TheSamba.com :: View topic - Fuel injection conversion shopping list

Thu Jan 05, 2017 9:13 pm

To link to this post copy and paste
Code: [url=https://www.thesamba.com/vw/forum/viewtopic.php?t=670338&start=0&postdays=0&postorder=asc&highlight=fuel+injection]Fuel injection conversion shopping list - parts required FAQ[/url]

While Tcash is on a Samba Sabbatical, I thought I would make a comprehensive list of parts required to reinstall the factory fuel injection in place of an aftermarket carbureted induction setup.

Eventually, I will make links to the Best Known Replacements for things like rubber hoses and bits. For example, many 45-year old rubber/plastic parts from storage boxes can be cracked or broken, while the electronic and mechanical parts will be perfectly usable.

Parts in BLUE are 75-76 only.
Parts in RED are 77-79 only.
Parts in ORANGE are 79 California only.
Parts in GREEN are automatic transmission only.
Parts in VIOLET are manual transaxle only.

Please let me know what I have missed,
Robbie

Without further adieu, The List:

Rubber/plastic bits:
S-boot
throttle body-to-plenum cone gasket
4 intake runner hoses
2 intake runner-to-head gaskets with phenolic spacer
AAR hose from s-boot
hose to plenum
AAR elbow
S-boot Y to AAR and decel valve
crankcase breather hose
decel valve hose from s-boot Y
decel valve hose to brake booster Y
Brake booster Y
charcoal cannister
fan shroud-to-charcoal canister hose
charcoal canister to EEC (evaporative emissions control) valve hose
small rubber lines from tank to charcoal canister
rubber T for tank vent lines
CSV gasket to plenum
4 small injector seals
4 large injector seals
7mm fuel hose, reinforced, rated for fuel injection use (around 100psi) with smooth-edged clamps
rubber mounts for air filter housing

Electronics:
4 fuel injectors
cold start valve (CSV)
thermo time switch (TTS) with mounting plate
auxiliary air regulator (AAR) with mounting plate
double relay (DR) - Double Relay T2 ID
resistor pack (not on 1979 donor systems)
six pin air flow meter (AFM) - AFM (air flow meter) MAF (mass air flow sensor) T2 ID
seven pin AFM - AFM (air flow meter) MAF (mass air flow sensor) T2 ID
full throttle/idle throttle switch
electronic control unit (ECU)
wiring harness
3-prong ground tab
fuel pump with bracket and rubber isolator mounts - Fuel injection Fuel pumps
wire from starter #50 terminal to DR
TSII, or Piaggio scooter sensor replacement with jumper wire
oxygen sensor, with the wiring harness and ECU to match
Vehicle-side double relay plug - PN 849 941 593

Please note, wiring harness, AFM, and air filter must match:
6-pin AFM/wire = air cleaner with warm air intake snorkel
Ideally, you'd also have the early FI style crossover pipe with warm air provisions. My limited testing found this to be irrelevant.
7-pin AFM/wire = air cleaner with built-in temperature sensor

The Late Karl von Salzen claimed that all the bus ECU units he tested ran the same, but it would be worth grabbing the correct ECU for your wiring/AFM setup.

Mechanical:
Exhaust - Bus 1700/1800/2000 Exhaust/Heater 1972-1979
EGR valve and pipe(electrical or mechanical)
intake runners
intake plenum
(upper case bolts must be long enough to secure intake plenum)
throttle body
throttle return spring (to plenum)
fuel pressure regulator (FPR)
brake booster hose/pipe through firewall
air filter housing
air filter element
S boot hose clamps
vacuum operated decel valve
1979 only vacuum operated decel valve(?)
electronic decel valve
FI compatible SVDA distributor - Distributor Bus Bay window ID T2
FI compatible DVDA distributor - Distributor Bus Bay window ID T2
FI compatible DVDA distributor - Distributor Bus Bay window ID T2
throttle cable (length determined by transaxle style)
various small* vacuum hose for distributor advance
various medium-small* vacuum hose for decel valve, FPR, and possible distributor retard
fuel tank with inlet and outlet
fuel filter
fuel rails, left and right (left side has 7mm screw for pressure test port)
left side engine tin with hole for EGR passthrough
EGR filter
Catalytic converter (when installing on CA buses 1976 and later only.)

