Suzuki SJ Samurai User Manual
READ AND UNDERSTAND ALL STEPS OF THESE INSTRUCTIONS
BEFORE BEGINNING THIS INSTALLATION.
SUZUKI SAMURAI
For kit no. K600
using (1) Weber 32 DGAV
(Legal in California ONLY for racing vehicles which may NEVER be used upon a highway.)
Tools and equipment needed: Parts supplied with installation kit:
Combination, box or open end wrenches 1- 32 DGAV Weber Carburetor
(metric) 1- Manifold Adapter
Socket set with 12mm socket 1- Air Cleaner Adapter
Screwdriver (regular and phillips) 1- Cable Bracket
Pliers 1- Hardware Kit
Gasket scraper
Cleaning solvent and rags
Knife
Gasket sealer
Tune-Up Specifications
All tune-up specifications for the Weber Carburetor remain the same as those specified by the
Factory for the original unit. Emissions tune-up should be carried out by a suitably qualified dealer
or independent garage, using infrared gas analyzing equipment.
NOTE: late model vehicles fitted with Emission Control Systems have many vacuum lines and
electrical connections in their fuel systems. It is essential when dismantling, that disconnected lines
be identified with a corresponding number tag or label system. To establish function, locate and
identify the source of each line. Use the under hood emissions diagram, or the factory service
manual for reference when identifying hoses.
Disassembly
1. Disconnect the vehicle’s battery.
2. Remove the gas cap.
3. Drain approximately one (1) quart of engine coolant.
CAUTION: Hot water may be present.
4. Using either the map inside the vehicle’s engine compartment, or a factory service manual
for your year/make vehicle: tag each hose, vacuum line and electrical wire/connector
attached to the original carburetor and air filter assembly for proper identification during
reassembly. Disconnect all connections once they are identified.
5. Disconnect and remove the flexible connector and the sheet metal elbow between the
carburetor and the air cleaner housing.
6. Disconnect the fuel line from the original carburetor.
Plug the end of the fuel line to prevent leakage.
7. Disconnect the throttle cable from the throttle lever and the cable bracket.
8. Remove the four (4) nuts that secure the carburetor to the intake manifold. Remove the
carburetor and the spacer/gasket. Insert a clean rag into the intake ports to prevent dirt
and gasket material from entering the engine.
9. Remove the stock carburetor mounting studs from the intake manifold. NOTE: For correct
stud removal or installation, use stud removal/installation tool or the “double-nut” method.
DOUBLE-NUT METHOD: Install two nuts approximately half way down the stud. Lock the
nuts together. Turn the lo
wer nut for removal and the upper nut for installation.
10. Clean the intake manifold flange surface thoroughly.
ASSEMBLY
11. Remove the rag from the intake manifold.
12. Apply Loc-Tite (supplied) to the 8mm end of the stud into the two holes of the manifold
closer to the passenger side fenderwell.
13. Using appropriate gasket sealer, slide the smaller of the supplied adapter gaskets over the
two studs so that the larger hole is closer to the valve cover.
14. Slide the manifold adapter over the two studs in the same manner as the gasket and using
Loc-Tite (supplied) on the tow allen bolts supplied secure it to the manifold.
Torque the bolts to 7 ft/lbs.
15. Install 8mm studs into threaded holes of the manifold adapter (apply Loc-Tite to the studs)
insuring that the studs go no further than flush with the bottom of the adapter.
16. Slide the remaining gasket over the studs (with the large hole facing the valve cover), fol-
lowed by the Weber carburetor (insuring that the linkage faces the firewall). The AntiBackfire Valve bracket may require bending for clearance.
17. Slide the supplied cable bracket over the two (2) adapter studs closer to the valve cover.
18. Using the nuts and washers supplied, secure the carburetor to the manifold and adapter;
and tighten, in a criss-cross fashion to 7 ft/lbs.
19. Re-route the throttle cable so that it runs from the firewall to the front of the valve cover and
back around to the installed bracket. (Run cable under and through the PCV hoses and tee.)
Install the cable on to the cable bracket and throttle lever.
20. Remove the throttle pedal stop adjustment bolt and nut from the floor of the passenger
compartment.
21. Adjust throttle cable at the cable bracket so that full throttle can be achieved, AND, the
throttle returns fully to an idle position (choke plates should be held open to bypass idle
kick-up of choke linkage).
CHECK THROTTLE OPERATION FOR FREE MOVEMENT. IF THERE IS ANY BINDING
OR STICKING, CORRECT AS NECESSARY BEFORE PROCEEDING.
22. Remove the original water choke hose from the back of the intake manifold. Using the new
hose and clamps supplied, install the hose between the fitting at the back of the manifold
and the upper fitting of the water choke housing on the Weber carburetor. Connect the
remaining original water hose to the lower fitting of the water choke housing.
23. Connect the supplied vacuum hose between the vacuum advance unit of the distributor and
vacuum fitting on the base of the Weber carburetor that faces the passenger side fenderwell.
24. Connect the original float bowl vent hose to the 90 degree fitting on the passenger side of
the Weber carburetor.
25. Remove the plug from the original fuel line and connect the line to the fitting on the driver’s
side of the Weber carburetor.
26. Cap off any exposed vacuum fittings from hose removal in step 4. (One (1) 1/4” vacuum cap
is included to cap the larger fitting on the EGR Valve.)
27. Install air cleaner adapter using supplied washers between the adapter and the 5mm allen
bolts for adapter. Torque bolts to 10 in/lbs.
28. Re-install the flexible connector and the sheet metal elbow removed in step 5. (The elbow
may require modification in order to fit flush to the air cleaner adapter.) Use the supplied
6mm bolt and the original sealing washer to secure the elbow to the adapter.
29. Reconnect the battery and replace the gas cap.
30. Depress the throttle pedal once to initiate the choke unit and start the engine. (Realize that
the float bowl is empty and it will require cranking the engine a few moments in order to fill
the bowl with enough fuel to start the engine.)
31. A. Check for leaks around the carburetor mounting base and the fuel line connection.
Correct as necessary.
B. Warm engine to operating temperature and recheck step A.
C. Set idle speed and mixture to factory specifications.
32. CHECK FOR ADEQUATE HOOD CLEARANCE BEFORE CLOSING THE HOOD.
REDLINE WEBER
TYPICAL DGV CARB INSTALL VIEWS
These views may vary depending on application. For general assembly assistance only.
32/36 DGAV
Part Number
22680.051
Water Choke
32/36 DGEV
Part Number
22680.033
Electric Choke
It is important to follow all linkage and lever installation instructions. The number one and two
reasons for tuning errors are improper linkage installations and over tightened linkage nut,
causing a binding in linkage assembly.
CALIBRATIONS MAY VARY DUE TO REGIONAL FUELS AND STATE OF ENGINE TUNE
AND PERFORMANCE. POOR RUNNING QUALITY DOES NOT MEAN A DEFECT IN THE
CARBURETOR. AN ADVANTAGE OF THE WEBER CARBURETOR IS ITS EASE OF
ADJUSTMENT AND TUNING.
SET UP ADJUSTMENTS
Start set up by confirming carb base line settings. Do not depend on the factory delivered settings.
Check them before the carb is installed.
1. All settings are done with choke disengaged or warmed up so that the choke is fully opened
and disengaged. This is done on automatic choke carburetors by first opening the choke
butterfly by hand and inserting a wood block or wedge of some kind to hold open while the
linkage is cycled (linkage operated through its full movement) to clear the choke cam. (You
will hear a metallic click as the cam is released. You can check the fast idle screw under the
choke assembly to confirm that it is not in contact with the choke fast idle cam.)
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