8.20816
B.20958
8.21442
8.21666
s.ter-
8.21750
8.21790
B.2 1792
8. 2 1890
B.2 19 19
B.21989
8.1BW
8.1BZ
8.22242
8. 22261
02010 1
020714
020965
2J
2K
2L
2M
2N
2P
B.1 9 147
8 .194 17
B. IA E
8 .2314 1
8.23200
2<
2B
2C
20
2E
2F
2G
2H
a. 1OK "'
S.IDL ~
8. 1DO
8. 105 ~
8. IDS
8. 1DT
B.1DV
8. 1ES B. IECB. I ED
B. I EE
8 .23230
8.23428
8.2348 1
8.23969
8. 23523
8.2356 1
8.23600
8.23619
8.23655
8 .2399 1
8. 25265
2S
2",
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A6-3
Part 5 Appendi x 6
No.
N_ .
0'
Modol o.ullt
CoJ*';ty
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1300 A~, ....... , ;c
1300 GT
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AUC 864 R
AUD " IF
AUD .l R
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AUD
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AUO 271
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86
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AUD 54 A
AUD 54B
AUD 117A
AUD 117 B
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1000 IUSAl
2000 TC t USAl
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2000 TC [USA ECE'I
1915a:
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1967/68
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A6- 11
Part 5 Appendix 6
-
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"""" •
""""
"'" rc
3.5
l itr~
VII
3.5
l i tr~
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3SOO V8 P6
3SODSva P6 ( USA)
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1973 1
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AU O 27tH.
AU O 21Ol'l
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1969170
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3500 V8 P6 (Ee E)
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A6-12
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Pa rt S Appendix 6
~
Model Det ails
Capacity
UNIVERSAL POWER DRIVES
ssecc
Unii>O_'
VANDEN PLAS
Pri""... 4 IiI.... DM4
Prine... 3 l itre He & L C
Pri""... 4 litre R
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1275
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AIIeo,o 17 &0
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1976
1975
1975
\975
1976
19 76
' 976- 77
1980
' 981
' 98'
\976
1975
1975-76
1975
\ 97 6
1976
\ 9 79
19 79
1976
197 6
1976
1976
1976
197 6
197 6
197 5
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1976
M;ox, 15OO
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~ x, 1500 Auto
Mu , l500
"'.x, 1750
M..; 17&0 Avla
Mu,175O
Ma ,; 1750 Hil; ne
1976
19 75
19 76
19 76
1976
19 76
1975
1975
M a, ; 1750 H L
1976
M. " , 750 A uto
M.1
'000
1000 I"lE
1000 HL E
1000 Van
1000 H lE
12 75
1275 Aut<>
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_
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M eaoT",bo
Meao Turbo
M ,ft, 850
M tn, 850
M ,fti 85 0
M tft, ' 000
M ,ft,looo
Mi ni 1000
Min, 1000
Mm , looo
Mm , 1000 {Swod en)
M in; 1000 (Sw eden )
Mm , ' l 00
Mm t 1100
Mi n' 1100
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1975
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1978
1975
1976
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1977
19 /5
1978
1978
1976
1978
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FZX 110 5
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AUD 6 28
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FZX HI78
FZX 1180
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1979
1979
1979
1979
' 975-76
1916-19
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1916-19
,,~
1979
1919
1979
1915
1975
22 00 M.n...1
1976-77
2200 M onual
1971-78
2200 M . nu.]
1979
IoI1r6
HI F6
HI F6
FZX 1241
197 6
1976-79
19 75
1976
1976· 79
1976
FZX 1285
FZX 1322
l'ZX1286
FZX 1323
AUD 684
I'D; 12'5
AUD 635
szx 1319
I'ZX , 108
FZX 1311
FZX 1272
szx 131 9
AUD 89 71'
AUD 6S7R
FZX 108 81'
FZX ' 085R
FZlt 1219 F
I'ZX ' 219R
FZX 1304 F
FZX '304R
FZX 1328F
F2X 1325R
,~
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FZX 1271
fZX 13 18
A U O S03
FZX 1099
1 75 0 Aul D
17&0 M .n ( 5. Africa)
~iO"
szx 13 15
197 5
197 !>-76
1977
197 :'-76
175 0 Man ( 5. A frico )
17SO Man (5. Alflea )
Part 5 Appendix 6
,,
,,
,,
,,
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1,12
CUD " 3'
CUD 1131
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AUO 4381
lZX 111 0
AUO 43 $6
AU O 43 55
AUO 4355
AUO 4355
AUe 438 7
lZX 1029
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lZX 1029
l,.ZX 1029
AUO 9148
AUe 4387
AUe 4387
AU e 4397
AUe 4397
Aue 116 7
AU e 116 7
AU e 1167
AUe 1167
AUC 1167
AUC 1167
AUe 1167
AUC 1187
AUe 1187
AUe 438 7
AUe 438 7
AUC 438 7
AUe 4387
AU C 4387
AUC 4387
AUC 4387
AUC4387
AUC 1170
AUe 438 7
AUC 1170
AUC 1170
AUC 1170
AUD 9148
AUD 9148
AUD 9148
UX 1028
tzx ' 028
AUD 9141
AUD 9142
AUD 9141
AUD 9142
AUD 9al
AUD 9142
AlJ D 9141
AUD 91(2
AU D 9148
AUD 9148
lZX 138 3
AUD 9148
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CUD
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CUD 1161
CUD " 6'
CUD 1161
CUD 116'
CUD 116 1
eUD "8 1
CUD 1161
cu o "81
CUD "6 1
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Part 5 Appendix 7
Needle charts for SU carburetors
N ot es on needles
Needle selection
Th e applications list (Append i~ 1, list A) details three eltenenve n~ les - Ric h. St a nda rd. Weak - for ea c h application of
cerbur encr to iI parti cular CiI'. These recomme ndatio ns apply only to the installation as designed by th e relevant vehicle
ma nufactu rer.
The standard needle should norm ally be used except in specia l circumstances.
The ric h needle g il/9$ a riCher mixtu re ratio , and therefore greater po w er, th rOlJg hout its range.
The w eak needles fOf carbun!ttor specif icat io ns fitt ed wtlh flxlld needl es are not economy needles - they are to compensa te for
operation at high altitudes. There is no gu arantee that greater economy will result from their use at normal alt itud es.