Handy tools:
fuel pressure gauge, up to 80psi.
digital volt/ohm meter (multimeter)
smooth-jaw vise-grips or hose clamping pliers
jumper wires (5’ wire with alligator clips on each end)
test light

Thu Jan 05, 2017 9:28 pm

Great list!

Under electrical you're missing Thermo-time Switch (TTS)

Thu Jan 05, 2017 9:29 pm

BayCreamPuff wrote: Great list!

Under electrical you're missing Thermo-time Switch (TTS)

Thanks! And I've added the TTS (and mounting bit!)
Robbie

Thu Jan 05, 2017 9:42 pm

Since you are calling out the '79 Cali model as special, make a note that the AFM and decel valve on that one are calibrated differently, and that the distributor has a vacuum advance/retard can. Not sure how detailed you are intending to get specifying year-to-year differences.

Good list.

Thu Jan 05, 2017 9:44 pm

SlowLane wrote: Since you are calling out the '79 Cali model as special, make a note that the AFM and decel valve on that one are calibrated differently, and that the distributor has a vacuum advance/retard can. Not sure how detalied you are intending to get specifying year-to-year differences.

Good list.

Thanks! I have been helping a few people find parts to convert their progressive carbs back to stock, and we have been deciding to buy whatever fuel injection system is available and economical; as of now I have not worked with one directly, so I don't know what is special I would eventually like to color-code or detonate certain components like the ones your mentioned. It's a work in progress and I would appreciate any other component differences!

Robbie

Thu Jan 05, 2017 9:44 pm

asiab3 wrote: BayCreamPuff wrote: Great list!

Under electrical you're missing Thermo-time Switch (TTS)

Thanks! And I've added the TTS (and mounting bit!)
Robbie

asiab3 wrote:
thermo time switch (TTS) without mounting plate

What you got against mounting plate?
Colin :P

Thu Jan 05, 2017 9:45 pm

Amskeptic wrote: asiab3 wrote: BayCreamPuff wrote: Great list!

Under electrical you're missing Thermo-time Switch (TTS)

Thanks! And I've added the TTS (and mounting bit!)
Robbie

asiab3 wrote:
thermo time switch (TTS) without mounting plate

What you got against mounting plate?
Colin :P

Nothin'.
Whatcha got against brain farts?
Robbie

Thu Jan 05, 2017 9:49 pm

I have a pretty thorough install checklist I put together when I redid my FI system. Happy to share here if you think it helpful. Otherwise I'll create a separate post.

Thu Jan 05, 2017 9:51 pm

BayCreamPuff wrote: I have a pretty thorough install checklist I put together when I redid my FI system. Happy to share here if you think it helpful. Otherwise I'll create a separate post.

Share here if you'd like, or shoot it to me in a PM and I'll incorporate anything in the original post.

Thu Jan 05, 2017 10:31 pm

Here's the FI instillation checklist. Some may be specific to 79 CA. Happy to make changes.

Disconnect battery ground strap
Install 3-prong ground tab
Install TS2
Install TTS
Install AAR
Install intake manifold to head gaskets
Install intake manifold sleeves
Install intake manifold
Mount CSV to plenum
Install plenum (14 ft/lbs)
Install 3/4 fuel rail with injectors and pressure gauge pre-mounted
Install fuel pump and filter
Install fuel pressure regulator
Install 1/2 fuel rail with injectors pre-mounted
Install throttle body with new seal 14 ft/lbs
Install throttle return spring
Install s-boot
Install air filter box with AFM attached
Install double relay
Install series resistor pack (all but 79CA)
Install decel valve
Connect s-boot to decal valve
Connect s-boot to AAR
Connect s-boot to oil breather
Connect AAR to plenum
Vacuum Hoses

Models with DVDA distributor

Connect distributor retard vacuum hose to back of throttle body
Connect distributor advance vacuum hose to front of throttle body
Connect distributor advance vacuum tee line to EEG valve on air box

