Syncro engine swap - DJ to AGG

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Thanks to Hugomonkey, Syncroandy and MickeTJ for pointing me at the resources for the correct pulleys and belts.
I can confirm the water pump pulley needs changing for a ribbed one 028121031K and the belts needed are ribbed 037903137E and V 037145271E
for an engine with PAS and no aircon. Belt tensioner not needed.

Anyone got a ribbed one? 028121031K

BTW partsbase website is no more, so instead use http://etka.cc/vw
Relevant page for all this is http://www.oemepc.com/vw/part_single/ca ... 375/lang/e
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Belt and pulley issues overcome.
Image

Cambelt also changed, and then managed to trash the crank sensor by dropping a tool and smashing it. Thats a £45 spend I could have done without :-(

In April it'll be time to mate engine and gearbox and offer them up to the van.
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silverbullet
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Re: Syncro engine swap - DJ to AGG

Post by silverbullet »

:ok
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

jes*b
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Re: Syncro engine swap - DJ to AGG

Post by jes*b »

Good to see the AGG coming together Patrick . (Flat tweed) cap off to you sir .

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

jes*b wrote:Good to see the AGG coming together Patrick . (Flat tweed) cap off to you sir .
Ta Jes.


I need some help with coolant hosiery. I have, primarily, a rubber hose set from a JX Syncro. I do not have the auxiliary water pump.

This hose comes from the water pump and goes to the radiator. The side pipe I think goes up to the coolant flange on the side of the cylinder head in next pic.
Image

The coolant flange on the cylinder head had two outlets - one I think goes to the front heater and I've popped on what I think is a suitable adaptor, - the second I think goes to the side pipe in the first pic. Do I just join these together?
Image

This is the other big hose, from the front of the cylinder head, which connects to the radiator. Have I got it correctly joined to the oil filter thingy? I've left on the AGG hose from the water pump, to the oil filter thingy and the side connecter on the front of the cylinder head.
Image
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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

Patrick,
take a look at the GTi conversion Facebook page and a document I posted to show the hose routes.

https://lookaside.fbsbx.com/file/2017-0 ... SEJRexHCq_
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

I think that your first hose is the one I have shown in two tones of blue on the above diagram and the end you ask about is intended to connect to the electric pump. Without a pump, it should connect to the second port on the oil cooler/heat exchanger. There is a different version of the hose to do this. 068 121 073 with G or H suffix depending on whether or not you have air conditioning.

The flange on the end of the cylinder head should only take one hose (maroon/brown in the diagram) which feeds hot water to the heater matrix. It is normally black plastic not the aluminium unit you have. No idea why you would have two outlets.

Also noticed in your first picture that the crank sensor wiring is going to need some attention!

Keep up the good work.
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Thanks Gary, that diagram is fab. You're a star!

I replaced the original plastic flange and must have bought the wrong one.
I bought this - https://www.brickwerks.co.uk/coolant-fl ... large.html
Should I have bought this? https://www.brickwerks.co.uk/coolant-fl ... small.html

Yeah, the crank sensor is creamcrackered. I thought I'd broken mine, but from looking at pixies I see the damage is pretty common. Got a new one ready to fit.
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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

Patrick,
The first of these (the alloy one) appears to be for the earlier, non-turbo, diesel engine and fits on the side of the cylinder head (between cylinders 2 & 3?). The second, plastic, flange is listed for the later TD engine and fits at the (flywheel) end of the cylinder head.

However, I don't recall it having the temp sensor fitting. There is a neighbouring fixing for the 'low' oil pressure sensor. I will check later and see what is actually on my engine.

For the 'side of cylinder head' flange, there is one which has the correct two hose spigots ('octopus' end and top spigot of water pump) plus an 8mm spigot suitable for the throttle body supply. It comes from a MkIII Vento 1.8/2.0 litre GTi & has the two sensor mounts and the 8mm branch.

The hose layout drawing is something I did very recently when it became apparent that people who, like you were converting from WBX engines rather than diesels, would have no model or memory to work from when trying to sort the hoses out. I have also seen some quite weird hose arrangements pictured!
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

Had a look at the engine and there is a temperature sensor in the flange at the end of the cylinder head. Memory failing again!

I think it may be the one for the dash temp gauge.
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Thanks again Gary. I had another go at this today and have worked this out now.
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

SORTED.
Diesel bottom coolant hose needed.
http://forum.club8090.co.uk/viewtopic.php?f=19&t=160183
Last edited by syncropatrick on 12 Jun 2017, 19:46, edited 1 time in total.
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

Patrick,
if this hose persists in being unavailable you might consider getting the later equivalent hose (for the TD engine with the coolant pump) and cutting & splicing that into the small hose on the intake side of the pump (ie- delete the pump).

If the number of conversions taking place is anything like the number of people wanting to join the facebook group I can well understand that there will have been a rush on this this non-turbo hose.
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Bottom coolant pipe on its way to me from Denmark.
:ok
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Well he's only gone and bolted the new engine in!
I never thought 14 bolts would involve such a lot of heaving, swearing and tea drinking, but its done now.
Wiring, plumbing, fuel, exhaust to go + a multitude of misc tasks.
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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