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Part 5 Appendix 8
Needle cross-refence chart
forSU carburetors
Port
Number
AUD1 000
AU 01001
AU01OO 2
AU01oo3
AU 0 1004
AU01005
AUD 1006
AU 0 1007
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•
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P.rt
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AU01 063
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BA
BC
BD
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BE
AU01066
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BF
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AU 01 0 13
25
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AU01020
AU01021
AU 01022
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AU01029
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53
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sa
59
60
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62
B9
70
74
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T6
TB
79
BO
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AA
AB
AC
AD
AE
AF
AG
AH
AI
AJ
AK
AL
AM
AO
AP
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AR
AS
AT
AU
AV
AW
sx
AY
AZ
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AU0 1073
AU01074
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AU01078
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AU01 081
AU01082
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BG
BH
BI
BJ
BK
BL
BM
BN
BP
Ba
BR
BS
BT
BU
BV
BW
BX
BY
BZ
BX1
BM2
BM4
BMB
BMB
C
CB
CC
CD
CE
CF
CG
CH
CI
CJ
CK
CL
CM
CN
CO
CP
CO
CR
cs
CT
cu
cv
cw
AU0 1121
AU01124
AU01 125
AU0 1126
AU0 1127
AU 011 28
AU01129
AU0 113 0
AU01131
AU0 1132
AU0 1133
AU01134
AU01 135
AU01136
AU01137
AU01 138
AU011 39
AU0 1140
AU01 141
AU01142
AUD1 143
AU01144
AU 011 45
AU0 1146
AU01 147
AU0 1148
AU0 1149
AU01150
.4.U01151
.4.U01 152
.4.U01 153
AU01 154
AU01155
.4.U01156
AU01157
AU01 158
AU Ol 159
AU0 1160
AUOl 16 1
AU011 62
AOO1163
AU01 164
AU0 1165
AU01 166
.4.U01 167
AU0 1168
AU011 69
AU 011 70
Needle
M arking
CX
CY
CZ
CIW
CP4
CS'
C52
DA
DC
DE
OF
DG
DH
OJ
OK
OM
ON
DP
DO
DR
OS
DT
DU
DV
OW
DY
01
02
03
04
DO
07
08
0'
EA
EB
EC
ED
"EG
EH
"EJ
EK
EF
EL
EM
EN
EO
EP
EO
ER
ES
ET
EU
EV
EV'
Port
Number
AU01171
AU 01 172
AU011 73
AU01 174
AU 01175
AUO'176
AUDl177
AU01178
AU01179
A U 01180
AU 01 181
AU01 182
AU0118 3
AU01184
AU0 1185
AU01186
AU0 1187
AU01 188
AUD1189
AU0 119Q
AU01 191
AU011 92
AU 01 193
AU01194
AU01195
AU01196
AU01197
AU01198
AUD 1199
AU 01200
AU01201
AU01202
AU01203
.4.U 01204
AU 01205
AU01206
AU 01207
.4.U 01208
AU 01209
AU01 2 10
AU012 11
AU 01212
AU 0 121 3
AU012 14
AU01215
AU01 216
AU012 17
AU 01218
AU01219
AU01220
AU 0 1221
AU01 222
AU0 1223
AU01 224
AU01225
AU01226
AU01227
Needle
Marking
EX
EY
EZ
"'"
"'"E4
EX'
FA
- FB
FC
FD
FE
FF
FG
FH
FI
FJ
FK
FL
FM
FN
FD
FP
Fa
FR
F5
FT
FU
FV
FW
FY
FZ
GA
GB
GC
GO
GE
GF
GG
GH
GI
GJ
GK
GL
GM
GN
GO
GP
GR
GS
GT
GU
GV
GW
GX
A8-1
Part 5 Append ix 8
P",
Nee d l.
Pe r-t
Ne edle
Port
N umber
Marking
Number
Ma rking
Numbe r
AU 0 1228
AU01229
GER
G2
HA
HB
HC
HO
HE
HF
HV2
HV3
HV.
HI
H2
H'
H'
JM
K
KI
KT
KW
KTA
KWR
KWI
KWZ
l
LS
lBI
lB2
lBA
LFN
LSI
l l1
l 12
M
MA
MO
MW
MME
MOW
MI
M2
M'
M'
M7
M'
A U0 130 1
Rl S
R3
R6
R32
RM
RMO
RM I
RM2
RM3
RM'
RMS
RM6
RM7
RMB
RM9
S
SA
SB
SC
SO
AU 0 13 74
AU 01375
AU 0 137 6
AU 0 1377
AU 01 378
AU 0 137 9
.4.U0 1230
AU01 231
AU0 1232
AU01233
AU 01234
AU0 1235
AU01236
A U0 1237
AU 01 238
AU01239
A U0 1240
AU01241
AU 01242
AU 01243
AU01 244
A U 01245
A UD 1246
A UD1247
AU D1248
A UD1249
AUD1250
AU D1251
A UD1252
AU D1253
A UD 12 54
A U0 1255
AU 01256
AUD1257
AUD 1258
AU D1259
AUD 1260
AU D1261
AUD1 262
AUD1263
AUD 1264
AU D1265
AU0 1266
AU0 1267
AUD1268
AU0 1269
AU D1270
AU0 1271
AUD 1272
AUD 1273
AU0 1274
AU D1275
AU01 276
A U0 1277
AU D1278
AU01279
AU D1280
AU D128l
A U0 1282
AU D1283
AU 01284
AU 01285
A UD1286
A UD128 7
A UD1288
A U01289
A UD1290
AU D1291
AUD 1292
AUD1 293
AU 01 294
AU 01295
AUD1296
AUD1 29 7
AU 01 298
A UD1299
AU D1300
M9
01
07
OA'
OA7
OA,
PJ
P4
PO
P61
OA
OW
RA
RB
RC
RO
RF
RG
RH
RJ
RK
Rl
RO
RP
RS
RU
RV
RlB
AU 0 1302
AU01 303
AU 0 1304
AU01305
AU01306
AU01307
AU 01308
AU 01309
A U 0 13 10
A U01311
A U01312
A U 0 13 13
A U0 1314
A U01315
A U01 316
A U0 1317
A U01318
A UD1319
A UD1320
AUD1321
AUD1322
AUD1323
AUD1324
AUD1325
A UD1326
AUD1327
AUD 1328
A U0 1329
AU D1330
AU D1331
AUD1332
AU D1333
AUD1334
AUD1 335
AUD 1336
AUD133 7
A U0 1338
AUD 1339
A U0 1340
A U0 134 1
A UD1342
AU D1343
AUD 1344
AU0134 5
AUD 1346
AUD134 7
AU0 1348
AU0 1349
AU0 1350
A UD135 1
AUD1352
AUD1353
AU 0 1354
AUD1355
AUD1356
A UD 1357
AU D1358
A UD 1359
AUD1360
AUD 136 1
AUD1362
AUD 1363
AUD 1364
AUD136S
A UD1366
AUD1367
AUD1368
A UD1369
A UD 1370
A UD 1371
A UD 1372
A U0 1373
SE
SF
SG
SH
SJ
SK
st.
