New project, 67 Baja Bug with FI

[Stray Catalyst]

I'm baaaack.

I swapped my 1970 bug with autostick for a 67 baja, and a chassis, and a few motors, and a few other odds and ends. I've never done anything with FI in the past, and this car came to me in pieces, so it's going to be a learning-curve adventure.



This bug has some really, really bad electrical bodges. I've already excised about six feet of old extension cord that was hooked between the battery and the alternator, and as far as I can tell, all of the lights are decorative but only the headlights and brake lights are likely to work.



It has half a roll cage, but not the part in the front... and it has the tube sticking forward, ready to leave dents in my skull if I get rattled around the interior.



The fuel injected motor. I'm not sure what year it's from - somebody went through the trouble of removing the engine number, you can see the tool marks where it once was. The case is AS21. The AFM has been mounted to the firewall, and the intake is on the inside of the cab! The tube needed to hook the AFM to the TB isn't included, the PO suggested fabricating it out of 2" flex hose.

I'm working on the parts of it I understand, but I'm likely to have a LOT of questions.

Stray

[Stray Catalyst]

The car had a bad alternator - from the looks of the bodged wiring harness, I suspect they wired the hot lead from the alternator to the negative terminal on the battery (I did that once... followed by replacing the entire wiring harness, the alternator, and the battery on that car.)

The doghouse was also ugly, and I had a spare, so I painted it and installed a new alternator.



Unfortunately, here's one of those places where my lack of FI knowledge becomes obvious. The doghouse was from a carbureted vehicle, so there's not a place for the throttle cable to reach the TB. I'll drill a new place in the correct location on this doghouse - simpler than cleaning up and repainting the previous one.

When I was removing the previous doghouse, I found the usual mouse nest over the cylinders.

[Stray Catalyst]

I drilled the holes for the throttle cable, and have put the engine back into the baja. Now I'm faced with the fun puzzle of connecting the fuel injection wiring harness, and jury rigging a duct from the AFM to the TB. For that duct, it looks like I should be connecting the oil breather, but I'm not sure if I should connect the blue tube as well?



You can sort of see the AFM in the back, behind the wires. It's not in the same location or orientation as the original, so changing back to stock parts would involve more work but is an option if I can't make a duct that works.



Here's a better view of the AFM. It's possible I could get a stock duct (whatever it's called) and just jury rig the elbow to allow this location to work.

[Stray Catalyst]

So far, I've learned a bunch, but accomplished little in making the tube from AFM to TB. Exhaust parts are too heavy, flex pipe has too large a bend radius, PVC seems too brittle, and duct tape/cardboard seems unlikely to keep air tight for long. 2 1/4" radiator hose won't bend without kinking.

So, I'm going to see if I can find some 2 1/4" (or so) vacuum cleaner hose or paper hose to use for this. If needed, I'll make a small section of radiator hose, to use as the part where the two other tubes (oil breather and the other one) connect.

I've not had any luck googling this, so I'm kind of flying blind.

[Stray Catalyst]

In the absence of any advice, time to experiment.



It looks like a redneck Habitrail, but it should work to get the air from the AFM to the TB. I made this out of plastic bottles, flex exhaust pipe, a short section of rubber tube, a hose clamp, and a lot of duct tape. If this works I'll add a way for the two breather hoses to connect, but at this point those are hanging loose.

Now to figure out the last few vacuum connections and electrical connections.

[Stray Catalyst]

I'm having difficulty figuring out this system. The manuals all seem to assume that you're only putting together an engine you also took apart, and that it was complete when you started...

I took this car in trade, in pieces, with an engine I've never heard run and don't know if it's complete.

The few pics I've found of factory fuel injection for 75-79 Beetle, have a smallish block on the top with three hoses. The block has two bolts through it, and is painted the same color as the car.

I have hoses from components I believe should be connected there, if I'm understanding what I've been reading. It looks like it connects the exhaust recirculation valve and this:

And has a hose leading to the AFM boot, as well.

What's this part called? And/or what's the name of the part that is missing from my engine, which would have three hoses but no apparent wires connected to it?