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Revised January 16th, 2013

Fuel Injection 

Vanagon Wasserboxer Digijet 1983 to 1985


Most of the electronic Fuel Injection components on your Vanagon are manufactured by Bosch. However, many of the other necessary components such as hoses, seals, air cleaner parts, etc., are manufactured by the respective OE manufacturers to Volkswagen, such as Continental, LMB, Goetz, Elring, etc. We have endeavored to supply as much OE components as is possible to obtain from sources both here in the United States and in Europe. Quality is our first priority when stocking and selling parts for fuel injection because it can be a major investment, even when replacing a relay. Below is our comprehensive list of replacement parts for the Digijet Fuel Injection System on your 83-85 Vanagon or Westfalia. Please note that where there are split years in certain components, we have provided your VIN Number, or in the case of a Bosch component within split years, the Bosch number in Parentheses ( ).

Rebuilt Item Cores are subject to inspection according to our Core Policy. Please read our core policy by clicking here:Bus Boys Core Policy

Air Filter Element 

Air Intake Elbow Boot

Air Flow Meter

Auxiliary Air Valve

Electronic Control Unit (ECU)

Fuel Filter

Fuel Injectors

Fuel Injector Seal Kit

Fuel Pump

Fuel Pump Relay

Gasket Block

Hoses

Idle Stabilizer Control Box

Oxygen Sensor

Pressure Regulator

Thermo-Time Switch

FI Harness Repair Parts

 


Air Filter Element - Mann or Mahle

Air Filters are very critical in determining how well your fuel injection runs. Too clogged up and the Air Flow Meter (Air Box) as well as the engine doesn't get enough air. In my opinion, filter elements should be changed every 10,000 miles, more so if you frequently drive in dusty conditions. Up until recently, we have been selling the German Mann units. Lately, our importer/supplier has been shipping Austrian Mahle, which is a division of German Knecht, an original supplier to Volkswagen. In addition, we have recently added K&N Filter Elements to our product line.

021-129-620 1983-1985 $9.70

ZAP-13772 K&N Filter Element 1983-1985 $59.07


Air Intake Elbow Boot

Runs between the Air Flow Meter (Air Box) and the Throttle Body. Old ones are usually cracked, allowing vacuum leaks that can be difficult to track down if you don't know this.

025-129-967A 1983-1985 NLA


Air Flow Meter - Rebuilt (Also called the "Air Mass" or "Air Box")

AFM's, or Air Boxes as some people call them, if left alone usually last a long time. There's a flap inside that swings around letting air in as the throttle body wants it and the flap attached to a potentiometer that sends the appropriate signals to the ECU in regards to air flow amount. The potentiometer wipes across a circuit board and that can wear as well over time with constant use. Another common malady is if you have backfiring coming through the intake for various reasons, it can bend, crack or blow apart the flapper. Engine heat can also dry the teeny bearings the flapper shaft rides on, causing it to jam or bind up, restricting the air flow. It is highly recommended that when installing a new (or rebuilt) Air Box, that you have a mechanic with a CO "sniffer" fine-tune the Air Bypass screw (or allen on some) that's off to the side for optimum running. Don't fool with this yourself or you might have a heap o' problems.

Part Number, Application, Price

 

Air Flow Meter - Rebuilt - Exchange

Our Rebuilt Air Flow Meters are completely gone through and our experience on our own Buses & Vanagons with these have been exemplary. Warranty is 6 months.

025-906-301X (0280200038) 1983-1985 $183.65 PLUS $75.00 Core

Note: Be sure to note the Bosch Number on your original Air Flow Meter. If the number on yours does not match the list above, please call us to properly interchange it for you.


Auxilary Air Valve

022-906-045A 1983-1985 NLA


Electronic Control Unit (ECU) - Rebuilt - Exchange

Bosch is currently obsoleting many models of ECU's. Therefore, we have been sourcing these from an independent remanufacturer for the past few years and the quality meets or exceeds the Bosch quality. In fact, we've only had one defect in 2 years, so that has to be a pretty good track record. The Digijet independent rebuilt is very affordable, compared to Bosch's original pricing on it . Warranty is 6 months on the independent rebuilt..

025-906-021X (Independent Rebuilt) 1983-1985 $595.00 PLUS $110.00 Core

 


Fuel Filter - Genuine Bosch

The heart of your fuel injection system is the fuel filter. Once they become dirty and plugged, engine performance suffers and too little fuel getting to the fuel pump can cause the pump to seize. Cheaper than replacing a fuel pump.  Never run a filter designed for carburetion on your fuel injection!