SM
SN
SO
SP
sa
SR
SS
ST
SV
SW
SY
SZ
54
55
S6
TA
TB
TC
TO
TE
TF
TG
TH
TJ
TK
Tl
TM
TN
TO
TP
'R
TS
TT
TU
7W
TX
UA
UB
UC
UO
UE
UF
UH
UJ
UK
UVA
AUDl 380
AUOI 381
AU01382
AUDl 383
AU01 384
AU 0 1385
AU OI386
AUDl 38 7
AUDl 38S
AU01 38 9
AU 01390
AUD 139 1
AU D1392
AU D1393
A UD1394
A UD 1395
AU D1396
A UD1397
AU D1398
AU D139 9
A UD1400
A U0 1401
AU01 402
A UD 1403
A U0 1404
A U0 1405
A U0 1406
AU 0 1407
A UD1 408
A U0 1409
A U0 1410
AU014 ll
AUD14 l2
A U0 1413
AU014l4
AU 0 14l5
A U0 14 l 6
AUD1 4l7
AU 0 14l8
A UD 14 l 9
AUD1420
A U0 1421
AUD1422
AUD1 423
AU 01424
AUD1 425
A U01426
A UD14 27
AUD 1428
AU D1429
AUD14 30
AUD1431
AU D1432
AUD14 33
AUD1 434
AU D1435
AUD 1436
AUD143 7
A UD1438
AUD1 439
AUD1440
AUD 1441
AU Ol442
A UDl443
AUD 1444
AUD144S
A UD 144 6
N eed le
Marki ng
UVB
UVC
UVO
UVE
UVF
UVG
UVH
UVI
UVJ
UVK
UVl
UVM
UVN
UVO
UVP
UVR
UVT
VA
VB
VC
VO
VE
VF
VG
VH
VI
VJ
VK
Vl
VM
VN
VO
VP
VR
VS
VT
V2
V3
WX
WXI
W02
W03
WOO
W3
WA
WB
we
WO
WE
WF
WG
WH
WI
WJ
WM
WN
XB
XC
XO
XE
XF
XG
XH
XI
XJ
XK
Xl
XM
XN
XO
XO
XR
XS
Part
Needl.
Number
Marki ng
A U 01 4 47
XT
AU 0 1448
AU 0 1449
XU
XV
XW
AU 0 1450
AU 0 1451
AU 01452
AU01453
A U01454
A U01455
A U01 456
A U0 14 57
AU 0 1458
AU 0 14 59
AU0146 0
AU01461
A U01462
AU 01 463
A UD1464
A UD1465
A UD1466
A UD1467
AUD1 468
AUD1469
AUD1470
AUD14 71
AU D1472
AUD14 73
AU D14 74
AU D147 5
AUD1476
AU01477
AU 01478
A U0 14 79
AUD1480
A UD1481
AUD1482
A U0 1483
A UD1484
AUD1 485
AUD1486
AUD148 7
AUD 1488
AU01489
AU01490
AUD 1491
AUD 1492
AUD1493
AUD 1494
AU01495
A U01496
A U0 1497
AU 01498
AU01 499
A U0 1500
A U0 150 1
AU01502
AUD1503
AUD1 504
A UD 1505
AUD1506
A UDl507
A UDl508
AUD1509
AUD1510
A UD1S1 1
AUD151 2
AUD1S13
AUD1S1 4
AU01S1S
AUD1S16
AU01517
A U01518
A UD1519
XX
XY
X2
YA
YB
YC
YO
YE
2A
ZB
ZC
ZO
ZE
2F
ZG
Ul
UM
GY
TZ
KA
TV
UO
GZ
UN
SU
SX
KB
AN
BB
CA
UG
UP
MB
UR
US
UT
RE
RI
MC
ZH
RN
UU
UV
RR
KH
HG
UW
UX
TV
KC
KO
KE
UY
UOI
U25
U3'
U45
U50
U69
U60
U7.
