1.9dg to agg conversion

for questions and answers about alternative power transplants on the T25, GTi, Porsche,Subaru etc, this is the place. You must register to post but anyone can read.

Moderators: Moderators, User administrators

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

1.9dg to agg conversion

Post by Hirst80 »

Could anyone be so kind and point me into the right direction of some information on an agg conversion into my 1.9dg I’ve got a good idea, but I like to be Crystal clear on things before I start them.
Thank you



Sent from my iPhone using Tapatalk

User avatar
Aidan
Trader
Posts: 5425
Joined: 11 Oct 2005, 19:21
80-90 Mem No: 742
Location: Llanfyllin, mid Wales : )
Contact:

Re: 1.9dg to agg conversion

Post by Aidan »

use the search function on here
contact GaryD for his info sheet
join the dedicated FB group

User avatar
Titus A Duxass
Posts: 5783
Joined: 24 Nov 2007, 08:22
80-90 Mem No: 4475
Location: Cologne

Re: 1.9dg to agg conversion

Post by Titus A Duxass »

Yes, please come and visit us on a*** book @ VW T25 GTi conversion

We have all the documentation that you need. 
VW T3 GTi Camper 2,0l

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

Re: 1.9dg to agg conversion

Post by Hirst80 »

Great, all joined up, thank you!


Sent from my iPhone using Tapatalk

Club Joker
Posts: 9
Joined: 10 Oct 2011, 21:52
80-90 Mem No: 8367

Re: 1.9dg to agg conversion

Post by Club Joker »

Hello, some info on my old thread on the Brick Yard. click here

Good luck, it's a great conversion!

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

Re: 1.9dg to agg conversion

Post by Hirst80 »

Club Joker wrote:Hello, some info on my old thread on the Brick Yard. click here

Good luck, it's a great conversion!
Your thread is actually the reason I decided to go AGG instead of EJ25,
I just have a couple questions if you wouldn’t mind :)
How is the paint lasting?
And did the 1.9dg gearbox bolt straight onto the jx bell housing?
Also what clutch and flywheel did you use?
Thank you!


Sent from my iPhone using Tapatalk

Club Joker
Posts: 9
Joined: 10 Oct 2011, 21:52
80-90 Mem No: 8367

Re: 1.9dg to agg conversion

Post by Club Joker »

Well the paint is lasting ok-ish.  It's still black, but has certainly roughened up a bit over time on he rocker cover. I think this is probably down to surface preparation as much as anything.  The main head is bare metal and the sump has stayed pretty black.  If I did it again I don't think I would bother.  I don't think you can get it clean enough for the paint to really stick.

Yes, the bellhousing bolted straight on. The most difficult bit was getting the input shaft out, just because it was difficult to see the circlip.  It's also a pretty oily, horrible job, but perfectly doable.  Don't forget that you need a new gasket.

For the clutch, I just used the JX one.  Not had any issues with it slipping at all.

Copies of my Brickwerks part list below.  Might not be 100%, but should be close!  Sorry it is not in a very convenient format!  Last number in the parts numbers is the number of them I bought I think.  Any questions, just ask!

Clutch Slave Cylinder Support Bracket - T3 Diesel T3721359A 1
Bell Housing Gasket - T3091 301 1311
Clutch release bearing - T3 AllT3141165D1
Engine to Bell Housing Bolt Kit - T3 D/TDT3 BHB KIT1
Gasket - T3 Reverse Light Switch Housing091301278B1
Gearbox Oil - 75W GL4 1litreOIL-75WGL44
Electric Fuel Pump - T3 Fuel Injection [BUDGET]11152033001
Sump gasket - 1.6D/TD 1.9D/TD rubber495.6201
Flywheel bolt set - inline 4cylVW902061031
Spigot shaft bearing - VW 4 cyl inline140981
Gasket - T3 Diesel Oil Filler068 115 315 A1
Sealing compound - 100g036.1611
Clutch - T3 Diesel [all]3000 162 0011
Coolant flange - T3 TDI ConversionsTDI1211321
Waterpump - inline 4cyl [late]VW121010C1
Alternator Tensioner bolt - T3/T4220501
Oil cooler/Heat exchanger - General VW use11135007001
Crank oil seal with housing - flywheel end804.8501
Bypass hose - T3 D/TDSP1062.51
Coolant hose - T3 D/TD [head to coolant pipe]SP1062.11
Coolant hose - T3 TD [Thermostat to coolant pipe]SP1062.21
Coolant hose - T3 D/TD water pump to header tankSP1062.111
Coolant hose - T3 TD "JX" Aux Water pumpSP1062.121
Hose Clamp - 16-27mm12677020212
Hose Clamp - 20-32mm12677020263
Hose Clamp - 25-40mm12677020323
Hose Clamp - 30-45mm12677020372
Gasket - 1.9D/TD Oil Filter Mount620.0611
Bellhousing Inspection port plug kit - T3 DieselT3 301 129 B1
Rocker cover breather grommet11120013001
Clutch Lever - T3 Diesel251141713C1
Drive flange oil seal - T3277.5252
Gearbox selector shaft seal - T3244.0821
Spigot/input shaft seal043.6051
CV Boot kit - T3 rear22451/3031494 
Bolt Kit - T3 Diesel Engine MountT3D199NBW2
Thermostat cover - T3 DieselV10-02831
Silencer Bracket - T3 1.7D/later 1.6TD LEFTT3D2513681
Engine Mounting - T3 Diesel [Budget]T3D199201G-ALT1
T Piece - 8mm 4mm 8mmUNI-T8481
Fuel Line Reducer 8mm-6mm8028.06041
Reinforcing Sleeve for Polyamide Tube - 8mm7026.06006
Fuel feed pipe - T3 2.1l Digifant/DigijetT3-201DJ-FEED1
Bulkhead Fuel Connection - T3 1.9/2.1 Injection32441
Omega Clip – Green 11mmFIX5310
Fuel line clamp - 14mm12089800146
Wiring Terminal - 1.6mm Socket [Female]WC-FEMRND1610
Fuel Hose - 7.3mm [FPM/ECO]2240.06001
Fuel Filter - PetrolWK321 Fuel Pump Mounting Brackets - T3 Injection
T3 113 547/9 A1Fuel Filter Clamp - T3/T4 Petrol
2512016791Polyamide Tube - 8mm Fuel Line / Black
PA8B2Polyamide Tube Reinforcing Sleeve - 8mm
PTRS82T-Piece - 6mm x 6mm x 6mm [Steel]
T3S1275631Oetiker Clip - 12.3-14.8
OET14804Oetiker Clip - 10.8-13.3
OET133010Omega Clip – White 17mm
FIX566Coolant 1.5l (purple) - G13 Equivalent
VW-G134