251-201-511A (Metal Cannister Style) 1983-1985 $12.50


Fuel Injectors - New - Genuine Bosch

Fuel Injectors can become clogged over a period of time or after a large amount of miles. Many people do not realize how sensitive these beasts can be. If loaded with junk, they can run either rich or lean, depending on where the junk is.  The art of keeping these clean is to regularly change your fuel filter and run a fuel injector cleaner at least once a month in a tank of gas.

025-906-031 1983-1985 $180.00 each

Fuel Injectors - Rebuilt - Exchange

Now available as a quality remanufactured unit, these can make changing out your injectors a little more affordable and a little less painful. Warranty is 6 months.

025-906-031X 1983-1985, Seals Included  $55.30 each PLUS $15.00 Core each


Fuel Injector Seal Kit

Contains 4 large and 4 small injector seals - does the the whole enchilada

311-198-261A 1983-1985 $7.35 kit


Fuel Pump - Electric - New

New electric fuel pumps are available now from two sources - Bosch and A.P. Pierburg, both German manufactured. Quality is of course excellent. Warning! Never run an electric fuel pump dry as it will cause it to overheat and seize up. The fuel acts as a coolant for the fuel pump, so this is very important to keep in mind. In otherwords, don't run outa gas!

251-906-091 Bosch, 1983-1985 $270.00

251-906-091 GR Pierburg, 1983-1985 $260.00

Fuel Pump - Electric - Rebuilt - Exchange

Now available as an affordable rebuilt, we feels these pumps are as good, if not better than Bosch new ones. Warranty is 6 months.

251-906-091X 1983-1985 $156.00 PLUS $50.00 Core


Fuel Pump Relay

Burnt contacts in these can sometimes cause failure of the fuel pump. These are relatively inexpensive compared to the earlier L-Jetronic "Combi Relay". Located on the left side of the engine compartment in a small black box with a cover on it. In addition, this particular relay is also used in various other locations in your Vanagon, so it's fairly common.

141-951-253B 1983-1985 $12.45
Note: The other relay in that box is called a "Contact Close Relay", probably for load reduction or current re-direction, but that's purely speculative on our part as we have never been asked for it before. If it needs replacement as well, order 321-919-505A - Price is $26.40


Gasket Block - Air Intake Runners to Cylinder Head

025-129-717C $6.40 each


Hose/Boot - Center Air Plenum to Air Intake Runners

These are those large diameter hoses that connect the center plenum to the individual intake runners going to each cylinder. Cloth braided original German is what we carry and 4 are required per Vanagon. A notorious spot for vacuum leaks.

039-133-241 1974-1985 $5.30

Hose - From Air Intake Elbow Boot to Aux Air Control Valve

N 20374.15 1983-1985 $5.25 (Hose Pre-Cut To Size)

Hose Elbow - Aux Air Control Valve to Hose above

049-133-783 1983-1985 $37.00

Hoses - Aux Air Valve to Center Air Plenum

N 20374.06 Valve To "Y" Fitting 1983-1985 $1.80 (Hose Pre-Cut To Size)

035-133-783F "Y" Fitting to Air Plenum 1983-1985  NLA

Hose - Fuel High Pressure

Genuine Continental 7mm High Pressure Fuel Hose with smooth covering, no outside braided cloth. Our opinion is that this is a much better hose than the original braided hoses you find on the some of the FI Vanagons. Sold by the foot, not the meter like some other places. 12 to 15 feet usually does the engine compartment, supply lines and return lines, depending on the year.

N 20281.12 1983-1985 $4.90 per foot
(Note: We do carry the cloth braided variety for the fanatics - order N 20357.12 $2.95 per foot.)


Idle Stabilizer Control Box - Also Called The "DLS" Box

The DLS Unit/Idle Stabilizer is usually located on the left engine wall next to the Ignition Control Module and has Round Plug Connectors. Because of the lean conditions associated with the emissions controls on your California (and some Federal models too) Model Vanagon, without this unit, your idle sometimes "hunts", going up and down. When it fails, the engine won't start or run usually. Maintenance Tip: If equipped with this device, never try to time your engine with it connected. The timing mark at idle jumps all over the place. Before timing the engine, shut it off, disconnect the round plugs from the unit, then connect the plugs together, start the engine, be sure idle is at factory specs, set your timing accordingly, then turn off engine and reconnect your Idle Stabilizer. A pricey item at the dealer ranging from $152 to $198, our price is a lot lighter on the wallet.