U14
U75
U76
U7B
U79
UZ
KF
KG
5
A8-2
PArt
Numblu
AU0 152 0
AUD 1511
AU Q1522
AUD 15 23
AUD1514
AU D1525
AUD1526
AU0151 7
AUD 1528
AUD1529
AUD 1530
AU D1531
AUD1532
AUD1533
AU Q1534
AUD 153 5
AUD1536
AU OtS3 7
AUQ 1539
AUDl54l
AUO l548
AUO l 549
AU01550
AU D1552
AU D1553
AU D1554
AUD l583
AU Dl58S
AU Ol644
AUD168l
AU 01682
AUD 1683
AU D1684
AU0168 5
AU016 86
AUD1 687
CU 01 000
CUD1 QOl
CUD1 002
CUD1003
CUD1004
CUD1005
CU D1006
CU01007
CUD1008
CUD 1009
CUD 10l0
CU D10l l
CUD1 012
CU 010l3
CUD 10l4
CU010l5
CU010 l6
CU010 17
CU D10l8
CUD 1019
CU01020
CUD102 l
CUD 1022
CU01 02 3
CUD1 024
CU 0 1025
CUD 1026
CU D102 7
CU01028
CU010 29
CUD 1030
CU 0103l
CU0103 2
CU01033
CU01034
CU 0 1035
CU01036
Part 5 Appendix 8
N.edle
Marking
KJ
UI
DL
DB
NA
OX
BQ
AAA
DZ
KK
FX
DO
UVU
BB2
BB3
BB4
KL
KM
KD
KP
UW
UVW
KQ
KA
KS
KU
KV
UVX
KX
NB
KY
KZ
HH
HI
HJ
HK
AAA
AAB
AAC
AA D
AAE
AAF
AAG
AA H
AAJ
AAK
AA L
AAM
AAN
AA P
AAQ
AAA
AAS
AAT
AAU
AAV
AAW
AAX
AAY
AAZ
ABA
ABB
ABC
ABO
ABE
ABF
ABG
ASH
ABJ
ASK
ABL
ABM
ABN
PArt
Number
CUDi 037
CUD1038
CU 01 039
CU01040
CUD 104 1
CUD104 2
CUD1043
CUD1044
CUD1 04 5
CUD 1046
CUD1047
CUD1048
CUD1 049
CUD1 0SO
CUD t OS'
CU D105 2
CUD 1053
CUD1054
CUD1 QSS
CUD10S6
CUD 10 57
CUD1058
CU D10 S9
CUD 1100
CUD ll0l
CUD ll02
CUDll03
CUDll04
CU01 105
CUD ll06
CUDll07
CU D1108
CUD 110 9
CUD ll10
CUD11 11
CUDl l l2
CU Dl l1 3
CU D111 4
CUD11 15
CUD1 1l 6
CUD1 117
CUDll 18
CUD11 19
CUD1120
CUD11 2l
CUDll 22
CUD11 23
CUD11 24
CUD1125
CUD1126
CU01127
CUD 11 28
CU Oll 29
CU01130
CU0113l
CUD 1132
CUD1 133
CUD1134
CUD1l35
CU Dl l36
CUOl 137
CUOl l 38
CU Dll 39
CUD ll40
CU Dl l41
CU D1 142
CUDll 43
CU Ol l44
CU0 114 5
CUDll46
CU01 147
CUD1148
CUDt 149
Needle
Marking
PArt
ABP
ABQ
ABR
ABS
ABT
ABU
ABV
ABW
ABX
ABY
ABZ
ACA
ACB
ACC
AC D
ACE
AC F
ACG
ACH
ACJ
ACK
ACL
ACM
BAA
BAB
BAC
BAD
BAE
BAF
BAG
BAH
BAJ
BAK
BAL
BAM
BAN
BAP
BAQ
BAR
BAS
BAT
BAU
BAV
BAW
BAX
BAY
BAZ
BBA
BBB
BBC
BBD
BBE
BBF
BBG
SBH
BBJ
BSK
BB L
BBM
BB N
BBP
BBQ
BB R
BBS
BBT
BBU
BBV
BBW
BBX
BBY
BBZ
BCA
BCB
CU0 1150
CUD11 51
Numbe r
CUD1152
CU D1153
CU D1 154
CUD115 5
CUO"56
CU011S7
CUDl158
CUOl159
CUD l1 60
CUOllS1
CU01 , 62
CV0 1163
CUD1 164
CU0 1165
CUD1 166
Needle
MarkIng
BCC
BCD
BCE
BCF
BCG
BC H
BCJ
BCK
BCL
BCM
BCN
BCP
BCQ
BCR
BCS
BCT
BCU
BCV
CUOl 167
CUDl168
sew
CU01169
CUD l 170
CUD l 17l
CUD 1200
CUD 120l
CU01 20 2
CU01203
CUD 1204
CU 01205
CU01206
CUD1 207
CU D1208
CU D1209
CUD1 2l 0
CUD12l1
CUD12 l2
CU0 1213
CU012l4
CU0 1216
CU D12l 6
CU01 217
CU012l8
CU 01219
CU01 220
CU D1 22l
CUD 1222
CU D1 223
CUD 1538
NZX4001
NZX400 2
NZX400 3
NZX4004
NZX400 5
NZX4006
NZX4007
NZX4008
NZX4 009
NZX4010
NZX401 1
NZX4012
NZX40 13
NZX401 4
NZX401 5
NZX401 6
NZX4017
NZX401 8
NZX40 19
NZX402Q
NZX40 21
NZX40 22
NZX4 023
NZX4 024
NZX40 25
NZX40 26
BCX
BCY
BCZ
CAA
CAB
CAC
CAD
CAE
CAF
CAG
CAH
CAJ
CAK
CAL
CAM
CAN
CAP
CAQ
CAR
CAS
CAT
CAU
CAV
CAW
CAX
CAY
COl
KN
ADA
AD B
ADC
ADD
ADE
ADF
ADG
ADH
ADJ
ADK
ADL
ADM
ADN
ADP
ADQ
ADR
ADS
ADT
ADU
ADV
ADW
ADX
ADY
ADZ
AEA
AEB
PArt
Number
NZX4027
NZX 4D2 8
NZX40 29
NZX4030
NZX 40 3 1
NZX4032
NZX4033
NZX40 34
NZX40 35
NZX4{l36
NZX4037
NZX40 38
NZX40 39
NZX4040
NZX4041
NZX404 2
NZX4043
NZX4044
NZX404 e:
NZX404 6
NZX 4Q47
NZX404S
NZX404 9
NZX40 50
NZX40 51
NZX4052
NZX40 53
NZX40 54
NZX40 55
NZX4CS6
NZX40 57
NZX4058
NZX4059
NZX4060
NZX40 61
NZX4062
NZX4063
NZX4064
NZX40 65
NZX40 66
NZX40 67
NZX4068
NZX4069
NZX4070
NZX4071
NZX40 72
NZX8 00 1
NZX800 2
NZX8003
NZX8004
Nz x 800 5
NZX8006
NZX8007
NZX8008
NZX8009
NZX80 10
NZX8 0 11
NZX801 2
NZX8 013
NZX801 4
NZX801 5
NZX801 6
NZX80 17
NZX8 018
NZX80 19
NZX8020
NZX8021
NZX80 22
NZX8023
NZX8024
NZX8025
NZX8026
NZX8027
N eedle
M arking
AEC
AED
AEE
AEF
AEG
AEH
AEJ
AEK
AEL
AEM
AEN
AEP
AEQ
AER
AES
AIT
AEU
AEV
AEW
AEX
AEY
AEZ
AFA
AFB
AFC
AFD
AFE
AFF
AFG
AFH
AFJ
AF<
AFL
AFM
AFN
AFP
AFQ
AFA
AFS
AFT
AFU
AFV
AFW
AFX
AFY
AFZ
BOA
BO B
BDC
BO D
BD E
BDF
BOG
BDH
BDJ
BOK
BDL
BDM
BON
BOP
BOQ
BOA
BDS
BOT
BDU
BDV
BOW
BOX
BOY
BDZ
BEA
BEB
BEC
Part 5 Appendix 8
P.rt
N_ dl.
