Club 80-90 Forums

Hi, I was looking for info, on changing a CS diesel engine for an AGG. There seems to have been plenty done, but I can't see much info.  I've tried the Wiki and searched. I thought someone might have done a detailed list of parts and procedures.                                                                                                                                                      I was trying to find what I would need. I intended to use my CS g/box. From what I can see I would need to use my sump and flywheel. I would need a differentbush in the crankshaft. My CS starter motor is possibly a direct fit. 
I wondered what was required in the way of electrics, wiring loom, ecu, cooling system, exhaust, fuel system. 
Pretty much any info at all.
I saw a clip on youtube, where a guy was cutting the nearside chassis leg for clearance, but I've not seen that from anyone else.
Any pointers or advice appreciated.

Drop Elvis a pm - he's big into AGG installations - there's probably a dedicated whatsapp or FB group for it, where he probably hangs about more these days

I can answer a few:

Use your sump and flywheel, make sure the clutch is in perfect condition.

You need to use the bottom half of your CS oil pump (with the pickup tube to suit the wedge sump) and the top half of the AGG oil pump
Fit a pilot bush to the AGG crank (same as what would be in a JX or CS, brickies will sell em)
CS starter will be fine.
Sometimes people need to bash the chassis leg a bit to clear the inlet manifold, sometimes not. I'm not sure why. I did two, and only one needed bashing?

Most likely use all the CS cooling system and alternator etc.
You'll need to work out an air filter. Just stuffing a cone on the end of the AGG throttle body will work but it'll be really noisy. Working out an enclosed airbox system would be much better, but the throttle body ends up nowhere near anything OE so you're on your own. You'd possibly get away with a 1.9 DG airbox and some custom piping.

Fit a fuel tank from a 2.1 DJ (with a swirl pot) and a 2.1 fuel pump, filter and all 2.1 fuel pipes.

Exhaust is a bit trickier, you will need to get a custom bit made up to connect from the AGG manifold to the CS backbox, at the very least.

The golf wiring loom will need picking apart to separate just the engine management part of it. It's tricky work for a beginner, maybe Elvis would do this for you?
The ECU has an immobiliser in it which is set up to read from a chip in the golf key. Either retain the key and reader under the back seat (I did this) or get the immobiliser disabled.