Engine CSV fire, even after everything is done right

[Wasted youth]

Bus Depot offers 0280170402 as a CSV for a 1983 Rabbit. Looks like they offer a plethora of CSV's beyond that one.

We might just take a look at the variety and select one less likely to fall apart or leak, maybe search out online Rabbit forums to get a read on any associated problems.

As far as securing the wiring harness, I would add extra plastic wire loom on the outside of mine where it came in contact with other parts and securing it with several plastic zip ties to guard against vibration.

WARNING: Opinion follows...

VW engineers were not tasked with the Apollo Program... they were tasked with developing something reliable enough to generate sustainable profit.

[BayCreamPuff]

Not sure the size, but you'll also need the hollow bolt and copper washers seen in this diagram and photo.

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Cream Puff
'79 CA Stock FI Deluxe Campmobile

Earl Grey
'87 GoWesty 2.2 Westfalia

Marsha Mellow
'00 Eurovan VR6 Full Camper

[Max Welton]

[BayCreamPuff]

From doing a little internetting I found that the bolt size is M8X1.0.

So this is what should be needed. Only problem is the M8 double barb banjo fitting doesn't seem to come with the correct barb sizes.

M8X1.0 Metric Banjo Bolt
https://www.belmetric.com/bolts-c-14_850_851/bnjb8x10-banjo-bolt-p-4399.html

M8X12 Metric solid copper Banjo Fitting gasket.
https://www.belmetric.com/banjo-fitting-gasket-c-1...-5059.html

M8 Double Barb Banjo Eye Fitting with a 4mm to 5mm barb
https://www.belmetric.com/double-barb-banjo-eye-fi...-4954.html
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Cream Puff
'79 CA Stock FI Deluxe Campmobile

Earl Grey
'87 GoWesty 2.2 Westfalia

Marsha Mellow
'00 Eurovan VR6 Full Camper

[Tcash]

8MM X 5MM X 8MM REDUCING STEEL BARBED T 3 WAY FUEL HOSE JOINER
http://www.advancedfluidsolutions.co.uk/8mm-x-5mm-...2172-p.asp

[BayCreamPuff]

Took a trip to the local pick-n-pull hoping to pull a CSV off an 86 Audi 4000. No such luck. Every car I looked at with an accessible CSV was removed (duh it's a $200 part). I eventually found one hiding under the intake manifold of a 91 Volvo 240. Took a lot of patience to get that little bastard out, but boy was it rewarding when it did.

There seem to be a lot of these cars at pick-n-pulls. I bet many of them still have their CSV since it's so awkwardly located.

Bosch Part # 0 280 170 445

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Cream Puff
'79 CA Stock FI Deluxe Campmobile

Earl Grey
'87 GoWesty 2.2 Westfalia

Marsha Mellow
'00 Eurovan VR6 Full Camper

[cmonSTART]

Looks a lot bigger than stock.
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'78 Bus 2.0FI
de K1IGS

[BayCreamPuff]

Why not skip the banjo fittings and use a copper t-fitting with M8X1 male threads and 7mm barbs. Something like this:

_________________
Cream Puff
'79 CA Stock FI Deluxe Campmobile

Earl Grey
'87 GoWesty 2.2 Westfalia

Marsha Mellow
'00 Eurovan VR6 Full Camper

[skills@eurocarsplus]

here's my solution

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[Wasted youth]

Nice work, BayCreamPuff!

Looks like it bolted right into the plenum no problem. Will it all fit up on top of the engine?

How much did Pic-n-Pull charge? Even if it was $35, and you added $30 for a professional ultrasonic cleaning and flow test, it would be a bargain.

Now that you had it in hand, after looking at the design and mount up, were you left with the impression that this route might be a safer improvement than what we are currently faced with... or do you think the benefits might be negligible?

[aerosurfer]

Fantastic it at least bolts up!

Creampuff, what did you search for that threaded t fitting? I can find anything with all search combinations? What did PaP hit you up for the injector?
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Rebuild your own FI Harness..My Harness

77 Westy 2.0L Rockin and Rolling Resto!

72 Sportsmobile (sold)
79 Tran$porter... Parts car money machine (gone)

[BayCreamPuff]

[Wasted youth]

Total score at the junkyard! For that price, maybe a little destructive testing and/or slicing a la Skills might be in order here.

Okay, so the wiring plug is 90 degrees out. And the fuel line arrangement will need to be reworked, but looks like not much when the banjo bolt and nipples are used. Might even be a nice opportunity to fabricate steel fuel lines with fittings.

[cmonSTART]

Actually it looks like it will fit pretty well - not much bigger at all. I was worried about space in that area, as things at least in my engine bay are tight there.

Nice!
_________________
'78 Bus 2.0FI
de K1IGS

[BayCreamPuff]

[skills@eurocarsplus]

that "T" fitting is even more of an abortion than you could imagine....for one, you'll still have the lines hanging off either end of it, two, when tight, where is the correct "clocked" position going to be and three, I think that is an even bigger fire risk than the OE set up.

I don't know what the real answer is, and we are still not 100% sure this has been the source of fires.

I am not 100% familiar with the FI harness and if it has un fused 12V running thru it or not. if it does, I would probably consider either 1) a piece of fusible link or 2) an inline fuse.

and don't make me dig thru my decades old collection of 240/740/940 shit to cut open a Volvo CSV
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[dwill49965]

[danfromsyr]

you can get a double tall Banjo bolt and use 2 regular banjo ends.
one in, one out and the bolt is your flow thru T-fitting.

it'll take a little hard searching to find an M8 banjo with 7-8mm hose barb. but I believe there's a rare application out there with one.

https://www.google.com/search?q=M8+double+banjo+bo...&dpr=1

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[Wildthings]

[BayCreamPuff]