P.rt
Num be r
Marking
N um ber
NZX80 28
NZX 80 29
NZX8030
NZX80 3 1
NZX8032
NZX8033
NZX8034
NZX8035
NZX80 36
NZX8037
NZX8038
NZX8039
BED
BEE
BEF
BEG
BEH
BEJ
BE.
BEL
BEM
BEN
BE'
BEO
BER
BES
BET
BEU
BEY
BEW
BEX
BEY
BEZ
BFA
BFB
BFe
NZX8052
NZX8053
NZX8054
NZX8055
NZX8056
NZX8057
NZX80 58
NZX8059
NZX8040
NZX8041
NZX8042
NZX8043
NZX8044
NZX8045
NZX8046
NZX8047
NZX8048
NZX8Q49
NZX80S0
NZX8051
NZX8D60
NZX8061
NZXSQ62
NZX80 63
NZX8064
NZX8065
NZX8066
NZX806 7
NZX8068
NZX8069
NZX8070
NZX80 71
NZXS072
NZX80 74
NZX8075
A8· 3
Needle
Marking
BFD
BFE
BFF
BFG
BFH
BFJ
BF.
BFL
BFM
BFN
BF'
BFa
BFR
BFS
BFT
BFU
BFV
BFW
BFX
BFY
BFZ
BGA
BGB
5
A9 -0
Part 5 Appendix 9
Jet identification information
for SU carburetors
Flo a t
Cha m b er
Angle
30'
H
H
H
H
202030'
30'
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
20"30'
H/ l 0'
H/ 10'
'0"
' 0·
' 0·
20·/ 30'
20·/ 30·
20·/ 30·
H/1 0·
H/ 10·
H{1 0·
20·/ 30·
20·/ 30·
Id ent ificati o n Info rm ation
Jot
Carb
Ty pe
Int e rPO"
connectio n Nu m ber
Sleeve Co lo u rs
(i)
(ill
(iii)
J et S ize
H
H
H
H
H
H
H
AUC41S5
AUC8182
AUC8183
AUC8188
AUC81 89
AUCB 186
AU Ca 187
01 25~
.09"
.10·
.OS"
.10·
.09"
.01·
HD
HD
HD
HD
HD
HD
A U C81 54
AUC8155
.OS"
.10·
.125"
AUeS' 56
AU 09030
AU 09 825
CU02637
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
HS
RH
RH
lH
RH
lH
RH
lH
lH
lH
RH
lH
lH
RH
RH
lH
RH
RH
RH
RH
lH
RH
lH
RH
RH
RH
RH
lH
RH
lH
RH
RH
lH
RH
lH
RH
RH
RH
lH
RH
RH
lH
RH
lH
HIF
HIF
HIF
HIF
HIF
lH
lH
RH
RH
lH
LZX1 027
LZX1029
LZX1026
LZX1028
LZX1068
AU09098
AU091 03
A U D9104
.4.U091 05
.125"
.125"
.125"
Black
Black
Wh ite
.OS"
Black
Brown
.09"
.OS·
Rod
Rod
Rod
Rod
G,.,
Orange
A U09141
,4,U09142
Green
Pink
Yellow
AU09148
Orange
A U 09149
AU 0 9451
.4.U 0 94 80
A UD9481
AU0 9596
White
Black
White
Black
G,,,,
A.UD9815
Rod
Rod
AU09879
While
AU DS883
AUD9888
AUD9889
AUD9971
CUD2697
CUD2698
CU D2708
CUS2709
CUD2752
CU02 753
CU0 3176
CU031 "
LZX1052
tZX1058
LZX1059
lZX1110
lZX1111
tZX 1112
lZX11 14
lZX1116
lZX11 17
LZXl l 1B
lZX1120
LZXl 121
LZX1 126
LZXl 127
Black:
W hi te
Blue
Blue
Orange
Green
Whit e
White
Yellow
Blue
Wh it e
White
Vio let
Vi ol et
Vi ol et
AU09814
.10"
.10·
.09'
.09 '
.10·
.10"
.09"
.09"
.125"
.125"
.OS"
09 "
.OS"
Yellow
AU0 9106
AU09450
J et H ead
Bl ue
Pink
Oran ge
Orange
Bro w n
Brow n
Rod
Pink:
Pink
Rod
.10Bl ue
.125.125"
.10"
Brown
.10'
.10'"
. 0 9~
Bl ue
Gree n
Pink
G,.,
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W h it e
Wh it e
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Yellow
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Bl ack:
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.09"
.09"
.OS"
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Grey
Blue
Yellow
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Haynes Automotive M anuals
NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle,
consult your local Haynes dealer for the latest product information.
