JBugs Video Series

Carburetor & Intake Manifold Installation:

Video Overview:

Looking for some tips on replacing your leaking VW Carburetor or rusted intake manifold on your VW Beetle? Follow along with our tech as he shows you how to remove your old air cleaner, carburetor and intake manifold and install new replacements. Our video covers the part numbers and tools we use along the way.

Video Tips:

Disconnect the Negative Side of the Battery:

Disconnecting the Battery
Any time you are working on a major car project, disconnect the battery to prevent a possible electrical fire.

Removing the Carburetor:

Removing the Air Cleaner
Remove the air filter which is clamped to the top of the carburetor. Loosen the clamp and disconnect any breather and vacuum hoses.
Removing Electrical Connections
Disconnect the electrical connections to the idle solenoid and choke element.
Removing Accelerator Cable Barrel Nut
Loosen and remove the barrel nut for the accelerator cable.
Disconnect and Cap Off the Fuel Hose
Disconnect the fuel hose from the carburetor, cap or plug the hose to prevent fuel leaking.
Removing Carburetor Mounting Nuts
Remove the two carburetor to manifold nuts and lift the carburetor up to remove it.

Removing the Intake Manifold:

Note: We are working on a dual port engine so there are steps involved that will only be necessary to a dual port intake manifold. With the exception of the intake manifold boots and clamps, most all of the following processes are the same for a single port engine.
Removing the Intake Manifold Nuts
Disconnect the spark plug wires to gain access to the intake manifold nuts at the heads. Remove the intake manifold nuts.
Loosening the Intake Manifold Boot Clamps
Loosen the intake manifold boot clamps and remove the intake manifold end castings and intake manifold gaskets.
Intake Manifold Center Mount
Some intake manifolds will have a bolt at the center of the manifold holding it in place at the top of the engine case behind the fuel pump. Loosen the nut and bolt.
Unbolt the Heat Risers from the Exhaust
This portion is not shown in the video as the heat riser tubes had been removed by the previous owner.
Unbolt the heat risers from the exhaust ports at the left and right sides.
Remove the Center Section of the Intake Manifold
To remove the intake manifold you will need to either remove the right side pre-heat tube (cut it near the center of the manifold) or remove the generator/alternator. Pull the accelerator guide tube from the shroud. Remove the generator/alternator clamp. Loosen the fan shroud nuts at the left and right sides of the shroud. You can now lift the fan shroud and generator/alternator up enough to pull the intake manifold out. The center section of the intake manifold can now be removed.

Installing the Intake Manifold:

Installing the Center Section of the Intake Manifold
Installation of the manifold is a reverse of the above steps. Put the intake manifold in to place. If your heat riser tubes are still attached to the intake manifold, you will have to lift the generator/alternator up as listed above. Reverse the steps to put the fan shroud and gen/alternator back in place.
Installing the Heat Riser Tubes
If you are installing a new intake manifold, insert heat risers tubes into the bottom the bottom of the intake manifold.
Install Heat Riser Gaskets & Bolts
Install new heat riser gaskets at the exhaust port and loosely bolt the heat riser tubes to the exhaust ports.
Install New Intake Manifold Gaskets
Install new intake manifold gaskets at each head.
Install New Intake Manifold Boots
Install new manifold boots on to the end castings. Slide the boots and end castings into place on the center section of the intake manifold and the intake ports at the head.
Install Intake Manifold Nuts
Install the intake manifold nuts on the intake manifold studs and tighten them.
Tightening Clamps, Center Mount & Heat Risers
Tighten the clamps on the intake manifold boots. Tighten the center mounting bolt for the center mount of the manifold. Tighten the bolts at the heat riser tubes.
Install Spark Plug Wires
The intake manifold installation is now complete. Re-install spark plug wires. The firing order is 1-4-3-2.

Installing the new Carburetor:

Installing a New Carburetor
With a new carburetor base gasket in place, set the carburetor in place on the manifold and tighten the two nuts holding the carburetor to the intake manifold.
Installing a New Fuel Filter & Fuel Hose
Install a new fuel filter and connect the fuel hose.
Connect Barrel Nut, Idle Solenoid, Choke & Vacuum Caps or Hoses
Install the accelerator cable into place in the barrel nut and tighten the barrel nut. Connect the wire from the coil to the idle solenoid and choke element. If you are using a vacuum advance distributor, install the vacuum hose and/or cap off any unused vacuum ports on the carburetor.
Install Air Cleaner & Breather Hose
Install the air cleaner and clamp it down securely. Attach the oil filler breather hose from the air cleaner port to the oil filler. The carburetor installation is now complete. Reconnect the battery and start the engine. Start up may take a few seconds as the fuel pump has to fill the new carburetor. Check all fuel lines for any leaks.Enjoy a job well done.