251-906-083 1983-1985 Calif. Model $41.80

251-906-083 1983-Early 1984 Federal Model (To VIN 25-D-200000) $41.80

321-906-083 Late 1984-1985 Federal Model (From VIN 25-D-200001) $44.95


Oxygen Sensor - Genuine Bosch

All Vanagon Digijet Models used a Single Wire Oxygen Sensor. Oxygen Sensors tell the ECU when to lean or richen your fuel mixture at the injectors by sending a small voltage signal in relationship to the presence of oxygen in the exhaust. Too much oxygen, it richens the mixture. Too little oxygen, it leans it out. A heavily sooted and carbonized probe won't allow the sensor to send a proper voltage to the ECU, usually making the engine run too rich, resulting in poor mileage and fouled spark plugs. I recommend replacing them at least every 50,000 miles. What we carry is the Universal Bosch Sensor. This sensor looks just like your original except it doesn't have your standard long wire and connector. It has just a little pigtail wire with a crimp connector. Simply cut the existing wire off your old sensor, strip about a quarter inch off the insulation and then crimp that end onto the pigtail crimp connector. There - you just saved about $50 bucks for the real thing, which is also available from Bus Boys as well.

035-906-265 UN Universal Oxygen Sensor, Bosch $29.75

035-906-265 Oxygen Sensor w/Factory Connector, Lead and Grommet, Bosch $150.00


Pressure Regulator - Fuel - Genuine Bosch

025-133-035 1983-1985 $160.00


Thermo-Time Switch

This operates your Cold Start Circuit to the ECU. Located in your Thermostat Housing, next to your Temp Gauge Sender, this is a temperature controlled probe that samples the temperature of your coolant. When your coolant is cold, ECU receives a signal from the Thermo-Time Switch, then the ECU tells the Injectors to richen the mixture a bit. After the coolant reaches a certain temperature OR after a pre-set time in the ECU is reached, the ECU switches to the Oxygen Sensor Circuit to regulate how much fuel is dispensed at the Injectors. While the engine is running however, the Thermo-Time Switch is still measuring the coolant temperature and also keeps the switch off if above a certain temperature. Over-Rich running may and can be caused by a defective Thermo-Time Switch not shutting off OR if your Thermostat is stuck open, allowing the the engine to run too cold, thus not allowing the Thermo-Time Switch to shut off. Please note - Your Oxygen Sensor may be also causing the over-rich running, so check that as well.

025-906-041 Genuine Bosch 1983-1985 $26.40


NEW! FI Harness Repair Parts

We have recently introduced the following items to aid in the repair of your FI Harness, particularly dealing with connnectors and terminals. We get dozens of calls every week looking for the complete connectors to repair existing harnesses. Unfortunately, many of these connectors only came with a new harness, with a few exceptions. In many cases, all that's needed to repair the harness are the "flat" spring-loaded connector terminals, which have been very difficult to find. These are brand-new, not used or reconditioned connectors. The following are the connector housings and special terminals we now have available, including the tool to work with them.

2 Pin Connector Housings

FI Contact Terminal With "Pigtail" Wire

FI Harness Pin Tool

Clip For 2 Pin Connector Housings

2 Pin Connector Housings

Fits Injectors, Thermotime Switch and Aux Air Valve. Comes as the Housing only (Re-use your harness and terminals) or pre-wired with contact terminals and short "pigtail" wires for reconnection to your harness. VW has obsoleted these numbers for sometime now.

022-906-231A Connector Housing With Clip $6.15each

022-906-231AK Connector Housing w/terminals and pigtail wires and clip  $7.80 each


FI Contact Terminal With "Pigtail" Wire

Fits the above Connector Housing, as well as a number of FI Multi-Pin Connectors and the connector to the Electronic Ignition Module.

357-971-741AW Contact Terminal w/Pigtail Wire $1.65 each


FI Harness Pin Tool

A handy tool to have when replacing the contact terminals above in almost any of the FI Harness Connectors

ZVT-90601 FI Harness Pin Tool $2.95


Clip For 2 Pin Connector Housings

This clip keeps the connector housings attached to your Injectors, Thermotime Switch and Aux Air Valve. Without these, engine vibration can sometimes cause the Connector Housing to come loose, even fall off what its attached to.

022-971-999 Clip, Connector Housing $1.25 each


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