Typical Install Instructions Read & understand all steps of these instructions before beginning this installation. Kit is for off-road use, not for use on the highways, or in California. WEBER Conversion Kits, K550 K550-38 K553 K553-38 by REDLINE 232 / 258 AMC JEEP INLINE 6 CYL WITH 1bl. Carter Carburetor Using Weber 32/36 DGV, DGEV or 38 DGES These instructions are intended as a general guide for installation. Certain steps may vary slightly for different vehicles. Jetting Specifications Jetting specifications of carburetors supplied in kits may vary slightly, and will always be correct for the intended application. Tools Needed Parts Supplied with Installation Kit Combination, box or open-end wrenches Weber 32/36 DGV, DGEV or 38 DGES Socket set Carburetor Adapter ( 1 piece style ) Screwdrivers ( regular and Phillips ) Hardware kit Pliers Linkage kit 6mm Allen Wrench Chrome air filter Gasket Scraper, Knife Wiping rags, Cleaning solvent Gasket Sealer TUNE – UP SPECIFICATIONS All engine tune-up specifications for the Weber Carburetor remain the same as those specified by the factory for the original unit. A suitable qualified dealer or independent garage, using infrared gas analyzing equipment, should carry out emission tune-up. NOTE: Late model vehicles fitted with Emission Control Systems have many vacuum lines and electrical connections in their fuel systems. It is essential when dismantling, that disconnected lines be identified with a number tag or label system. Establish function of any device reconnected or disconnected. RECOMMENDED ADDITIONAL PARTS 1. It is recommended to obtain a new fuel filter and install it when installing this kit. 2. Many late model vehicles use a high-pressure fuel system. The WEBER only requires 3 lbs Maximum. For aggressive driving or off road use, REDLINE recommends the float height of 18mm from the gasket to top of plastic float, DO NOT depress the ball and spring in the needle valve, then, set the float drop to 1.5mm “needle” travel. Use a fuel pressure regulator #31800.063, adjusted to 2 lbs. for more stable fuel and float control. 1 445-550 label http://www.redlineweber.com Universal Disassembly 1. Disconnect battery. 2. Remove the gas cap. 3. Drain some water from the cooling system, (enough so the water level in the engine is below the intake system.) CAUTION: Hot water may be under pressure and dangerous. 4. Remove factory air filter assembly and all attaching hardware and hoses. Use a tag and numbering system to identify hoses for reinstallation. 5. Remove factory vacuum lines from carburetor Use a tag and number system to identify hoses for reinstallation. 6. If emission control equipment is not to be used, disconnect and remove it completely, leaving vacuum lines intact unless noted otherwise. (We will require that the charcoal canister portion of the fuel evaporative emissions system remains intact in order to properly vent the fuel tank.) Bench assembly 7. Remove fuel lines and disconnect the choke Install the new REDLINE lever on the carburetor. heat pipe from the carb and exhaust manifold. Disconnect the throttle position solenoid if so CAUTION: Do not over tighten throttle shaft nut Proper tightness can be achieved by installing nut just equipped. slightly more than finger-tight (finger tight then one more flat of the nut) and bend lock tab. After tightening, open 8. Disconnect the throttle linkage from stock choke and check for full throttle operation from idle stop carburetor. to wide-open throttle. If any sticking or binding occurs, loosen nut and re-tighten with reduced torque. If 9. Loosen the carburetor mounting bolts, and excessive torque has been applied, re-centralization of remove the stock carburetor. the throttle plate may be necessary. This may require loosening nut and rapping on the end of the shaft with a 10. Be sure to temporarily cap fuel line to prevent small plastic mallet or a screwdriver handle (We are not leakage and fire danger. driving nails here firm, but not abusive). 11. Insert shop towel into manifold opening before cleaning carburetor mounting surface. Clean carburetor mounting surface manifold. 12. Plug all open vacuum and thermal switch fittings on the intake manifold. 