New Plenum and Intake tubes, cleaned injectors too!

[dhaavers]

^^^ All depends on the size of your hose...

After rereading this thread, my plan for the old 2.1 is 1.5" hose plus
cable ties for insurance. If I had a 1.9 I'd use screw clamps for sure...

- Dave
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[djkeev]

I've had way too many cable ties break on me over the years.

For something as important as intake manifold vacuum? Clamps for sure!

Dave
_________________
Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[dhaavers]

Good point...
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[shagginwagon83]

I am thinking about doing this to eliminate any possible vacuum leaks. How difficult is this job? I plan on upgrading my fuel rails and it might be a good idea to tackle this. From what I understand, I need

4x Intake Manifold to Plenum Boot
2x Engine Intake Manifold Gasket
1x O-Ring for Breather Tower
1x Throttle Body to Intake Manifold Gasket

new fuel injector seals also will be going in.

Am I missing anything? Does anyone know a good source for silicon plenum boots?
_________________
Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan

[westina]

[dougass]

[shagginwagon83]

[dougass]

Shag - those clamps may be overkill... I think I picked mine up at autozone or something for much cheaper
_________________
'91 GL - 2.1 automatic named Klaus for weekend adventures.

#klausvan & @thisisklausvan

[shagginwagon83]

[tmart]

Just a quick heads up that link goes to 2.5" clamps.

Here's the 2": https://www.amazon.com/Squirrelly-Stainless-T-Bolt...3427JH5RQY
_________________
1990 Vanagon 2.2L Manual
The van that samba built

[dhaavers]

[shagginwagon83]

[westina]

If u have a lowes home imp. store around you, they sell contractor pack of clamps, 10 pieces SS about 8 bucks. 7/8 to 1 3/4 in. sizes. Great deal.

[IdahoDoug]

Yeah, I don't think this is a place needing high end clamps.

Doug
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[djkeev]

[shagginwagon83]

Boy oh boy what fun!

I removed the plenum today. I found out one of the 4 bolts holding the oil breather was very loose! The O-ring gasket for that was very brittle and snapped when I slightly bent it. I have quite a bit of oil on the engine that was behind that tower. Phone died so I could not get a picture tonight. I am hoping that was the reason for all that oil on that top side of the engine.

Any tips on removing the old gasket? I stuffed shop rags down the holes. I guess I should take the time to test my aux air regulator.
_________________
Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan

[shagginwagon83]

As far as removing the gasket I used a wire toothbrush. It took a lot of work, but I got the job finished. It seems to run better. My engine still shakes quite a bit but that could be because of motor mounts.

To summarize, I replaced

-intake gaskets
-fuel injector rubber/seals
-MAF sensor gasket (wasn't really needed)
-Oil breather gasket (highly needed)
-Throttle body gasket
-4x Plenum tubes
-All vacuum lines with clamps on almost EVERY connection
-All new fuel lines per GoWesty with anti-rub sleeves
-Van Cafe's fuel rails
-NGK spark plugs with .028" gap
-Added capacitor to MAF for vanagon syndrome

While I was in there I cleaned up the engine a little

-Cleaned MAF sensor
-Cleaned Throttle body
-Cleaned inside Plenum + intake tubes, painted both
-added dielectric grease to electrical connections
-added liquid electrical tape to some electrical connections
-tested aux air valve

It was a lot of work, but I am confident in everything I replaced.
_________________
Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan

[robcurtis2]

[MarkWard]

I'd add, the intake runner gaskets have a correct orientation, that could be easily missed. Ask me how I know.
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☮️

[robcurtis2]