AGG conversion - few quick questions

[dcfb77]

I've finally got someone to do the AGG conversion and I've a few queries I'm hoping someone may be able to help with:

- Input shaft: They have said they will be using standard input shaft. Is the standard diesel input shaft up to the job of handling the torque the AGG has?
- Clutch: As above, said they plan to use standard clutch from the diesel. Maybe an uprated one such as the black diamond one Brickwerk sells.

What are people's thoughts on the above? Can the standard input shaft & clutch from the diesel/JX setup handle the AGG?

Thanks, David.

[Titus A Duxass]

Simply -

Yes
and
Yes

[dcfb77]

Thanks for the reply. Thats a sigh of relief...

Why is it that all the AGG conversion's I've seen online all have TDI input shaft and TDI clutch and not standard setup?

I see on Brickwerks website that TDI clutch needs modifying once TDI input shaft is on. Anyone know what needs to be done to it? If its nothing major I'll get it done at same time as the engine goes in.

[Titus A Duxass]

Maybe you've been looking at TDi conversions and not AGG.

I have an ADY and it uses the standard Sachs 1,6td clutch and standard mainshaft.

This is taken from Gary's bible (essential reading if you are doing the conversion yourself) -
"Remove car clutch, flywheel and engine back plate. Fit JX back plate and flywheel using new stretch
bolts. Check depth of crank shaft centre drilling to confirm it is sufficient for the gearbox input shaft.
This is easiest if you have the JX engine to hand for comparison. Clean out the drilling and fit a JX
spigot bearing and then the JX clutch."

[dcfb77]

So...things are nearly there with the conversion.

Trying to figure out where to connect rev counter as alternator won't allow to connect to it.

I remember seeing somewhere that signal can be had from the coil?

If anyone knows how/where to connect it to please do let me know..

Also, massive thanks to Jes and Gary(s) for all bits and info/documents for the conversion. Not all done myself as I didn't have the time but it all turned out to be essential in making all this go to plan. Will post photos once it's all complete.

[garyd]

Trying to figure out where to connect rev counter as alternator won't allow to connect to it.

Try taking the alternator to an auto-electrician and asking them to wire in a 'W' terminal - even if it's a short fly lead.

[dcfb77]

Thanks, I'll do just that.

Another thing...any idea why oil pressure buzzer goes off as I rev out?

Everything seems well connected. No pressure issues with the engine according to read outs.

How can I get that thing to shut up?

[ELVIS]

You can take take the tacho feed straight off the plug that goes into the coil pack ,obviously tacho signal (green?) from ECU is digital so wont work.

Double check wiring to AGG loom - T3 to AGG loom colours match up (yellow to yellow and blue/black to blue/black) but think a few have managed to cross them.

[jes*b]

Good news on the progress swing by for a test drive when you are down this way

[dcfb77]

Yeah! New engine running and very nicely at that.



Pulls up hills and I can now overtake!! Thats everything I wanted. Estimate mpg is around 30mpg when on motorway and light on the throttle and around 15mpg when going flat out too much - which I dare anyone to resist in first week of it being fitted, that engine really sings.

Huge thanks to Jes B for supplying/sending the engine & bits, GaryD for all that info on doing the conversion & Badgerfax & Patrick for the AGG inspiration & others who photo document these conversions and share for others like me to get inspired. Especially for all those pictures (they really do speak a thousand words).

Though I didn't do the actual conversion myself, all the info & problem solving from people's past experiences on here has made it all possible. It allowed me to wrap my around what needed to be done, bought/made and planned for, and was appreciated by the guys who did the conversion). Was going to take the conversion on but had too little time before going away on holiday - and the electrics scared the sh!t out me. That said I've worked on the van myself up to now (excluding when gearbox & diff came out) so I still feel I've learnt a fair bit and felt I deserved not to have to do this one in a hurry at the last minute for once. Seriously dont know how I'd get through Syncro ownership and its quirks if it wasnt for this club & its people. I've never met any of you (excluding Lloydy - picked up set of seats from him once) but your passion for our vans has kept me/my family on the road and enjoying every mile of our travels and more recently with the Syncro, off the beaten track, so massive thank you!

Still a few things to sort out like exhaust (damn its loud with diesel exhaust), air intake (cant find air box that fits anywhere - using apollo one) and where to stick the expansion tank in the engine bay (currently strapped to battery).

More pictures of the van's resto: https://www.dropbox.com/sh/6orouwlitci2 ... iziMa?dl=0

Has anyone who's done this conversion managed to find a decent air filter box setup thats suitable for off roading?

[dcfb77]

Good news on the progress swing by for a test drive when you are down this way

I will do. Likely be getting exhaust done in Ashford but not till next month (booked out).

Still got your straps/box! PM me your address and I'll send them back to you pronto.

Thanks again.

[jes*b]

Excellent. I am chuffed that another unloved GTI was recycled. Not often they turn up on sensible miles with all the paperwork . Usually still on the road or tucked away by enthusiasts. Really would like to have a snoop around the engine bay when you are in Ashford . Would also like an introduction to the exhaust man as all local contacts are good . Hold off on the straps until we hook up . I shall aim to bring The Axeman with me as he lives Ashford way now. Cheers jes

[garyd]

Congratulations on getting this all together. I've lost track of just how many times I have sent out the conversion information but there must be dozens of AGG T25s out there now.

Has anyone who's done this conversion managed to find a decent air filter box setup thats suitable for off roading?

I am using an enclosed cone filter similar to this one

http://www.ebay.co.uk/itm/FORCED-COLD-A ... 1203977090" onclick="window.open(this.href);return false;

I managed to adapt it to take the snorkel elbow directly into the input end and then the MAF directly on the other end. It sits in the left side behind the rear lamps. Have a look at pages 13 & 14 of my fitment report.

I don't expect that it sufficiently sealed to fully cope with a prolonged submersion but it is rather more than 'splash-proof'.