yes

Thanks man, appreciate it...I'll just buy a new section of hose and run it from the fuel pump down to the fuel tank return line by the fuel filter...and that should do it for now...

Used a brass hose barb to connect the other outlet hose from the fuel pump to the return line that came off the base of the stock Mikuni, so that should close the loop as far as the fuel feed/return lines go.

There were two hoses on the stock air cleaner, one for the valve cover breather and the other to that gizmo on the exhaust side. I removed the valve cover breather hose and just put one of those small APC pleated filters on top of the valve cover fitting, and just left the other hose as is. Would it be worth doing anything fancy with this other hose, like trying to route to the inner fender air inlet for the stock airbox, or just leave it there on top of the valve cover?

There is one odd thing going on. When I first start the Monty in the morning, or after it's been sitting for a few minutes, it makes this rattling noise, and it's running a little rough. After a few minutes, it's like a switch gets turned on, and the idle smooths out and it runs fine. Is this the electric choke working?

My initial impressions are very positive. 'Course this is comparing a fully functioning two-barrel to my Mikuni with faulty secondaries, so it's not a fair comparison. But it's nice to get my daily driver back! The Weber is so simple compared to the Mikuni, but I supposed that's why the Weber isn't street legal in CA, because it doesn't have all those freaking vacuum hoses going to God knows what.

I'd say the Weber kit was worth the $295 I spent on it, since trying to find a rebuilt Mikuni or getting one rebuilt is FAR from easy. 'Course I probably could've picked up the intake side of the SQ turbo system for less money than I spent on the Weber, but knowing my luck, I would've FUBAR'd the EFI install. At least this way I have my daily driver back, runs great, hopefully will get a little better mpg, and I can keep the SHO for sunny days.

Here's a couple pics of the finished installation:

Items of note in this pic: 1) small red pleated filter that replaced the valve cover breather hose that went into the stock air cleaner. 2) larger black hose from the exhaust gizmo that went into the stock air cleaner is left unconnected. 3) yet another hose that went into the stock Mikuni is left open, you can see the end at the lower left corner of the Weber air filter, this tube goes into a black canister at the right front part of the engine compartment, not sure what it does, but it's uncapped for now. 4) fuel fitting on the Weber is larger than the fuel pump, and the kit-supplied fuel hose (5/16?) is larger than the stock fuel pump hose (1/4?), so I had to use a hose clamp on the fuel pump end, pinch clamp worked fine on the Weber end. 5) at the "U" bend on the fuel inlet hose, you can see where I joined together the other fuel pump hose and the return line from the stock Mikuni using a brass hose barb and two pinch clamps, notice the difference in fuel hose sizes. 6) used the kit-supplied distrubutor vacuum hose and ran it directly from the distributor to the Weber. 7) connected the Weber electric choke wire to the same colored wire that was on the Mikuni (red with silver) - I didn't want to cut any wires on the Mikuni wire harness in case I had to put it back on, so I just stripped the end of the kit-supplied wire and pushed it into the red/silver connector on the female end of the harness.


Only item of note in this pic is the accelerator cable. I had to bolt it down on top of the valve cover. Still trying to figure out a way to hold it down closer to the Weber, but it works for now. Also, around the middle of the bottom of this pic is the stock Mikuni water hose that has a bolt in the end, with a hose clamp, angled up and clipped behind two vacuum hoses.

Looks good, Robert. As to your point #3 above, the line from the black canister is meant to purge the fumes from the gas tank into the intake when the engine is running, as opposed to venting them to open air. Shouldn't be too big of a deal. Also no biggie with the big hose from the secondary air system coming off the exhaust.

Did the filter come pre-oiled? If it's not a paper filter, it requires oil to function properly and should be moist. I seem to recall mine was a K&N style that required periodic cleaning and re-oiling, but yours may be paper??

If you wanted to get all fancy, you could rig up fittings on the top of the air filter cover to plumb the open fittings that used to go to the stock air cleaner housing...but I wouldn't bother.

Good job!

John B.

John B - thanks for the info, makes me feel a little better leaving those hoses as is. There's a small fitting on the bottom of the air cleaner, that I could connect a hose from the valve cover, to replicate the stock air cleaner setup. But I think I'll leave the small pleated filter on the vc breather for now. Good point about the Weber air filter. I didn't even check that, so I'll go outside and make sure if it needs to be oiled or not. I didn't even notice if it's pleated paper/gauze or foam, so I'll check and oil if needed.

It runs SO much better than before, it's hard to believe it's the same truck. But like I said, that's the difference between a malfunctioning Mikuni and a new 2-barrel Weber!

If anything, I might hook up that charcoal canister hose to the fitting. It'd be better than having raw gas fumes vent in the engine compartment.

If you four wheel at all, be prepared for the truck to stall at extreme angles. Webers are sensitive to especially being pointed downhill, I found. There's a fix, but I never got to fiddling with it. Somebody else can probably tell you what's up with that.

Enjoy!

John B.

I went ahead and connected the end of that line that goes to the charcoal canister with the three lines coming off of it (the one marked "to carb"). I hooked it up to the fitting on the bottom of the air cleaner. I cut the hose that was on the valve cover breather and used that, since it had a sharp bend in it already. It went on the air cleaner fitting nice and snug, but was a little big to go around the end of the pipe, so I had to used a hose clamp on that end.

I doubt I'll be doing any extreme angling in this thing, most likely just fire roads and beach sand. So this Weber should do me just fine, as long as I don't make it back to CA and try to register it there, lol...

I went ahead and hooked up the end of that one pipe that went into the stock Mikuni, coming from the charcoal canister marked "to carb". I cut the VC vent hose, since it had a sharp bend in it already, and used it to connect the pipe and the fitting on the bottom of the air cleaner. It makes a sharp bend leaving the end of the pipe, but not so sharp that it pinches shut.

If you look at the 9 o'clock position in the picture, you'll see a hole in the valve cover, close to the accelerator cable. I might try to use that hole to install a bolt with some kind of cable holder, with a nut underneath to raise the cable holder so it pretty much stays in the position where it is. The cable binds just a little bit at times, so I think if I can secure it in another place, like this one, that might take care of the occasional binding problem. The cable is pretty straight from that point down to the carb linkage, so I don't want to change it too much...

Can you post the link to where you bought your Weber? I'm looking at this as an interim solution until my TSI engine is ready. My Mikuni has no secondaries either now.

About climbing - check out this link for a Weber mod.

How to make a Weber climb