Early FI models

Connect vacuum hose from the plenum port (or throttle body) to a 4-way tee
Connect distributor advance vacuum hose to 4-way tee
Connect vacuum hose from EEG valve on air box to 4-way tee
Connect vacuum hose from EGR valve to 4-way tee

Connect plenum vacuum hose to fuel pressure regulator
Connect pressure regulator to decel valve
Connect FI connectors

Double Relay
Series Resistor Pack (all but 79CA)
Ignition Control Module (79CA only)
Injectors
CSV
AAR
TTS
AFM
TS2
O2S (79CA only)
EGR (early models)
EGR Microswitch on throttle body (early models)
Full-Throttle Switch (76 & 79CA only))
#1 to Coil

Connect all fuel hoses
Double check all clamps are tightened
Double check distributor cap is clamped down if you happened to remove it
AFC system check with multimeter
Connect battery ground strap
Turn key on
Open flap in AFM to activate pump.

Check fuel pressure
Check for leaks

Start engine

Fri Jan 06, 2017 3:30 am

Nice install list- might want to add a few points about existing equipment removals.

At what point do I remove the carb? Right after the battery disconnect? After the carb is off, is that when I pull the firewall to remove the now drained and empty gas tank if I do not already have an FI tank? Or is it easier to pull the tank after removing the carb, plenum, and intake runners?

Fri Jan 06, 2017 5:31 am

SlowLane wrote: Not sure how detailed you are intending to get specifying year-to-year differences.

Ratwell has a good table showing all the different year FI parts and interchangeability along with the VW/Bosch numbers on his website that some of you may have seen before.

I'd post a shot of it here, but his website is still down, and I can't get through to the archive site here at work (blocked).

Fri Jan 06, 2017 6:06 am

might install the ground tabs before the plenum chamber..

Fri Jan 06, 2017 7:08 am

Now we're on a slippery slope! Some buses will still have the ground tabs installed. Hell, some progressive-equipped buses still have the double relay, decel valve, and resistor packs installed.

Point is, a few friends have asked me for a shopping list, and here it is,
Robbie

Fri Jan 06, 2017 7:12 am

Makin' my list and Checkin' it twice......

Or three times or four times........

Boxes of partial systems and sorted bits needed are slowly arriving in anticipation of wresting with this - come weather warmer than -3*.

Would it be prudent to anticipate purchasing all - or nearly all - of the "Rubber Bits" new?

I am praying the VW Gods will be kind to me in this transition back to fuel injection.

Fri Jan 06, 2017 7:56 am

Robbie - the Federal takes an EGR but no Cat. Up to 1978 the California takes an EGR and Cat. These two lists may help you:

http://www.type2.com/library/fuel/fuelibo.htm

ratwell.com under FI once his website is back up or use archive.org.

Fri Jan 06, 2017 8:02 am

Thanks Robbie and BayCreamPuff!

I've been using various scraps of paper with FI parts required for Chloe's conversion. Now there is one good list of it all, along with some of the bits I've overlooked.

And I was unsure in what order to make the change, so now it's clear.

Thanks guys! =D> =D>

Fri Jan 06, 2017 11:18 am

When shopping for parts. This guy might come in handy for hoses and intake S boot.

http://www.thesamba.com/vw/classifieds/detail.php?id=1321070

Fri Jan 06, 2017 1:03 pm

How about:

- matching distributor for FI
- '79 ignition module / system, if needed

Fri Jan 06, 2017 1:06 pm

for the 79 CA system the air flow meter and the ECU are different. Don't forget the electronic ignition system - control unit, distributor, coil and wiring. Installing the converter will require all the different exhaust system/heat exchanger components on the left side as well as the crossover pipe. The O2 sensor bung is in that plumbing. There is a pic somewhere on the forum of all the piping some of which may fall into the unobtanium category.

Oh and the left rear engine tin is different as the air hose from the fresh air fan enters in a different place to accommodate the unique left heat exchanger.

There may be some additions but it is too dam cold to go and sit on my ass in the snow and do a visual in the engine bay. FYI.

Edit. Here are the exhaust components less the crossover pipe.