Please help - Weber 32/34 carb on 1.8 clipper

Been pulling my hair out with problems trying to get a weber 32/34 carb to replace my pierburg on my 1991 golf 1.8 clipper.

A golf specialist garage is fitting it today but just had a call to say, the weber carb is on the engine fine, but the K&N air filter i bought to go on it fits perfectly on the weber but it wont fit under the bulkhead on the car. (not sure if bulkhead is the right word, the metal bit with the scuttle tray in it. He said the filter sits too high and wont fit under.

What can i do?

He is botching the old air filter on it so i can run it home atleast. Do i need a different air filter? different fitting?

So confused  

PLEASE HELP GUYS.

P.S: this is the air filter: K&N 56-9025 Custom Racing Assembly single

Thanks a lot

suggest you fit the OE air box, have tried fitting an K&N, it's no good and will rub and buzz on the bulkhead, just buy a insert performance air filter.

I have been there and bought this particular T shirt, it will also run badly when the weather gets colder if you run the K&N, fit an insert (BBT do them) and you will be happy as a sand boy!

thanks for your help mate. Got the car back from the garage just now. Im gonna keep the original air box and get a filter like you said to fit in it, but i need to buy an adapter plate for the carb for the box to fit on it properly. Just cable tied on at the moment.

The carb is amazing, such a difference, although it some trouble starting up quite badly and the emissions are sky high on it at the moment, its second hand so im hoping it just needs bedding in properly. been off a car for quite a while.

quick update, starting is still a little rough, but once moving and warmed up it idles nicely. I cant seem to find an adapter plate anywhere. Does anyone know where to get one or to fit the OE air box to the weber carb? its literally just cable tied on at the moment.

Suggest you set the emissions up (using a gas analyser) find a local garage to set it up.

When you say adaptor plate, do you mean between the carb and air box housing??  On mine it was just a plate that screwed on to top of carb??  is this part of the Webber kit, sounds like you might be missing a bit??

Will set the emissions up properly as soon as the air filter is secured properly so I can get an accurate reading.

And yes it's a plate that will sit between the carb and the air box, definatly missing this so need to find one to buy, harder than I thought to find though.

I take it you brought a 2nd hand weber as new comes with plate for original air filter box, it is attached by 4 screws into the top of the carb, you should be able to get one from a weber dealer.
You will need the S bracket which connects to the carb via a small stud screwed into the carb and secure with a 10mm nut, along with that you need the hex headed small bolt and washer which will go through the hole on the original airbox, if you've not noticed your box will have a rubber bung, simply remove this and the bolt and washer go there and screw onto the S bracket fitted on the cab
AlsoMay i suggest you stay clear of those air filter units you just brought as in the older days, winter months you will suffer carb icing as no warm air feed going to the carb.
on the 1.6, 1.8 blocks replacing with a weber is excellent choice, but in order for one to fit it needs an adaptor plate which sits between the bottom of carb and the black rubber carb flange thus the weber sits higher and you can nt fit the airbox you brought.
Simply as i do use existing airbox and buy a performance air filter for that box, i have 2 new here, spares for the future, one is a brand new in box K&N air filter, exactly what i use on both my mk1 & mk2's, use for approx 5 month and i clean them out and re-oil.
Also when weber fitted you can not fit standard top mount strut brace due to the height rise of carb as it would put alot of pressure on the carb flange thus causing it to break, split etc and cause air leaks and bad running.
Whereas with pierburg original carb you can fit brace.
Fit original airbox, get performance air filter for the original box and you can then enjoy the carb more.
Not being funny but the word 'specialist' is being used too much, a golf specialist? i doubt it, as clearly he should have told you the airbox wouldn't have fited if you fitting a weber carb
Pete

Excellent reply thankyou so much, (this is the reason i joined the forums)

The original air box is already on the carb all linked up, but its just not got the proper adapter plater to fit it on, so it just tied down (temporary fix) I have sent out some emails to webcom and other places asking if the can supply me an adapter plate.

Booking the car into another garage to get them to tune it for me, so fingers crossed. Would love to attempt to tune it myself but dont know anywhere near enough yet lol

Thanks again! i will keep you posted.

Here's pic of one of my webers, you can see the top part of carb you need for the airbox to fit snug and the s bracket i mention with the washer and bolt that goes through the top of the air filter box

thanks a lot for the photo, helped a lot. Ive managed to find the parts for £66 but im still waiting on replys from other places as i thought this was quite expensive for an adapter plate.

