Replacing 28/32 with 32/36 DFEV - Need some advice

[parsok]

Well I've finally gotten to the intake side of the engine and have assembled the new parts. I'm replacing the stock 28/32 ADHA and dual plane intake manifold with a new Weber 32/36 DFEV and a single plane manifold from a '74 1800. I chose this setup on the excellent advice provided by this forum - thanks.

I took off the air cleaner can and then stopped and stared. OMG - what a mess of hoses. . As far as I can tell there are 7 or 8 hoses attached to the 28/32 but only 2 attachments on the DFEV ( fuel inlet and vacuum port advance). My conundrum - what to do with all the extra hoses? I've read the shop manual, the various posts and Brad's paper and have a good idea that the majority of the hoses are related to emission control. Here in Ontario the age of the car allows me to eliminate the emission control 'features' of the '80 so want to ditch the EGR and the various vacuums. Now I just need to figure out what to do with the hoses. This is where I am turning to forum for help, please.

Here are my questions:

1. What to do with the hoses connected to the carb:
* Crankcase blow-by connection tube
* Fuel return hose
* Float bowl vapor outlet
* Distributor vacuum signal (is this the same as the vacuum port advance?)
* EGR vacuum source
* vapor canister connector
* automatic choke hot water connections

2. What to do with the other 'connected' emissions hoses
* Thermovalves and vacuum lines that are connected to the intake manifold but not present on the 1800 manifold - I assume that these just 'go away' with the new configuration?
* gulp valve and electrovalve - I assume that I eliminate both of these as they seem to hook up to the thermovalve?

3. What about the Air pump check valve that connects to the engine and the air cleaner and the air pump? I am replacing the air cleaner with a 2.5" air filter. Do I remove the check valve from the cylinder head and insert a bolt in its place or do I leave it there and block off the hoses? If so, any recommendations for the bolt size and thread?

4. I figure some of the hoses will need to be blocked off. For the vacuum hoses I understand that I can buy vacuum plugs. But what about the others i.e fuel return hose, etc. how do I plug these?

5. Which existing hose do I use for the DFEV vacuum port advance?

I greatly appreciate any help that you can provide. Many thanks in advance.

Dave

[124JOE]

the vacume line from the dizzy to the carb
a big vac hose for the brake booster
cross the water lines from the old choke together

as for other hoses plug and seal
trim to hide them
wires can be taped back to the harness "some say cut them off"

when you have the old intake off most of the hoses go with it

hope this helps

[dmwhiteoak]

And with your crank case vent hose you can put it into your air breather. I have a freedoms breather and just took a knockout out of it and installed a fitting to secure the hose.

[parsok]

124Joe - many thanks

dmwhiteoak - By crank case vent hose do you mean the air pump hose that routes thru the check valve?

Dave

[So Cal Mark]

crankcase vent hose comes from the oil separator on the left side of the block and goes to the air cleaner. I'd remove the air pump check valves and plug the holes. Fuel return isn't used with the 32/36.

[parsok]

Ok, is this some kind of sick joke?????

I spent the last hour trying to get at the middle two bolts holding on the intake manifold. Unless I grow an additional joint in my arm and another in my wrist and shrink my arms to the size of a two year olds there is no way I'm going to get these off.

Do i have to take off the fuel pump in order to get at these two bolts??

Any on the topic of this can't be a good thing - the oil dipstick popped out after I unbolted it from the manifold. I assume that I just pop it back in and find a new may to bolt it in place. do i need a new gasket??

Dave

[So Cal Mark]

you need a swivel socket and extension for those two middle bolts.

[tartan18]

Ok, is this some kind of sick joke?????

I spent the last hour trying to get at the middle two bolts holding on the intake manifold. Unless I grow an additional joint in my arm and another in my wrist and shrink my arms to the size of a two year olds there is no way I'm going to get these off.

Do i have to take off the fuel pump in order to get at these two bolts??

Any on the topic of this can't be a good thing - the oil dipstick popped out after I unbolted it from the manifold. I assume that I just pop it back in and find a new may to bolt it in place. do i need a new gasket??

Dave

Getting the two middle (lower) nuts off their respective studs is a PIA. I used a flexible extension with a 13mm socket but it took awhile and skinned knuckles to get them secured. My car is a 1975 with the 1800 manifold so there is precious little room to maneuver. If you take the mechanical fuel pump (that is what I have -- not an electric pump) off you'd have more room to get at the nuts on the manifold but then you'd have the challenge of putting the fuel pump back and hooking up the fuel hoses. Good luck.

[digitech]

Also, you will find there is not a location to secure the dipstick to on the 1800 intake - you will have to fabricate something (what I did with varying degrees of success) or get the dipstick/bracket off of a fuel injected spider (what I finally did and is soooo much nicer).

[124JOE]

get a set of SHORTY metric wrenches
youll need them somewhere

[parsok]

Well I got to Princess Auto and bought a flexible extension and a set of dual swivel socket adapters. The former is going back to the store as I bent it into the shape of a pretzel trying to get the bolt out. The latter worked like a charm. Makes me wish I knew they existed a couple of months ago

I got the manifold off and it is a thing of beauty. I can now access the starter to undertake the 'brown wire fix'.

Many thanks to everyone who was kind enough to offer their much needed advice!! I'm sure I'll have a couple more questions when I put the 1800 manifold on later this week.

Cheers,

Dave

[parsok]

Trying to figure out a couple of hose connections:

1. On the 1800 intake manifold there are 3 tube outlets (connectors). One is a dual connector and I assume the one on the right connects to the brake booster. Not sure what the one on the left is for or the single one just above them. Ideas?

https://picasaweb.google.com/1175995241 ... 1353097858

2. The hose from the breather (located near the bottom of the motor next to the fuel pump) has a hose that connected to the air cleaner can. I am replacing this with one of the smaller square air filters. I assume that I connect the breather hose to the air filter? Just want to be sure.

Thx. D

[124JOE]

just need the one for the brake boster
you can plug the rest

[parsok]

Cool. What do you recommend to plug it? A hose and a screw?

[124JOE]

when it comes to plugs you have some choices
QUICK cut the hose and find a bolt "fine thread is best"
you need somthing for length for the bolt
ive even used a silicone sealer in the hose and trimed it clean buy cutting it off

CLEAN get some plugs i think there in the plumming department
unscrew the vacume tees that are not needed and pulg the holes