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Fuel injection conversion shopping list - parts required FAQ
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asiab3
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PostPosted: Thu Jan 05, 2017 9:13 pm    Post subject: Fuel injection conversion shopping list - parts required FAQ Reply with quote

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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
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Last edited by asiab3 on Tue May 01, 2018 6:47 pm; edited 12 times in total
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BayCreamPuff
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PostPosted: Thu Jan 05, 2017 9:28 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

Great list!

Under electrical you're missing Thermo-time Switch (TTS)
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PostPosted: Thu Jan 05, 2017 9:29 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

BayCreamPuff wrote:
Great list!

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


Thanks! And I've added the TTS (and mounting bit!)
Robbie
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PostPosted: Thu Jan 05, 2017 9:42 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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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Last edited by SlowLane on Thu Jan 05, 2017 9:52 pm; edited 1 time in total
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PostPosted: Thu Jan 05, 2017 9:44 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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
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PostPosted: Thu Jan 05, 2017 9:44 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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 Razz
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asiab3
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PostPosted: Thu Jan 05, 2017 9:45 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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 Razz


Nothin'.
Whatcha got against brain farts?
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PostPosted: Thu Jan 05, 2017 9:49 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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.
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PostPosted: Thu Jan 05, 2017 9:51 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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.
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PostPosted: Thu Jan 05, 2017 10:31 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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

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Last edited by BayCreamPuff on Fri Jan 06, 2017 8:19 pm; edited 2 times in total
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PostPosted: Fri Jan 06, 2017 3:30 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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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PostPosted: Fri Jan 06, 2017 5:31 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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).
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PostPosted: Fri Jan 06, 2017 6:06 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

might install the ground tabs before the plenum chamber..
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PostPosted: Fri Jan 06, 2017 7:08 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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
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PostPosted: Fri Jan 06, 2017 7:12 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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.
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PostPosted: Fri Jan 06, 2017 7:56 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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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PostPosted: Fri Jan 06, 2017 8:02 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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! Applause Applause
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PostPosted: Fri Jan 06, 2017 11:18 am    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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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PostPosted: Fri Jan 06, 2017 1:03 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

How about:

- matching distributor for FI
- '79 ignition module / system, if needed
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PostPosted: Fri Jan 06, 2017 1:06 pm    Post subject: Re: Fuel injection conversion shopping list - parts required Reply with quote

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.

Image may have been reduced in size. Click image to view fullscreen.
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