1990 VW Westfalia 2.0 litre I4 Conversion – Intake

 

 

*  The conversion was shipped without an airbox, but pictures indicated it was originally bungee corded at the rear passenger corner of the engine bay, and run with an entirely inadequate intake made from ABS plumbing pipe.

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(This is the fast forward installation)

 Here's the ABS plumbing pipe intake provided by David at www.FastForward.ca

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*  As I had power steering and AC to fit in that section I decided to fabricate an airbox to fit behind the passenger side taillight, and make use of the stock snorkel for sound reduction.  As many have noted, the intake is very loud otherwise.  Using the stock snorkel ensures that cool, dry and relatively clean air is provided to the engine.

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*  I fabricated an adapter that allows the digifant air flow meter to be connected to a K&N cone filter.  Intake tubing is 3 inch mandrel bent aluminium from the local speed shop which is cut to fit and joined with silicon couplers and hose clamps.

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* This is the 9 inch sewer pipe I got for free at a local plumbing outfit.  It is fitted into the space behind the passenger tail light.  The end caps, one of which is visible at the back, are just lexan, cut to fit with a router.  You can see the 3 inch 90 degree fitting (white) at the back of the pipe which is connected to the intake "muffler" shown in the next photo down.  I've since painted it and secured it properly in the cavity.  The AFM assembly shown above fits into the pipe and is held in place with 4 screws.  The pipe itself needed some work with a power planer to allow it to slide in.  I wanted the largest air box possible to allow good air flow, and just as importantly, muffle low frequency intake "booming".

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* Here is the piece that fits behind the passenger side, engine compartment vent.  It is connected to the air box via a foil/cardboard tube....mine collapsed on the first big trip and created some anxious moments.  I replaced with a standard 3 inch intake tube from Canadian Tire.  This piece is necessary to keep intake noise from booming in the cabin. 

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*  I was originally concerned with the distance between AFM and throttle body, however, the engine performs well and there is no noticeable throttle lag.

 

*  I had to redo the overflow tank to allow room for the intake over top of it.  It is welded from stainless with brass hose fittings tapped in.  The fill spout is a short length of threaded pipe welded on, and cap from the local hardware store.  The cap is half filled with epoxy and then a rubber O-ring set in for sealing.

 

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