Fuel injection conversion shopping list - parts required FAQ

[airschooled]

To link to this post copy and paste

[BayCreamPuff]

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

[airschooled]

[SlowLane]

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.
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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

[airschooled]

[Amskeptic]

[airschooled]

[BayCreamPuff]

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

[airschooled]

[BayCreamPuff]

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

1. Disconnect battery ground strap
   
2. Install 3-prong ground tab
   
3. Install TS2
   
4. Install TTS
   
5. Install AAR
   
6. Install intake manifold to head gaskets
   
7. Install intake manifold sleeves
   
8. Install intake manifold
   
9. Mount CSV to plenum
   
10. Install plenum (14 ft/lbs)
    
11. Install 3/4 fuel rail with injectors and pressure gauge pre-mounted
    
12. Install fuel pump and filter
    
13. Install fuel pressure regulator
    
14. Install 1/2 fuel rail with injectors pre-mounted
    
15. Install throttle body with new seal 14 ft/lbs
    
16. Install throttle return spring
    
17. Install s-boot
    
18. Install air filter box with AFM attached
    
19. Install double relay
    
20. Install series resistor pack (all but 79CA)
    
21. Install decel valve
    
22. Connect s-boot to decal valve
    
23. Connect s-boot to AAR
    
24. Connect s-boot to oil breather
    
25. Connect AAR to plenum
    
26. Vacuum Hoses
    
    
    
    1. Models with DVDA distributor
       
       
       
       1. Connect distributor retard vacuum hose to back of throttle body
          
       2. Connect distributor advance vacuum hose to front of throttle body
          
       3. Connect distributor advance vacuum tee line to EEG valve on air box
          
       
       
    2. Early FI models
       
       
       
       1. Connect vacuum hose from the plenum port (or throttle body) to a 4-way tee
          
       2. Connect distributor advance vacuum hose to 4-way tee
          
       3. Connect vacuum hose from EEG valve on air box to 4-way tee
          
       4. Connect vacuum hose from EGR valve to 4-way tee
          
       
       
    
    
27. Connect plenum vacuum hose to fuel pressure regulator
    
28. Connect pressure regulator to decel valve
    
29. Connect FI connectors
    
    
    
    1. Double Relay
       
    2. Series Resistor Pack (all but 79CA)
       
    3. Ignition Control Module (79CA only)
       
    4. Injectors
       
    5. CSV
       
    6. AAR
       
    7. TTS
       
    8. AFM
       
    9. TS2
       
    10. O2S (79CA only)
        
    11. EGR (early models)
        
    12. EGR Microswitch on throttle body (early models)
        
    13. Full-Throttle Switch (76 & 79CA only))
        
    14. #1 to Coil
        
    
    
30. Connect all fuel hoses
    
31. Double check all clamps are tightened
    
32. Double check distributor cap is clamped down if you happened to remove it
    
33. AFC system check with multimeter
    
34. Connect battery ground strap
    
35. Turn key on
    
36. Open flap in AFM to activate pump.
    
    
    
    1. Check fuel pressure
       
    2. Check for leaks
       
    
    
37. Start engine
    

_________________
Cream Puff
'79 CA Stock FI Deluxe Campmobile

Earl Grey
'87 GoWesty 2.2 Westfalia

Marsha Mellow
'00 Eurovan VR6 Full Camper

[my59]

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?
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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.

[dwill49965]

[williamM]

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!

[airschooled]

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

[andrewtf]

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

[SGKent]

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.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[KentABQ]

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

[Xevin]

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
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Keep on Busin'

[telford dorr]

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)

[pittwagen]

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.