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Rebuilding a Weber 40/44/48 IDF using Redlines kit (92.3240.05)
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Pelican Technical Article:

Rebuilding a Weber 40/44/48 IDF using Redlines kit (92.3240.05)

Neil Harman


3 hours3 hrs






11mm socket or wrench, metric socket and metric wrench set, needle nose pliers, workbench vise, workbench, small flathead screwdriver, small Phillips head screwdriver,

Applicable Models:

Porsche 911 (1965-89)
Porsche 912 (1965-69)

Parts Required:

Redline's Weber Carb rebuild kit (92.3240.05)

Performance Gain:

Smooth power delivery thanks to an even flow of fuel and air to your 911's mill

Complementary Modification:

Replace the fuel pump


Rebuilding a Weber 40/44/48 IDF

using Redlines kit (92.3240.05)


The kit arrives with an assortment of ˜O' rings, two accelerator pump diaphragms, and a mix of fiber gaskets, none of which will probably be the same as the one you remove! The O' rings and diaphragm are fairly obvious  where they go, but in the Redline diagram below, note item 6 - the main gasket.

O' rings are items 23, other parts are items 11 ( Needle and seat gasket) and 54 ( Accelerator pump feed)

If you look carefully, you will see item 6 resembles the first gasket below:

But the part in the kit is like this :

Do not attempt to cut it to match, it would work - these are the steps to use the gasket as it is:

  1. As part of the rebuild kit you get a new needle for the float assembly. Go ahead and push out the brass pin holding the float assembly ( 52 in the diagram) , and remove completely.

  2. The instructions tell you to set the float to 14mm with the metal assembly C vertical, and the float - this is without the gasket in place. You can do this, but it will require you to disassemble the float assembly again to install the gasket, and reinsert the pin
    OR -" and much easier -
    Put the correct gasket on now, and set the float to 13mm from the gasket - " the gasket is 1mm thick.

  3. You must remove the extended valve holder (50 in diagram) before you install the top plate with the gasket, it will not go on if you don't. Place the plate on top of the main body, drop in the valve holder extensions and screw them in slightly, secure the top with screws (55) and tighten down the holders (50)

Good luck with your rebuild - don't forget Weber fuel pressure must be 3psi maximum, or the carbs will flood as soon as you turn on the supply.

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Comments and Suggestions:
Tom Comments: Referance your IDF rebuild kit 92.3240.05 instructions #2, claim the float height is set at 10mm w/gasket & 11mm without gasket. REDLINE instructions claim 14mm.
Just a note to eliminate floading.
December 29, 2015
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
James Comments: i have two weber 44 idf for a hot 2180 vw motor. Iam looking for the springs that go inside the body next to the two hole inspetion plate.
December 5, 2011
  Followup from the Pelican Staff: Cantact one of our parts specialist at 888 280 7799 and see if they can't help you find what you need. - Kerry at Pelican Parts  
pshieldo Comments: i am installing a weber 32/36 DVG-5-A on a B 20 Volvo. I have rebuilt the carb with the kit. It idles fine, but won't accelerate without violent pumping. The clear fuel filter seems to show sporatic fuel delivery from the pump. Should I install an electric pump with regulator and try again, or might it be something in the carb. I took it apart and soaked in cleaner,rinsed and blew it out. The Acc pump was dry as was the power valve. Both are new. This carb was on a B 20 Volvo of mine 10 years ago and ran fine.
October 21, 2011
  Followup from the Pelican Staff: Check the fuel pressure and volume coming from the fuel pump. - Nick at Pelican Parts  

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