 Clutch pipe - Flexi to Slave T3 Early [SHAPED]
T37210011Clutch Pipe - T3 / Early
11310001001Clutch Slave Cylinder - T3 / Alternative
11305007001

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

Re: 1.9dg to agg conversion

Post by Hirst80 »

Club Joker wrote:Well the paint is lasting ok-ish.  It's still black, but has certainly roughened up a bit over time on he rocker cover. I think this is probably down to surface preparation as much as anything.  The main head is bare metal and the sump has stayed pretty black.  If I did it again I don't think I would bother.  I don't think you can get it clean enough for the paint to really stick.

Yes, the bellhousing bolted straight on. The most difficult bit was getting the input shaft out, just because it was difficult to see the circlip.  It's also a pretty oily, horrible job, but perfectly doable.  Don't forget that you need a new gasket.

For the clutch, I just used the JX one.  Not had any issues with it slipping at all.

Copies of my Brickwerks part list below.  Might not be 100%, but should be close!  Sorry it is not in a very convenient format!  Last number in the parts numbers is the number of them I bought I think.  Any questions, just ask!

Clutch Slave Cylinder Support Bracket - T3 Diesel T3721359A 1
Bell Housing Gasket - T3091 301 1311
Clutch release bearing - T3 AllT3141165D1
Engine to Bell Housing Bolt Kit - T3 D/TDT3 BHB KIT1
Gasket - T3 Reverse Light Switch Housing091301278B1
Gearbox Oil - 75W GL4 1litreOIL-75WGL44
Electric Fuel Pump - T3 Fuel Injection [BUDGET]11152033001
Sump gasket - 1.6D/TD 1.9D/TD rubber495.6201
Flywheel bolt set - inline 4cylVW902061031
Spigot shaft bearing - VW 4 cyl inline140981
Gasket - T3 Diesel Oil Filler068 115 315 A1
Sealing compound - 100g036.1611
Clutch - T3 Diesel [all]3000 162 0011
Coolant flange - T3 TDI ConversionsTDI1211321
Waterpump - inline 4cyl [late]VW121010C1
Alternator Tensioner bolt - T3/T4220501
Oil cooler/Heat exchanger - General VW use11135007001
Crank oil seal with housing - flywheel end804.8501
Bypass hose - T3 D/TDSP1062.51
Coolant hose - T3 D/TD [head to coolant pipe]SP1062.11
Coolant hose - T3 TD [Thermostat to coolant pipe]SP1062.21
Coolant hose - T3 D/TD water pump to header tankSP1062.111
Coolant hose - T3 TD "JX" Aux Water pumpSP1062.121
Hose Clamp - 16-27mm12677020212
Hose Clamp - 20-32mm12677020263
Hose Clamp - 25-40mm12677020323
Hose Clamp - 30-45mm12677020372
Gasket - 1.9D/TD Oil Filter Mount620.0611
Bellhousing Inspection port plug kit - T3 DieselT3 301 129 B1
Rocker cover breather grommet11120013001
Clutch Lever - T3 Diesel251141713C1
Drive flange oil seal - T3277.5252
Gearbox selector shaft seal - T3244.0821
Spigot/input shaft seal043.6051
CV Boot kit - T3 rear22451/3031494 
Bolt Kit - T3 Diesel Engine MountT3D199NBW2
Thermostat cover - T3 DieselV10-02831
Silencer Bracket - T3 1.7D/later 1.6TD LEFTT3D2513681
Engine Mounting - T3 Diesel [Budget]T3D199201G-ALT1
T Piece - 8mm 4mm 8mmUNI-T8481
Fuel Line Reducer 8mm-6mm8028.06041
Reinforcing Sleeve for Polyamide Tube - 8mm7026.06006
Fuel feed pipe - T3 2.1l Digifant/DigijetT3-201DJ-FEED1
Bulkhead Fuel Connection - T3 1.9/2.1 Injection32441
Omega Clip – Green 11mmFIX5310
Fuel line clamp - 14mm12089800146
Wiring Terminal - 1.6mm Socket [Female]WC-FEMRND1610
Fuel Hose - 7.3mm [FPM/ECO]2240.06001
Fuel Filter - PetrolWK321 Fuel Pump Mounting Brackets - T3 Injection
T3 113 547/9 A1Fuel Filter Clamp - T3/T4 Petrol
2512016791Polyamide Tube - 8mm Fuel Line / Black
PA8B2Polyamide Tube Reinforcing Sleeve - 8mm
PTRS82T-Piece - 6mm x 6mm x 6mm [Steel]
T3S1275631Oetiker Clip - 12.3-14.8
OET14804Oetiker Clip - 10.8-13.3
OET133010Omega Clip – White 17mm
FIX566Coolant 1.5l (purple) - G13 Equivalent
VW-G134