2 445-550 label http://www.redlineweber.com Universal Reassembly Reassembly 13. Remove rag from manifold opening. Install the carburetor adaptor as follows; (Use Loctite on all bolts and studs during installation of adaptor.) a. Select the gasket that matches the intake manifold carburetor-mounting surface and coat it with grease or a suitable gasket sealer (Silicone or RTV is NOT suitable). Install the universal adaptor noting the position of the carburetor for the cable operation. Torque nuts to 12 ft. lbs. b. Install the 8mm studs with the kit into the tip adaptor half. Hand tighten these studs. c. Set the carburetor base gasket over the studs on the adaptor. Install the Weber carburetor onto the adaptor and gasket. Install the throttle cable bracket on the two mounting studs opposite the choke housing. Install washers and nuts supplied. Torque the carburetor nuts to 12 ft. lbs. d. Cycle the linkage by hand to check for sticking or binding. Remember over tightening causes binding. Correct any linkage problems now before proceeding. NOTE: the automatic choke will be set in the cold start position and unless the choke plate is held open the throttle will not return to the fully closed position. 14. Remove the throttle cable from your original bracket, install your cable into the supplied bracket that you installed on the carburetor in step 13c. Connect the cable to the ball or trunion on the throttle lever. Connect (your original) throttle return spring to the throttle lever 15. Connect the original electric choke wire to the terminal on the choke unit of the Weber carburetor. Use a “keyed” 12 volt source if you don’t have an original choke wire 16. Connect fuel line using the new hose and clamps supplied. WE SUGGEST THAT A NEW FUEL FILTER BE USED IN ALL APPLICATIONS. 17. Use the 3/8” hose to connect the PCV system to the fitting on the top adaptor half. If the PCV is not to be used them the 1/8 npt hole in the adaptor must be covered with the supplied plug. NOTE: On later models the PCV is tee’d with the canister purge and anti-backfire valve. 18. Connect the original carburetor bowl vent hose to the fitting on the Weber carburetor top. 19. “77 – ’88 Remove the vacuum lines that attached to the EGR valve, and coolant temp. Override switch (CTO). The EGR will not be used in this application. a. ’79 – ’88 Remove the vacuum line that attached to the EGR valve, thermal vacuum switch (in the air cleaner) and the (CTO). Plug the CTO fitting left exposed by the removal of the vacuum line with the supplied vacuum cap. 20. There are several vacuum “advance” or “retard” systems from ’77-’88. Determine which system you have, advancing the distributor timing uses “ported” vacuum and the distributor retard system uses “manifold” vacuum. Proper vacuum routing is very important to engine performance and engine life. a. ’77 – ’82 connect the “ported” vacuum hose that was originally connected to the stock carburetor to the vacuum port on the choke side of the Weber carburetor. 3 445-550 label http://www.redlineweber.com b. ’83 – ’88 the spark advance is “manifold” vacuum operated and not affected by the installation of the Weber carburetor. Note: If either vacuum port is not in use be sure to cover it with a vacuum cap 21. Re-connect battery and replace the fuel cap. 22. START ENGINE a. Check for vacuum leaks around the carburetor-mounting base and correct as necessary. Use spray can of carburetor cleaner with hose attachment to isolate a leak, by spraying around carburetor mounting base. If any of the spray is entering the induction system, the idle speed will change. Note: Some leakage at the throttle shaft is expected b. If engine has poor idle, or will not idle at all, shut engine off and re-set idle by setting the Idle Speed Screw to 1 ½ turns in maximum after contact with the throttle lever. The Mixture Screw after lightly seating it, comes out 2 turns. See tuning procedure page 5 & 6. 23. STOP ENGINE a. To install air filter assembly remove the four studs in the carburetor flange. Install the gasket and use the appropriate bolts or nuts (supplied with air filter) to secure to the carburetor. Connect new valve cover vent line using hose and clamps. 24. Two different air injection systems as follows: a. ’77 – ’82 the air injection system is an air pump type that is unaffected by the installation of the Weber carburetor b. ’83 – ’88 The air injection system has two inlet hoses that must be connected to a filtered air source. There are two plastic fittings supplied with the kit for this purpose. Two holes must be drilled in the air cleaner top to accommodate the fittings (Placement is not critical as long as the air injection receives filtered air). Use the supplied hose connectors and hose to connect the air injection hosed to the fittings. 25. Check for adequate hood clearance before closing hood. WEBER Model DGV/DGEV FAST IDLE ADJUSTMENT With the engine warmed up and turned OFF, open the throttle and manually engage the choke plates (butterflies). Release the throttle, then release the choke plates. The fast idle cam should now be activated and the fast idle speed screw should be positioned on the cam shoulder. Start the engine DO NOT DEPRESS THE THROTTLE PEDAL OR THE CHOKE WILL BECOME INOPERATIVE.