ACURA
1 2 02 0 Integra '86 thru '89 & Lege nd '86 Ihru '90
1202 1 Integra '90thru '93 & Lege nd '91 Ihru ' 95
AM C
Jeep CJ - see JEEP (50020)
14 02 0 Mid _s ize models '70 thru ' 83
14025 (RenaUlt) Allia nc e & Encore '83 Inru '87
AUDI
1502 0 4000 a ll models '80 Ihru '8 7
15025 5000 all models '77 thm '83
15 02 6 sooo a ll mode ls '84 tnru '88
AUSTIN-H EALEY
Sprltll- See MG Midget (660 15)
BM W
" 8020 3/5 Series not including dleset or
all-wheel drive models ' 82 ttl .... '92
18021 3-Se rlIlS incl. Z3 mod els '92 thru 118
18025 3201 all 4 c yl models 75 thru '83
18050 1500 thru 20 02 except Turbo ' 59 thru 7 7
BUICK
" 90 10 Buick Centu ry '97 I nru '02
century (fro nt- wh8fl1 dri ve) - _ GM (38005)
"9020 Buick, Oldsmobile & Pontiac Full -size
(Front-wheel drivel '8S thru ' 02
Buick Electra, LeSalxe and Pan.:Avenoe;
Old smobile Delta 88 Royale, Ninety Eight
and Regency; Pon t iac Bonneville
19 02 5 Bu ick Oldsmobile & Pontiac Fu ll-slze
(Rear wh ee l d rive)
Bu lek Estate '7(l thru '90, E1ectra'70 thru '84,
t es eere 7 0 thru ' B!.>, Umited '74 thru'79
Old smobile Cust o m Cruiser '70 th ru ' 90,
Delta 88 ' 70 thru 'B!.>,Ninely -eight 70 tIlru '84
Pontiac Bonnev ille '70 thru '81,
Catal ir>a'70 thru ' 81, Grandv ille '70 thru '75,
Paris oenne ' 83 thru '86
19030 M id -eize Reg al & C entury all rear -drive
models wi th va, va and Tumo '74 t hru '87
Reg al - see GENERAL MOTORS (38010)
Riviera - see GENERAL MO TORS (38030)
Roadmaster - see CHEVROLET (2404 6)
Skyhawk - s ee GENERAL MOTORS (380 15)
Skylark - see GM (38Q2O, 38025)
Somerset - see GENERAL MOTORS (38025)
CADILLAC
21030 Cadillac Rear Wh e el Drive
all gasoline models '70 th ru '93
Cimarron - see GENERAL MOTORS (380 15)
DeVille - see GM (38031 & 38032)
Eldorado - see GM (38030 & 38(31)
Fleetwood - see GM (3803 1)
Seville - see GM (38OSQ, 38031 & 38032)
CHEVROLET
' 24 010 Astro & GM C Safa ri M in i-van s '85 thru ' 03
24015 C amaro V8 al l models '70 thru '81
24016 Camaro all models '82 th ru '92
240 17 Camaro & Firebird ' 93 thru '02
Cavalier - see GENERAL MOT ORS (38016)
Ce le brity - see GENERAL MO TORS (38005)
24020 Ch evelle, Ma li bu & EI Camino '69 th ru ' 87
24024 cneveee & Pontiac T1000 '76 thru '87
Citation - see GENERAL MOTO RS (38020)
24032 CorsIca/Beretta all mod els '87 thru ~6
24040 Co rvette al l V8 mod els '68 thru ' 82
24041 Co rve tte all models '84 thru '96
10305 Che vrolet Eng in e Overhau l Man ual
24045 Full -size Sedan s Caprice, Impala, Biscayne,
Bel Air & Wagon s '69 t hru '90
24046 Imp ala SS & Caprice a nd
Bu ic k Roadm alrter '91 thru '96
Im pa la - see LUMINA (24048)
Lu m in a ' 9O thru ' 94 - see GM (380 10)
' 24048 Lumina & Monte Cario '95 thru ' 03
Lum ina APV - see GM (38035)
2 4050 Luv Pic k_u p all 2WD & 4WD '72 th ru '82
Mali b u ' 9 7 Itoru '0 0 - see GM (38026')
24055 Mo nte Ca rlo all mod els '70 thru '88
Monte Carlo '95 thru '01 - see LUMINA (24048)
24 059 Nov a all V8 mod els '69 thru '79
24060 Nova and GeD prtzm '85 1hru '92
24064 Pick-ups ' 6 7 t hru '8 7 - Chevrolet & GMC,
all V8 & in-line 6 cy l, ':!WD&4WD '67thru '87;
Suburban s, Btazers & Jimmy s 'ff? thru '91
24065 Plck_ups '88 thru ' 98 - Chevrolet & GM C,
fu ll-size p ick-ups '88 th l\l '98,
C/K Ctassic '99 & '00 , Blazer &
Jimmy '92 thru ' 94; Suburban '92 thru '99;
Tahoe & Yukon '95 thru '99
'24066 Pick-ups'99 thru '03 - Chevrol et Silverado
& GMC Sierra fu ll-size pick-ups '99 thru ' 02,
SuburoanlTahoeJYukonIYuko n XL ' IJO th ru '02
24070 5-10 & 5-15 Pick-ups ' 82 tIlru '93,
Blazer & Jimmy '83 thru '94,
' 24 0 7 1 5-10 & 5 _15 Pick_ups '94 th ru ' 01, Blazer
& Jimmy '95 th ru '01, Hombre '96 tIlru '01
' 24 0 72 Che vrolet TrailBlaze r & TrailBlazer EXT,
GMC Envoy & Envoy XL, Oldsmobile
Bravada '02 and ' 03
24075 sonm -es thru '88 & GeD Metro ' 69 th ru '01
24080 Vans - Chevrolet & GMC '68 t hru '96
CHRYSLER
25015 Ch ry sle r CIrrus, Dodge stratus,
Pl ymouth Breeze '95 ! hru '00
10 310 Ch rysler En9ine Overhaul Ma nual
25 020 Fu ll _size Front_Wh eel Drive '88 th ru '93
K _Cars - see DODGE ArIes (30008)
Laser. see DODGE Daytona (30030)
25 025 Chrysler LNS, Concord e , New Yo rke r,
Dodge Intrep id, Ea9le Vision, '93 thru '97
' 25 02 6 Chrysler LHS, Concorde, 300M,
Dodge Intrep id, '98 thru '03
25030 Chrysler & Pl ym outh Mid-siz e
front wheel d rive '82 tIlru '95
Rear -wheel Dri ve - see Dodge (30050)
· 2 5 035 PT Cruiser all mod els '01 th ru '03
· 2 50 4 0 Chrysle r Sebring, Dod ge Avenger ' 95 tIlru '02
DATSUN
28005 200sx all models '80 th ru '83
28007 B-21 0 all models '73 th ru '78
28009 21 0 all models '79 thru ' 82
28012 240Z, 260Z & 280Z Coupe '70 thru '78
2801 4 280ZX Coupe & 2+2 '79 th ru '83
3OOZX- see NlSSAN (7201 0)
2 8016 310 all models '78 thru '82
2801 8 510 & PL521 Pick-up '58 thru '73
28020 5 10 all models '78 thru '81
28022 620 Se r ies Pick-up all models '73 thru ' 79
72 0 Se ri es Pick_up - see NISSAN (72030)
28025 8 10JMaxima all gasoline models, 'n thru '84
DODGE
30003
3 00 10
· 3 001 1