Hey guys, i bought a K&N panel filter that arrived the other day but its too big, its like double the size of the orignal one, the description matched my car exactly but its obviously not right.

Can anyone give me a link to the right air filter that i need?

I bought this one on ebay quite cheap - http://www.knfilters.com/search/product.aspx?Prod=33-2002

and its twice the size of my original one, do you think i need this one instead: http://www.knfilters.com/search/product.aspx?Prod=33-2092

im not too sure…

Thanks chaps.

Hey guys. I have now fitted the carb properly using the brackets, so the air box is now fitted correctly, also got the new K&N panel filter in it. Had the carb running lovely for about 2 weeks and then just yesterday developed a problem, the idle is kangarooing, is not steady at all, it likes to jump up and down a lot and the car is greatly underpowered when driving it, there is big delay in acceleration when i press the pedal. I have tried tuning it again, by adjusting the fuel/air mixture and idle screw but cant get it back to where it was.

Starting to become a pain in bum now

Any suggestions?

The mixture and idle speed appear to be co-dependant, and other than putting "baseline" settings on, then tweeking by sound/feel, it's hard to get far without a gas analyser.

Couple of thoughts though…

1: Do you have any fuel/rust issues?
2: Was the Weber new, or used? If used, could be a needle valve issue/
3: Return fuel line… On the 'rocco,(1.8 EX engine) I found I had to restrict the return line (down to 1.5mm)
4: Vacuum issue? You only actually need a pipe from the dizzy to the weber for it to function. You'd need to T off to the air flap in the airbox, but that's all.

hey thanks for you help, im not too switched on with all this so i have taken a bunch of photos that should help me out, i think i have photographed eveything. I would be extremly grateful if you could all look through them and help me out sorry if i have uploaded massive photos.

Not too sure why in the 1st photo the box doesnt fit in clip properly? i had to add a little bracket in to help it fit in properly.

Also noticed on some of the other photos from other forum posts that i dont have a 'T-piece'? well i cant find one anyway.

Also in the 4th pic down, (this baffled me the other day) the two pipes coming off the bigger one that goes fromt he bulk head to slave cyclinder for the brakes (ithink) one has a round cap on, and the other is just contantly sucking in air, but if you cover the pipe up the engine increases revving and actually runs better. CONFUSED.COM

my brain hurts.

My brain is hurting trying to look at these massive pics lmao.
Right, can i ask, have you looked at my pipe diagram, i take it you haven't as this is why air is sucking in, you have no t-piece as you have to buy one lol.
The bracket on the front with new weber you get two extended hex type length adaptors that screw onto the 2 middle rocker cover studs. these you should be able to get from a dealer.
Reason you need these is the weber as an adaptor plate underneath thet the carb bolts too and that plate bolts to teh carb flange on teh inlet manifold which in turn raises the height of the carb, thus once a weber fitted you can not use a top strut brace as no one as made for them a weber conversion.
You over come it by simply making an extension yourself.
Also may i ask what is the gold colour metal under the bolt and washer on the top of air box as it is not needed and i have never seen one comes with a weber.
Don't forget make an earth from carb to rocker.

Here is how to for your vac pipe setup and also your original pics resized

http://www.vwgolfmk1.org.uk/modules.php?name=Forums&file=viewtopic&t=50160

Pete :wink:

Hey Pedders. Thanks a lot for your help. I have just finished doing all the piping on the carb with your instructions, so thats all set up now.

so…i started the car and for about 3 mins it ran amazing, perfect running, then it just went back to its old tricks again, after it warmed up it just started hunting for idle again, it still runs but its not smooth, the exhaust sounds like its puffing out loudly, not smooth at all. Wonder if there is a deeper underlying problem somewhere.

quick question though (pics attached - correctly this time i hope )

The pipe with the red arrows was connected to a pin on the air box, you can see this in the 3rd photo above in the last post, but this is where the next piping is now attached, so i didnt know where it supposed to go. The green labled pipe in the 2nd photo looked just like a breather pipe, so for now i just connected the 2 together which didnt really make a difference, but i dont know where its supposed to go. any ideas?

ok images too small lol, will try that again.

quick update. That little unit on pictured in no.2, has another pipe coming off it on the right, one with the shiny clip on it, this is just angled down and goes nowhere, but it is sucking in air unlike the other pipe (green arrow pipe) that isnt sucking in air but also didnt go anywhere.

Can anyone shed any light on this? Thanks