Author |
Message |
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Thu Jan 05, 2017 9:13 pm Post subject: Fuel injection conversion shopping list - parts required FAQ |
|
|
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 _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com
Last edited by airschooled on Tue May 01, 2018 6:47 pm; edited 12 times in total |
|
Back to top |
|
|
BayCreamPuff Samba Member
Joined: August 10, 2015 Posts: 769 Location: Oakland, CA
|
Posted: Thu Jan 05, 2017 9:28 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
Great list!
Under electrical you're missing Thermo-time Switch (TTS) _________________ Cream Puff
'79 CA Stock FI Deluxe Campmobile
Earl Grey
'87 GoWesty 2.2 Westfalia
Marsha Mellow
'00 Eurovan VR6 Full Camper |
|
Back to top |
|
|
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Thu Jan 05, 2017 9:29 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
BayCreamPuff wrote: |
Great list!
Under electrical you're missing Thermo-time Switch (TTS) |
Thanks! And I've added the TTS (and mounting bit!)
Robbie _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com |
|
Back to top |
|
|
SlowLane Samba Member
Joined: July 11, 2005 Posts: 1044 Location: Livermore, CA
|
Posted: Thu Jan 05, 2017 9:42 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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. _________________ Present:
'81 Westfalia: 2L, manual. Originally Canadian, now Californiated
Back in the day:
'72 Super Beetle
'69 Camper Van - Corvair powered
'71 Window Van - Transferred Corvair from '69
"With sufficient thrust, pigs fly just fine." - Internet RFC 1925
"They say a little knowledge is a dangerous thing, but it is not one half so bad as a lot of ignorance." - Sir Terry Pratchett
Last edited by SlowLane on Thu Jan 05, 2017 9:52 pm; edited 1 time in total |
|
Back to top |
|
|
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Thu Jan 05, 2017 9:44 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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 _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com |
|
Back to top |
|
|
Amskeptic Samba Member
Joined: October 18, 2002 Posts: 8568 Location: All Across The Country
|
Posted: Thu Jan 05, 2017 9:44 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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 _________________ www.itinerant-air-cooled.com |
|
Back to top |
|
|
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Thu Jan 05, 2017 9:45 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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 |
Nothin'.
Whatcha got against brain farts?
Robbie _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com |
|
Back to top |
|
|
BayCreamPuff Samba Member
Joined: August 10, 2015 Posts: 769 Location: Oakland, CA
|
Posted: Thu Jan 05, 2017 9:49 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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. _________________ Cream Puff
'79 CA Stock FI Deluxe Campmobile
Earl Grey
'87 GoWesty 2.2 Westfalia
Marsha Mellow
'00 Eurovan VR6 Full Camper |
|
Back to top |
|
|
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Thu Jan 05, 2017 9:51 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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. _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com |
|
Back to top |
|
|
BayCreamPuff Samba Member
Joined: August 10, 2015 Posts: 769 Location: Oakland, CA
|
Posted: Thu Jan 05, 2017 10:31 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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
_________________ Cream Puff
'79 CA Stock FI Deluxe Campmobile
Earl Grey
'87 GoWesty 2.2 Westfalia
Marsha Mellow
'00 Eurovan VR6 Full Camper
Last edited by BayCreamPuff on Fri Jan 06, 2017 8:19 pm; edited 2 times in total |
|
Back to top |
|
|
my59 Samba Member
Joined: August 13, 2003 Posts: 3790 Location: connecting the dots
|
Posted: Fri Jan 06, 2017 3:30 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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? _________________ my59: Well son, my grandfather died before I got to drive it, so does that answer your question?
our79: sunroof bus w/camper interior and 2.0 FI
Other:'12 Jetta, '77 Benz 300D, and a 74 MG Midget. |
|
Back to top |
|
|
dwill49965 Samba Member
Joined: August 08, 2005 Posts: 1396 Location: Dartmouth, Nova Scotia
|
Posted: Fri Jan 06, 2017 5:31 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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). _________________ Darryl
--------------
'78 Westy, Boston Bob built 2.0 L, FI, MSD 6A
Meyer wrote: |
Lastly, you just referred to US citizens as 'Americans'. Exactly what kind of Canadian are you? From what continent? |
|
|
Back to top |
|
|
williamM Samba Member
Joined: August 07, 2008 Posts: 4333 Location: southwest Arizona
|
Posted: Fri Jan 06, 2017 6:06 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
might install the ground tabs before the plenum chamber.. _________________ some days I get up and just sit and think. Some days I just sit.
opinion untempered by fact is ignorance.
Don't step in any! |
|
Back to top |
|
|
airschooled Air-Schooled
Joined: April 04, 2012 Posts: 12721 Location: on a bike ride somewhere
|
Posted: Fri Jan 06, 2017 7:08 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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 _________________ Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com |
|
Back to top |
|
|
andrewtf Samba Member
Joined: August 10, 2011 Posts: 602 Location: Illinois
|
Posted: Fri Jan 06, 2017 7:12 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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. _________________ '75 Riviera - 'BIG EMMA' (Pan American highway trip paused for a make over)
'77 Riviera - Murphy' (being reborn.... slowly)
'63 Austin Healey
Last edited by andrewtf on Sat Jan 07, 2017 10:35 am; edited 1 time in total |
|
Back to top |
|
|
SGKent Samba Member
Joined: October 30, 2007 Posts: 41031 Location: Citrus Heights CA (Near Sacramento)
|
Posted: Fri Jan 06, 2017 7:56 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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. _________________ “Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin |
|
Back to top |
|
|
KentABQ Samba Member
Joined: September 11, 2016 Posts: 2406 Location: Albuquerque NM
|
Posted: Fri Jan 06, 2017 8:02 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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! _________________ -Kent-
1976 Riviera, 1.8l FI chrome yellow VAN - "Chloe"
"I must say, how can you be in a bad mood driving this vehicle full of vibrant color.
Cars of today are so bland in comparison. It's like driving a celebration!" ---WildIdea
Bus ownership via emoticons:
---williamM |
|
Back to top |
|
|
Xevin Samba Member
Joined: January 08, 2014 Posts: 7623
|
Posted: Fri Jan 06, 2017 11:18 am Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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 _________________ Keep on Busin'
67rustavenger wrote: |
GFY's Xevin and VW_Jimbo! |
Clatter wrote: |
Damn that Xevin... |
skills@eurocarsplus wrote: |
I respect Xevin and he's a turd |
SGKent wrote: |
My God! Xevin and I 100% agree |
|
|
Back to top |
|
|
telford dorr Samba Member
Joined: March 11, 2009 Posts: 3551 Location: San Diego (Encinitas)
|
Posted: Fri Jan 06, 2017 1:03 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
How about:
- matching distributor for FI
- '79 ignition module / system, if needed _________________ '71 panel, now with FI
'Experience' is the ability to recognize a mistake when you're making it again - Franklin P. Jones
In theory, theory works in practice; in practice, it doesn't - William T. Harbaugh
When you're dead, you don't know you're dead. The pain is only felt by others.
Same thing happens when you're stupid. - Philippe Geluck
More VW electrical at http://telforddorr.com/ (available 9am to 9pm PST) |
|
Back to top |
|
|
pittwagen Samba Member
Joined: November 08, 2005 Posts: 765 Location: North of the 49th parallel
|
Posted: Fri Jan 06, 2017 1:06 pm Post subject: Re: Fuel injection conversion shopping list - parts required |
|
|
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.
|
|
Back to top |
|
|
|