Syncro engine swap - DJ to AGG

[syncropatrick]

OK.
Bell housing getting both breathers, with no bung in oil drain for now.
Hoses ordered in time for weekend activity, before some replies up, so I do hope I can get a 5.5mm on a 8mm spigot! I didnt think to size hozes by spigot. Seems obvious now its been pointed out to me.
I'm using the Syncro fueling system - injection pump and filter behind nearside shock tower, so the feed line using hose I've just bought will need some sort of adaptor and AGG sized hose, as Simon mentioned, at the engine end.
Oh, and no over-braid ordered, as advised not to.

My head hurts munging together a Syncro petrol van, Syncro diesel conversion parts and Golf petrol engine! It's easy to make mistakes when one is dipping in and out of the project.

[syncropatrick]

Top shock bolt came undone with a bang. Filler pipe removed to enable easier tank insertion. Pipe heavily corroded on outside but no holes found, so wire brush, vactan and chassis black getting used.

Filler neck has holes in it and the filler hose was delaminating on inside and rubber splitting on outside, so thats another £150.

Tank all built up with new hoses and new sender etc. If the rain stays away I intend to get tank in this afternoon.

[silverbullet]

Make sure that the big hose wants to come out of its conduit! I gave up on mine and left it alone, despite a bit of perishing round the top. The hose appears to have a plastic membrane liner as well as fabric reinforcement so should be good for a very long time.

[syncropatrick]

Make sure that the big hose wants to come out of its conduit! I gave up on mine and left it alone, despite a bit of perishing round the top. The hose appears to have a plastic membrane liner as well as fabric reinforcement so should be good for a very long time.

It came out, after some push/pull and swearing. I'll slip some lube down the neck to help insertion.

I'm determined to loose the fuel smell as part of this work, so anything that is suspect to do with fuel is getting replaced.

[syncropatrick]

I've entered a select club!


Once I'd worked out that the coolant and PAS hoses and battery cable were in the way it went in easily, even with the sender already installed.
It took longer to get the straps on! I was intending to put some closed cell foam sheet between the tank and straps, but the stuff I had at 6mm and even when compressed was too fat. Ah well.

Do feel like I've been wrestling a black bear though. Radox bath and beer here I come.

[silverbullet]

All this talk of lube and straps... Elvis will be along shortly.

[syncropatrick]

I'm after the upper bell housing breather socket. Anyone?
http://forum.club8090.co.uk/viewtopic.php?f=19&t=144115

[Orbit]

Hi guys I'm also half way through an AGG into my air cooled bus. I fitted the engine yesterday but had to remove the thermostat cover and elbow. (Plastic) and the hoses just above it just so I could fit the the engine mount in place.

[Orbit]

Sorry got bit a bit fat fingered then and hit send. What I'm asking is do I have to change the alternator bracket or is there some form of an extension that I can add to the housing to bring it out enough to pass over the bracket.

[ELVIS]

You have to use a jx thermostat housing, sounds like you have the golf one on still. Jx routes down 45' under Ali arm.

[Orbit]

Cheers Elvis your a star.

[Simon Baxter]

Maybe get one made Patrick.
Chances of finding one are pretty slim I reckon.
It won't hold the conversion up, not that important in the grand scheme of things.

[syncropatrick]

Maybe get one made Patrick.
Chances of finding one are pretty slim I reckon.
It won't hold the conversion up, not that important in the grand scheme of things.

Yeah - it's a nice to have, but not essential.

[tforturton]

Any progress with this, Patrick? It's gone a bit quiet recently....

[syncropatrick]

Any progress with this, Patrick? It's gone a bit quiet recently....

Good timing! My first day back on this after nearly a month doing other stuff.

All new fuel pipes, hoses and bits back on today. Getting the large fuel hose down the inlet pipe was fun. Hopefully thats the end of fuel smells.
Heavy rain forecast tomorrow so it'll be a paperwork and shopping list day.