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my3bugs
Samba Member
Joined: June 18, 2003
Posts: 949
Location: Moreno Valley
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 Posted: Thu Nov 06, 2025 1:16 pm Post subject: trouble installing plug wires with dual 40 IDF carbs |
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years back i installed the aftermarket red plug wires , they have a rather large DONUT that installs in the cylinder tin cover ..........ran for several years like that .......just had the carbs rebuilt and now i cant get those donuts back in the holes , too stiff or what ? so i ordered a set of these empi plug wires pretty much like original wires but not Bosch ..........now with those installed there in the way trying to install the manifold ..... this is my only bug with dual carbs ........what is the trick ? do the plug wires need to go in after the manifolds ? my hand or arm doesnt even fit back there on the passenger side once the manifold is in place ? what is the trick ???
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Rob Combs
Samba Member
Joined: December 30, 2020
Posts: 836
Location: South Bay LA, California
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| Posted: Thu Nov 06, 2025 1:56 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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I think your manifolds will need to be in place first.
You didn't mention which carbs you have. Is there a way to install the manifolds without carbs, install the plug wires, then install the carbs? That might give you a bit more room... |
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my3bugs
Samba Member
Joined: June 18, 2003
Posts: 949
Location: Moreno Valley
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| Posted: Thu Nov 06, 2025 2:01 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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your prolly right Rob . its dual 40 IDF's . i installed the carbs on the manifolds first and they look sharp !!! im 70 years old and just cant remember how i originally did it . it was over a decade ago .
i also installed the velocity stacks n dual linkage plates . all that stuff is what my arm cant fit past . so looks like i need a DO OVER . |
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67rustavenger
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Joined: February 24, 2015
Posts: 11520
Location: Oregon
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| Posted: Thu Nov 06, 2025 2:26 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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I do the manifolds and carbs as one piece. Leave the filter bases and velocity stacks off and install the plug wires.
Doing the above, will gain you some arm room to get the wires on.
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my3bugs
Samba Member
Joined: June 18, 2003
Posts: 949
Location: Moreno Valley
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| Posted: Thu Nov 06, 2025 2:42 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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well i took one carb off a manifold , and got the manifold and plug wires installed in the drivers side . all that dual linkage and velocity stack stuff it what i was trying to avoid doing in the engine compartment on my 70 year old KNEES !!!
im just going at it slow , i have a large piece of foam im kneeling on . |
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Glenn 
Mr. 010
Joined: December 25, 2001
Posts: 80392
Location: Sneaking up behind you
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| Posted: Thu Nov 06, 2025 2:57 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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Wires go on after the manifolds.
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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
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עַם יִשְׂרָאֵל חַי |
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Cusser
Samba Member
Joined: October 02, 2006
Posts: 33448
Location: Hot Arizona
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| Posted: Thu Nov 06, 2025 2:58 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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| my3bugs wrote: |
I was trying to avoid doing in the engine compartment on my 70 year old KNEES !!!
im just going at it slow , i have a large piece of foam im kneeling on . |
I borrow Mrs. Cusser's knee pads from Harbor Freight.
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297 |
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my3bugs
Samba Member
Joined: June 18, 2003
Posts: 949
Location: Moreno Valley
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| Posted: Thu Nov 06, 2025 3:25 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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OK , thanks for all the help here . i have both manifolds installed now as well as all 4 plug wires .........none of this is going what i would call easy  the new plug wires dont use the nipple on the end of spark plugs , ya know how hard to get those nipples off of spark plugs thru the cylinder tin hole ..... every litte thing is a pain .....
im prolly calling it day for now , once the sun is on the other side of the house the mosquitos started coming out ......
i will still need to install the cross bar when i drop the carbs in place .
then i start wondering of i should have put in new spark plugs in while i was here . they have very little mileage on em , just back n forth to some car shows . but i think all this needs to come out just to change plugs . no other way to work in there ..... |
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Rome
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Joined: June 02, 2004
Posts: 10751
Location: Pearl River, NY
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| Posted: Thu Nov 06, 2025 4:24 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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| when i drop the carbs in place . |
I think you're going to curse those dual carbs when attempting to install them this way, after the manifolds are in place. Big risk of dropping one of the 2 inner fastening nuts while getting them down past the fan shroud. Per Murphy's Law that nut will fall into the spark plug hole and be trapped. And I hope you placed a lock washer under the 2 nuts for the manifold base, to prevent loosening from vibration and heat cycling if you only have the nuts on the manifold.
Installing the carb onto the manifold while off the engine- per 67rustavenger- has the benefit of you having unrestricted access to the 4 nuts that hold the carb to the manifold. When you maneuver the assembly down onto the head's 2 attachment studs, what I do is stand up next to the car, bend over with the assembly in one hand and guide it down into the open space between the side of the fan shroud, the engine bay side wall, and the firewall. You can feel when the front stud comes through the manifold base front hole. Then reach down with just a lockwasher/wavy washer. Pull your arm back up, and install the nut. Reason for doing only 1 fastener at a time instead of holding both in your hand, is the risk of dropping the other one as it slips out of your hand, or because your fingers get cramped. I'm only a few years younger than you...
Hopefully you checked the 2 manifold studs that the nut runs easily down the threads with your fingers beforehand... When you have both manifold nuts down finger tight, rock the top of the carb frontwards/rearward while pressing down. You want to wiggle/work the manifold down as far as possible against the friction of the attachment studs' threads. Usually you can turn the nuts a bit more with your fingers.
Only then do you start to tighten the nuts down, using a swivel-head socket and several extensions. I use small 1/4" drive sockets and extensions, and a short-arm ratchet.
After the carbs+manifolds are tightened, install the air cleaner base, the air horns, and the air cleaners.
Last edited by Rome on Thu Nov 06, 2025 4:45 pm; edited 1 time in total |
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Cusser
Samba Member
Joined: October 02, 2006
Posts: 33448
Location: Hot Arizona
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| Posted: Thu Nov 06, 2025 4:30 pm Post subject: Re: trouble installing plug wires with dual 40 IDF carbs |
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In the 1970s I invented what are now sold as Weber Windows (Wolfgang International) for access to the spark plugs and wires for my 1970 with 1835cc DP engine and dealer-installed AC. Mine is held in place by two sheet metal screws.
Since my 1970 now sports a 1600cc DP engine with single 30/31 PICT carburetor, I don't need to make use of that access panel any longer.
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297 |
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