 Clutch pipe - Flexi to Slave T3 Early [SHAPED]
T37210011Clutch Pipe - T3 / Early
11310001001Clutch Slave Cylinder - T3 / Alternative
11305007001
That’s awesome! A massive help! Thank you! And I’ll let you know how it goes, I’m picking the new engine up Monday!


Sent from my iPhone using Tapatalk

Club Joker
Posts: 9
Joined: 10 Oct 2011, 21:52
80-90 Mem No: 8367

Re: 1.9dg to agg conversion

Post by Club Joker »

Good luck with it!  Any questions just ask  :D

booted
Posts: 32
Joined: 29 Mar 2007, 18:34
80-90 Mem No: 3712
Location: Luton, Club 80-90 mem no 3712,

Re: 1.9dg to agg conversion

Post by booted »

What is the  "T Piece - 8mm 4mm 8mmUNI-T8481" for?

Club Joker
Posts: 9
Joined: 10 Oct 2011, 21:52
80-90 Mem No: 8367

Re: 1.9dg to agg conversion

Post by Club Joker »

That was for connecting the Eberspacher into the return fuel line. You won't need it if you don't have one.

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

Re: 1.9dg to agg conversion

Post by Hirst80 »

Club Joker wrote:That was for connecting the Eberspacher into the return fuel line. You won't need it if you don't have one.
Hi again Joker, I have a question about the engine bars, I've received the jx bars in the post today but I can't figure out where they mount to, do they just bolt in? Thanks

Sent from my SM-G780F using Tapatalk


User avatar
axeman
Posts: 1176
Joined: 07 Feb 2009, 19:50
80-90 Mem No: 6410
Location: Smeeth kent country side

Re: 1.9dg to agg conversion

Post by axeman »

The bars bolt on to the chassis rails and along the rear cross member. There are 2 diesle specific reinforcing plates that are spot welded to the rear crossmember. These are triangular in shape which give the 3rd bolt. There should be 2 bolt tappings in your cross-over to recive the 2 lower m8 bolt. I can take a photo in the morning if needed. Where abouts are you in the in the country as I have a recently converted agg on my drive.

Neil
Back in the game with an uncut 2wd panel van

Hirst80
Posts: 10
Joined: 06 Dec 2020, 20:45
80-90 Mem No: 0

Re: 1.9dg to agg conversion

Post by Hirst80 »

axeman wrote:The bars bolt on to the chassis rails and along the rear cross member. There are 2 diesle specific reinforcing plates that are spot welded to the rear crossmember. These are triangular in shape which give the 3rd bolt. There should be 2 bolt tappings in your cross-over to recive the 2 lower m8 bolt. I can take a photo in the morning if needed. Where abouts are you in the in the country as I have a recently converted agg on my drive.

Neil
Thank you for your reply! I haven't had a proper look under it yet, I'm always inspecting for rust if I do, so I will have a look tomorrow. Mine being a late 1983 1.9 DG will I have the diesel plates there or will I have to spot weld them in? I am in Hampshire, where abouts are you located? If you're close that would be awesome to see, would give me a lot of help
Thanks

Sent from my SM-G780F using Tapatalk


Club Joker
Posts: 9
Joined: 10 Oct 2011, 21:52
80-90 Mem No: 8367

Re: 1.9dg to agg conversion

Post by Club Joker »

Mine was an 84 dg and didn't have the mounts, but it did already have captive nuts in the chassis rail at the back, so it was easy to weld them in the right place. I will try to take some pictures tomorrow so you can see what's what. It would be easy to fabricate them if you need to, or ideally get someone to chop them out of a scrap diesel van for you.

Post Reply