3 00 12
3 00 16
3 0020
'30021
30025
30030
' 3 0034
3 00 35
30040
"3 0041
3 004S
30 050
30055
30 060
' 30 06 5
400 & 600 - see CHR YSLER (25030)
Aries & Plymouth Reliant '81 th ru '89
Car avan & Plymouth VOYllg er '84 thru ' 96
Carav an & Plymouth Voyage r '96 th ru ' 02
ChaliengerlPlym o uth Saporro '78 thru '83
Colt & PIyrnouth Champ '78 thru '87
Dakota Pick-Ups ail models 'ff? tIl ru '96
Durango '98 a ' 99, Dakota '97 thru '99
Dart, De mo n, Plymouth Barracuda,
Ouster & Vali ant 6 cyI models 'ff? t hru '76
Daytona & Chrysler Laser '84 thru '89
Intrepid - see CHRYSLER (25025, 25026)
Neo n all mod els '95 thru '99
Omni & Plymouth Horizon ' 78 tIlru '90
Pick-up s all fu ll-size models '74thru '93
Pick-Ups all full -size models '94 thru ' 01
Ram 50/D50 Pick-ups & Raider and
Plymouth Arrow Pick-ups '79 tIl ru '93
DodgelPlymo utltlChryslet' RWD '71 thru '89
Shadow & Plym outh Sundance '87 Itoru '94
Sp irit & Plymouth Acclaim '89 ! hru '95
Va ns _ Dodge & Plymouth '71 th ru '03
EAGLE
T alo n _ see M /TSU B/SHI (68030, 68D31)
Vi sion _see CHRYS LER (25025)
FIAT
34010 124 Sport Coupe & Spider ' 68 thru '78
34025 X1I9 all mod els '74 thru '80
FORD
10355 Ford Automatic Transmission Overhaul
36004 Aerostar MIn i-va ns al l mode ls '86 thru ' 97
36006 Contour & Mercury Mrstique ' 96 Itoru 'OO
36008 Cou rier Pick-up all models '72 thru '82
' 36012 Crown Victoria & Mercury Grand
Ma rq uis '88 th ru ' OO
10 32 0 Ford Eng ine Overhaul Man.... 1
36016 EscortIMercury Lyme all mode ls '81 th ru '90
36020 Escort/Mercury Tracer ' 91 tIl ru '00
36022 Ford Escape & Mazd a Tribute ' 01 1to",'03
36 02 4 Explore.- & Mazd a Navajo '91 Ito'" ' 01
36025 Ford Explorer & Me rc ury Mountaineer
'02 and '03
36028 Fainnont & Mercury Zephyr '78 th ru '83
36030 Festlva & Asplre '88 tnru ' 97
36032 Fiesta all models 'n th ru '80
' 3 6 034 FOClJS all models '00 and '01
36 03 6 Ford & Mercury Full-size '75 1toru '87
36044 Ford & Mercury Mid-size ' 75 Itoru '86
36048 Mus ta ng V8 al l mod els ' 84-112 tnru '73
36 04 9 Mustang 114cyI , V6 & va model s '74 thru 78
36050 Mu stang & Mercury Capri all models
Mustang, '79 thru ~3; Capri, '79 t hru '86
'36051 Mu sta ng all mod els '94 thru '03
36054 Pick-Ups & Bronco ' 73 thru '79
36058 Pick-u ps & Bronco '80 th ru '96
'36059 F-150 & Expedition '97 tIlru ' 02, F-260 '97
itoi'll '99 & U ncoln Navi gato r '98 thru '02
'36060 SlI per DlIty Pick-up s, Excu rsion '97 thru '02
36062 PInto & Mercury Bobcat '75 thru 'SO
36 066 Pro be al l models '89 thru ' 92
36070 RangerlBtonco II gasoline models '83 thru ~2
· 3 60 71 Ranger '93 thru '00 &
Mazd a Pick-ups '94 thru '00
36074 Taurus & Me rcury sable '86 thru ' 96
· 3 60 7 5 Taurua & Mercury sable'96 th ru '(}1
3 6078 Tempo & Mercury Topaz '84 th ru '94
36082 Th underbird/Mercury Couga r '83 thru '88
36086 Th un de rb ird!Me rcury Couga r '89 and '97
36090 Van s all VB Eco noline models '69 thru '91
'36094 Vans lu ll size '92 thru ' 01
"36097 Wlnd star Mi n i-van '95 thru '03
GENERAL MOTORS
10360 GM Automatic Transmission overhaul
38005 Buick Century, Chevrolet Celebrity,
OldsmoOlJe cutlass Cleta & Pontiac 6000
all models '82 th ru '96
"38010 Buick Regal, Chevrolet Lu m ina ,
Old amobile Cutlass Supnme &
Pontiac Grand Prix (FWD) '88 thru '02
38015 Buick Skytoawk, Cad illac Cimarron,
Chevrolet Cavalier, Oldsmobile Flrenza &
Pontiac J-2000 & Sunbl rd '82 thru '94
"38016 Chevrolet Cav alier &
Pontiac Sunflre '95 th ru ' 04
38020 Buick Skylark, Chevrolet Citation,
Olds Omega, Pontiac Phoenbl '80 thru '85
38025 Buick Skylark & Somerset,
Old am obUe Achle va & Calais a nd
Pontiac Grand Am all models '85 thru '98
' 38 0 26 Ch evrolet Malibu , Olds A1ero & Cutlass,
Po ntiac Grand Am '97 th ru '00
38030 cadillac Eldo rado '71 t hru '85,
Sev ille '80 thru '85, Oldsmobile
Toronado 71 thn,J
Buick Riviera '79thru '85
'38031 Cadillac Eld ora do & Seville '86 thru '91,
DeVille '88thru '93, Fle etwood & Okls
Toronado '86thn,J '92., BlIlok RI'Il&l'll'86 thru '93
38032 Cad illac DeVI lle '94 thru '02
& Seville - '92 thru '02
36035 Chevrolet lumina APV, Olda Silhouette
& PontIac Trans Sport all models '90 thru '96
"38036 Chevrolet Ventu re, Olds Silhouette,
Pontiac Trans Sport & Montana ~ 7 thru '01
Gen era l Motors Full-eize
Rear_ wheel Drive - see BUICK (19025)
'as.
GEO
Metro - see CH8IROLET Sprint (24()71;;)
Prizm - '65 thrv '92 see CHEVY (24060),
'93 tnns '02 See TOYOTA Coro lla (92036)
(Continued on other side)
" Lis ting s s ho wn with an asterisk ( ") indicate model CQvera ge as of this priming. These lit/es will b e periodically upda ted to include la ter modet yea rs - consult your
Hayn es dealer for more in fomra tion.
Hayn es North Ameri ca, Inc., 861 Lawrence Drive, Newbury Park, CA 91320·1514 · (805) 498·6703
Haynes Automotive Manuals (continued)
NOTE: New manua ls are added to this list on a pe riodic basis. If you do not see a listing for your Vehicle,
consult you r local Haynes aeeter for the latest producf information.
