Syncro engine swap - DJ to AGG

[syncroandy]

[axeman]

come on the proof is in the pudding, where are the photos?

neil

[syncropatrick]

come on the proof is in the pudding, where are the photos?

neil

Bliddy P'bucket innit!
I'm a muppet - I use Flickr!

Ignore the various hoses draped around, they were tied up out of the way for the hippo wrestling that is winching an engine in.

[syncropatrick]

Cooling system all plumbed in.


I assume the WBX airfilter bracket needs to come off, if I want to fit the diesel battery and header tank bracket.



Can anyone describe/show where the diesel battery and header tank bracket is welded to the rear valance?


And my fingers will never forgive me, I made the loom.

[silverbullet]

Good man! Glad to see some progress. Did the td snorkel arrive ok?

Sent from my S60 using Tapatalk

[syncropatrick]

Did the td snorkel arrive ok?

Yes. Sorry - forgot to say so.

[PaulcT3]

Hi

just looking at your belt setup, how have you tensioned the belt? Is the alternator able to be adjusted?

[syncropatrick]

Hi
just looking at your belt setup, how have you tensioned the belt? Is the alternator able to be adjusted?

The AGG non-PAS alternator and bracket setup uses a spring under the alternator to push it away and thus tensions the belt.

[PaulcT3]

Hi
just looking at your belt setup, how have you tensioned the belt? Is the alternator able to be adjusted?

The AGG non-PAS alternator and bracket setup uses a spring under the alternator to push it away and thus tensions the belt.

Ah awesome thats just what I need for mine, any info on what to look/search for on ebay for example to find one?
Also, not a lot of sources for that pulley 028121031K. Where did you obtain one from?

Many thanks
Regards
Paul

[syncropatrick]

Hi
just looking at your belt setup, how have you tensioned the belt? Is the alternator able to be adjusted?

The AGG non-PAS alternator and bracket setup uses a spring under the alternator to push it away and thus tensions the belt.

Ah awesome thats just what I need for mine, any info on what to look/search for on ebay for example to find one?
Also, not a lot of sources for that pulley 028121031K. Where did you obtain one from?

For the water pump pulley I put a search on ebay, it eventually emailed me details of a second hand one from Germany still attached to a pump that was cheap enough. the pump was gash, but at least I got the pulley and could swap it onto my good pump. Otherwise try breakers, on the many Golf MkIII forums and Fb pages to get the parts you need.

For the non-PAS alternator and bracket it's best to start with a source car with no PAS. I didn't, and had to source the parts. Searching VW parts catalogues reveals the part numbers needed. I was lucky and a friend came up with the goods, otherwise ebay again. At the top of p.14 I reference an online VW parts catalogue with exploded diagrams. Unfortunately that link now has malware on it which my browser helpfully blocks. I someone else has a link to a good online catalogue you'll be laughing.

[PaulcT3]

for the record (as of the 15/03/2018) there are 6 of these pulleys listed as available new in the uk from vw. Hopefully only 5 now as ive just nabbed one.

£17.50+vat so a little over £21.

[PaulcT3]

Just been in the workshop and it turns out that I had this pulley and the spring loaded alternator fitted all along....

[syncropatrick]

Just been in the workshop and it turns out that I had this pulley and the spring loaded alternator fitted all along....

Yep, been there, done that!

[bmouthboyo]

Was this ever completed?

[syncropatrick]

Was this ever completed?

Not yet - I’m a slow mechanic.