40030 Storm " models '90 Itvu '93
TrKker - see SUZUKJ SMnurlIi (90010}
GMC
Va",, " P'lek ... ps . see CHEVROLET
HONDA
4 2010 "!>Cord CVCC all mode~ '16 tnru '83
4 2011
42 0 12
4 2013
' 42 0 14
42020
42021
4 20 22
42023
4 2024
' 4 202 5
","orG all
mode~
'84 tIl ru '89
Accord all mod els '90 thru '93
Accord alIlTIOdels '94 thru '!17
Accon:I .. models '98 ttvu '02
CMc 1200 .. models 73 thru 79
CIwi<:1300 " 1500 CVCC 'SOtIYv '83
CMc 15 00 CVCC all models 7 5 thnI79
CIvic aI modttIs '84 tIlru '9 1
Civic: .. eMl Sol '92 ttlru '95
C ivic ' 96 th ru ' 00, CR·V '91 thru '00,
Ac ura lnttlgra '94 th ru '00
42026 ClYte ' 01 thnJ '04. CA.V 112 thru '04
42040 ......ud e CVCC all models 79 thru '89
HYU NDAI
' 430 10 ElMtra aI rnoclels '96 thru '01
43015 Excel & ~ aI models'86 thnl '98
IS UZU
JAGUAR
49010 XJ& al 6 q1 models -e8 tlwu '86
4901 1 l(J6 allTI(>(kl$ '88 th ru 'io4
49015 XJ 12 " XJS all 12 cyl models 7 2 thfU '85
J EEP
50 01 0 Cherokee, Coman che & W~r UnIited
all mod els '84 th ru ' 01
50020 CJ aI models '49 thN '86
' 50025 Qnnd Cherokee aIlll'lOMls '93 thfU 114
500211 GI'WId
Wav- & Picll_
72 thfU '91
Grand Wagone« '8411WU '91, ct-olpa 3 1800" 1800 all model$ '63 thru 73
~ Vanagc>n AI air..::ooled models ' SO thru '83
VOL VO
9 701 0 12 0. 130 series" 1800 Sporta '$1 thru 73
9 70 15 140 Serl" all models '68 thru 74
9 7020 240 Se rl " all modele 76 thru '93
97040 740 &. 7 80 Series al l models ' a2 thru '88
9 70150 650 Sarln aU mod els '93 thru '97
1020S
10210
102 15
10220
10226
10230
10240
103015
10310
10320
10330
10340
1~1
RENAULT
· 8401 0
' 9 208 2 RAV4 all models '961hru '02
9208S Ten;eI all models '87 thru '94
TECHBOOK MANUALS
PONTIAC
Turbo 7 9 thru '88
SATURN
UNCOLN
81035
a.-
SAAB
LEX US
61030
68020 CordIa, Tradia, Galant. Precis &.
Mirage ' 83 Itnl '93
68030 Ec Hpsa, lagla Talon & Ply,
'901hru '94
'68031 Ec lipse '951l'11\1 '01, b illa Talon '95 11vu'96
68035 M itsubish l Galant '94 tIvu ' 1)3
68040 Pick_up '83 thru '96 &. Montero '83 thru '93
CHEVAOL£T or GENERAL "'OTMS listing,
Hombre · see CHEVROLET 5- 10 (24()11)
'47017 Rode o '91 thru '02; Am Igo '89 tIlru '94 and
'98 thru '02; Hooda Passport '95 thru 112
47020 T rooper & Pick...p '81 thru '93
810 10
8 1011
61 015
· 81018
81020
MITSUBISHI
"8 70 10 Satum all models '91 thru '02
8 7020 Satum " L- e mogine Repair ........1, 5 HP &.Less
Sma n Eng ine Repair Manual, S.s _ 20 HP
Suspension, Stearlng & Drivellne Manu81
Ford A utoma t ic T ran smissi on OVarhaul
GM Automatic T ran sm ission Ove rhaul
Automotlve 80dy RelN"r" Pa inting
Automotive Brak a Manual
Automotlve Anti-lock Brake tA8Sl 5 ptems
AIltomot!'H Detaiinv Man....
10355
10380
10406
10410
1041 1
10418
104 20 AIltomot!'H ~ Manual
10425 Automottve HeatIng & Air Conditioninll
10430 Automollwa ~ Manual &. Oictionary
10435 Automotive T ool s Ma nual
10440 Used Car Buying Guide
10445 Wel dIn g Ma n ual
104!50 ATV Bas ic s
SPAN ISH MANUALS
98903
98905
98910
98815
99040
99041
99042
99058
99075
99077
99088
990111
99095
991 00
991 10
991 18
99125
Reparacl6n de ~ &. PiIrtl.lra
COcligos Autornotric. . de la ComPllbKlonl
Frenos Automotrtz
Inyeeel6n de Combustible 19M 81 1999
Chevrolat & GM C Camlonetal ' 67 al 'a7
lncl uye Sub Urban, Blazer &Jimmy '67 al '91
Chevrolet &. GMC Camlonetas '88 aI '98
lrocluye Subu rban '92 al '98, Blazer &.
Jimmy '92 al "94, Tahoe "f Vukon '95 aI '98
CheYnIlet & GMC Ce mlonetea
Camtdas '68 aI '95
Dodge
&. I'I7mouth VO"f8ll8l" 'A4 III ~
Ford e-alonetas y Bronco ' SO al '94
e-
Ford Ce mlonetas Cemtdas ' 69 aI '91
Ford Modalos de Tlmafto Mediano 75 aI '86
Ford Ta unJs" Me rcu ry Sabl e '88 aI ' 95
GM Mc dalos de Tam, tio Grande 7 0 aI '00
OM Modale s da Tam. 1ID Mediano ' 70 aI '88
Hissan camkwseta '80 II '96. Patld'indar '87 III '95
Ni$$an8entra '82 a1 '94
Toyota Cemionetasy4Ru...... 79a1 '95
Ovllr 100 Hayne&
motorcycle tnlInuals
-.0 available
Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514· (805) 498-8703
Common spark plug conditions
NORMAL
Symptoms: Brown to grayish-tan color and slight
electrode wear. Correct heat rang e for engine and
operating condit ions.
Recommendation: When new spark plugs are
inst alled. replace with plugs of th e same heat range.
TOO HOT
WO RN
s ymp toms: Aoo.nled electrodes
Wltl'l a smaI il!TlO
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